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CurrentIssue > Recycling > GoingLiveIndia'sFirstC&DRecyclingPlant

GOINGLIVEINDIA'SFIRSTC&DRECYCLING
PLANT

Indiaproduces10to15milliontonnesofConstruction&Demolitionwasteannually.ThetraditionalpracticeinIndia
istodisposeofthiswasteinlandfills.Facedwithwithgrowingenvironmentalconcernsandalackoflandfillspace,
thecountry'sfirstC&Dwasterecyclingfacilityhasopened.

byDhruvMehta&SnehalSauravPandey
AccordingtoprojectionsmadebytheIndiangovernment'sCentralPublicHealthandEnvironmentalEngineering
Organization(CPHEEO)initsreport'ImprovingMunicipalSolidWasteManagementServices',theIndianhouse
buildingindustryaloneisfacingashortageofaggregatestotheextentof55billionm3.Furthermore,anadditional
750millionm3ofaggregateswouldberequiredtoachievethetargetsoftheroadbuildingsector.Sucha
discrepancybetweensupplyandwillleadtoincreasedpressureonnaturalresources.
Toaddressthedifferencebetweentheavailablesupplyofmaterialsanddemand,India'sInfrastructureLeasing&
FinancialServicesLimited(IL&FS)recentlysetupIndia'sfirstConstruction&Demolition(C&D)wasterecycling
facilityinBurari,NewDelhi.
Operatingatacapacityof500tonnesperday(TPD),theplanthasbeensuccessfullyprocessingC&Dwasteinto
recycledaggregateswhichcanbeusedforbrickmakingandbuildingroads.

ClicktoEnlarge

PlantDetails
IncollaborationwithMunicipalCorporationofDelhi(MCD),IL&FSEnvironmentalInfrastructure&Servicesltd(IEISL)
hasdevelopedapilotprojecttodemonstratethepotentialbenefitsofincreasingtherecyclingratesforC&Dwastein
Delhi.
TheprojectitselfhasbeensetuponaPublicPrivatePartnership(PPP)basis,whichhasprovedsuccessfulasit
servesthedualpurposeofsavinglandfillspaceontheonehandandalsodevelopingthemarketforC&D
recyclables.
ThefacilityislocatedinBurarionapproximatelysevenacresoflowandmarshylandwhichhasprovidedbytheMCD

FOLLOW US ON SOCIAL MEDIA

foraperiodof10years.

TheC&Dwasteprocessedattheplantisusedinreadymixconcreteand
otherconstructionmaterials

TacklingthelogisticsofC&Dwastesindelhi
Intheprocessingfacility,IEISLcollectssome500tonnesperdayofC&DwastefromthreedesignatedzonesinDelhi
KarolBagh,SadarPaharganjandCity.TheC&Dwasteisrecycledintoaggregatesatthewastemanagement
facilityandinturnconvertedtoReadyMixConcrete(RMC),pavementblocks,kerbstones,andconcretebricks.So
farIESLhascollectedapproximately450,000tonnesofC&Dwasteoveraperiodof22months.
A175metrelongroadconnectsthegatetothemainroadsouthoftheplant.Internalperipheraltracksdevelopedto
facilitatethesustainedmovementofloadedvehiclestotheweighbridgeinallweatherconditions,andfurthertothe
unloadingareasfollowedbytheirexittothemainroad.ThebuildingsconformtotheIScodestandards.
IEISLoperatesandmaintainsanoptimumnumberofvehiclesinaccordancewiththeprevailingdemandfor
collectionandtransportationserviceswithinthedesignatedareas.ThevehiclesareequippedwithGPSsystemto
tracktheirmovementonacontinuousbasis.Asingleshiftrunningfrom9pmto6amisusedforthemovementof
wastefromdesignatedareastotheplant.
Theaverageloadcarryingcapacityofadoubleaxeltippertruckis15tonnesandthatofasingleaxletippertruckis
ninetonnes.
Sevensingleaxleandfivedoubleaxeltippertrucksarecurrentlybeingused.Eachtippertruckmakesfourtripsper
shiftwhereoneroundtripisapproximately40km.Theplantisdesignedtoworkintwoshiftsi.e.16hoursaday,
operating330daysinayear.
AnMCDrepresentativeispresentatthetimeofloadingtheC&Dwasteandadigitalweighbridgeweighsthe
tonnageofwastereceivedattheplant.Furthertothis,avideosurveillancesystemhasbeeninstalledattheplantand
bothrealtimeandrecordedfootagecanbeaccessedandviewed.
The30tonnecapacityweighbridgeisusedtomaintainanelectronicdatabaseofthedetailsofeachconsignment
receivedatthesite.

Tomeetitsroadbuildingobjectives,Indiawouldrequireanadditional
750millionm3ofaggregatesCredit:Drajay

WORKINGPROCESS
Astationarycrushingunithasbeeninstalledfordryprocessingofwaste.Ithasacapacitytoprocessupto60tonnes
perhourofC&Dwaste.Awetprocessingsystemknownas'CDEC&Dsystem'isalsoinstalledtoextractsoilfromthe
unprocessedsoilandplasterrejects.
UponarrivalthemixedC&Dwasteneedstoundergomanualsegregationtosegregatethewasteintowholebricks,
bigconcretepiecesandmixedC&Dwaste.Alllargesizedpiecesareresizedto200mmto400mmbyboth
mechanicalandmanualmeans.
TheresizedparticlesandthemixedC&Dwastearethenfedtoahopperwhichisequippedwithavibratinggrizzly
feeder.Thegrizzlyfeaturesa60mmopeninggridforbatchprocessing.The<60mmfractionissentdirectlyforwet
processing,whilethe>60mmfractionissenttothecrusherforsizereduction.

WholebricksandconcretepiecesareseparatedfromthemixedC&D
wastewhenitarrivesatthefacility

Washingmachines
Thewetprocessingunitconsistsofagrizzly,alogwasher,vibroscreens,anEvowashsandwashingmachineanda
thickenerwhichiscapableofsegregatingsandfrommixedC&Dwaste.Theprocessingsystemisdesignedforafeed
capacityof60tonnesperhour(TPH)andsandwashingcapacityof40TPH.Thestaticfeedconveyordelivers
materialtoaprescreenforremovalof3mmandbelowparticles.Theprescreenmaterials(<3mm)reporttothesump
forfurtherprocess.
Materialfromthegrizzlyisfedtothelogwasherwhereitundergoesintensescrubbinginwetconditionswhich
removeslightcontaminantssuchaswood&plastic.Thewateraddedalongthefeedtothemachinehelpsloosen
particlesadheringtothelumpsofwasteandtherepeatedtumblinginthemachinereleasesthefineslime.Thewaste
exitingtheprocessisthensentforfurtherprocessing.
RinsingandResizingscreensareusedtosizeaggregates.Threedeckprogradescreenequipmentisusedfor
screeningandgrading.
Thescreenisprovidedwithahighpressurejetwashingsystemineachdeckwhichensuresthoroughrinsingofthe
materialandremovesmostofthefinesunder3mmfromthefeed.
Thewashedoversizematerialfromthetopdeckofscreenformsthe>20mmproductandthatfrommiddledeckforms
the10mmto20mmproductandthatfromthebottomdeck3mmto10mmproduct.
The>20mmmaterialissentbackintothecrusherforfurthersizereductionand<3mmmaterialissenttothe
Evowashforfurtherrecovery.TheEvowashisusedtoremovemostofultrafinesoutofthesystemasclay.The
overflowfromthesystemisfedintotheaquacyclehighratethickeners.
Heredensesludgeofcircaisaddedtoaidsettlementofsludge.Therecycledwaterisreleasedfromthethickenerto
thewatertank.Thesettledsludgeissenttothefilterpresswhichseparatesthesandsolidfromtheliquidwater.

Awarenessofgoodrecyclingpracticesareslowlygainingtractionin
Delhi,andmorefacilitiesareplanned

Newfromold
Afterseparationofthesolidsfromtheliquid,allaggregatesofmixedC&Dwastearecrushedtoasmallersizewith
thehelpofVerticalShaftImpactor(VSI),alsoknownassandmakingmachine.Thematerialiscrusheduntilthe
desiredfinenessisobtained.
Similarly,aggregateproducedfromtheconcretepiecesintheC&Dwasteissenttoabatchingplantforthe
productionofRMC,whichcanthenbeusedinnonloadbearingstructures.Thusawidevarietyofprecastproducts
canbeproducedbyusingrecycledC&Dwasteasarawmaterial.Todate362,244tonnesofC&Dwastehasbeen
collected,ofwhich92,700tonneshasbeenprocessedandusedforthedevelopmentoftheplantsite,54,912tonnes
hasbeenusedtodevelopSunahariandBarapullaNallah,153,000tonneshasbeenusedtoproducematerialssuch
aspavementblocksandkerbstones.Theremaining61,332tonneshasyettobeprocessed.

ClicktoEnlarge

ProjectCost
Thecapitalinvestmentforthisplanthasbeenestimatedtakingintoconsiderationthelatestmanufacturingcostand
thecostsoftheequipmentandmaterials.IEISL'scommitmenttotheprojectis$3.32millionoutofwhich$2.21million
hasalreadybeenspent.
The$3.31millionofexpenditureconsistsof$1.18millionofcapitalinvestmentand$1.01millionofworkingcapital.
Thecapitalexpenditureincurredbytheprojectisproposedtoberecoveredoveraperiodof10yearsbyderiving
valuefromtheprocessedC&Dwaste.

Conclusion
TheamountofC&DwastegeneratedinIndiaistremendous.Recyclingthiswastewouldnotonlyleadtoreduced
pressureonthenaturalresourcesbutwouldalsoleadtomassemploymentinthewastesector.Eventhoughthe
projectisstillatanearlystage,C&Dwasterecyclingpracticesareslowlygainingawareness.TheplantatBurarihas
provedtobeasuccess.Asaconsequence,thecompanyissettingupitsoperationsinEastDelhiandGurgaonas
well.
DhruvMehtaandSnehalSauravPandeyarestudentsinEnvironmentalEngineringatDepartmentofEnvironmental
Engineering,DelhiTechnologicalUniversityandrecentlycompletedaresearchprojectattheBurariC&Drecycling
facility.

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