HEM is GOLD. We have the Midas Touch in CONVERTING WASTE TO GOLD IN SANSKRIT. Col (Retd.) K C Achappa Vice President.

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1 NOTHING SHOULD GO WASTE Biogas Plant -A Quality Project by Col (Retd.) K C Achappa Vice President Mailhem Engineers Pvt. Ltd. India Disposal of Waste at it s Source of Generation MAILHEM GROUP IN SANSKRIT MAIL is WASTE HEM is GOLD We have the Midas Touch in CONVERTING WASTE TO GOLD Typical View of Mailhem Biogas Plant Biogas Plant at Aundh Ward, Pune Biogas Plant at Aundh Ward, Pune Biogas Plant at Aundh Ward, Pune 1

Salient Features of MAILHEM Biogas Plant at Aundh, Pune Plant Capacity Biogas Generation Total Electrical Units Organic Manure Generated Water Required 5 Ton per day Segregated Wet waste from

2 Salient Features of MAILHEM Biogas Plant at Aundh, Pune Plant Capacity Biogas Generation Total Electrical Units Organic Manure Generated Water Required 5 Ton per day Segregated Wet waste from Households, Hotels, Hostels, Canteens and Fruit & Vegetable Markets in Aundh ward. Approx. 300 Cum/day Electrical Units/month 50 kva genset run for Hrs. daily Approx. 165 Ton per annum Approx. 5 Cum/day CUSTOMER AND QUALITY FOCUS Liquid Organic Overflow Approx. 5 Cum/day Area Required 300 Sq.m. (20 m x 15 m ) Payback Period 4.5 Years QUALITY IMPROVEMENT WASTE COLLECTION SYSTEM: IN AUNDH Overflowing Garbage Waste Dumped in open places CRUSHING: Manual Cutting of waste Unhygienic conditions Frequent fire and health hazards Segregated waste receiving platform constructed Neat and hygienic Safety precautions taken by the waste collectors At the sorting table, mechanized shredders are used to crush the waste into slurry Personnel Protective Equipment used Sorting table DIGESTER: Digester overflow : Floating Dome Digester Foul smell around the area Life cycle only 5 years. slurry directly flowing in open drains unhygienic disposal Air tight digester covers constructed in RCC with MS reinforced FRP top cover. Life cycle now 20 years No foul odour Digester The slurry from the digester will be dewatered in the Liquid Manure Tank (LMT) using bag filters Compost is directly used by Garden Dept of PMC. Slurry handling system using bag filters 2

02/05/2012 BIOGAS CLLECTION & STORAGE SYTEM: The top part of a fixed-dome plant (the gas space) must be gas-tight. Concrete, masonry and cement walls are not gastight.

rodent proof, non explosive Biogas Balloon Generated Biogas is cleaned in Biological Scrubbers. Biogas will be automatically flared if there is excess gas production or during breakdowns / shutdowns.

Unaesthetic surrounding Bad Odour from piled up garbage Stray animal & Flies / Mosquito Outbreak of diseases.

Decided to go for Decentralized Disposal of Solid Waste to implement the waste segregation at source.

3 02/05/2012 BIOGAS CLLECTION & STORAGE SYTEM: The top part of a fixed-dome plant (the gas space) must be gas-tight. Concrete, masonry and cement walls are not gastight. BIOGAS CLEANING AND UTILIZATION SECTION: There was no Biogas cleaning / utilization system, biogas let off Biogas stored in Biogas Balloon with enclosure These balloons can be automated, UV proof, rodent proof, non explosive Biogas Balloon Generated Biogas is cleaned in Biological Scrubbers. Biogas will be automatically flared if there is excess gas production or during breakdowns / shutdowns. Scrubber Flare DIAGNOSTIC APPROACH DIAGNOSTIC APPROACH Meeting was held between Aundh Mohalla / Society and Local NGO s to discuss the common grievances such as:- Open dumping / overflow garbage Unaesthetic surrounding Bad Odour from piled up garbage Stray animal & Flies / Mosquito Outbreak of diseases. Awareness Campaign was organized by PMC and local NGO s to educate the common masses regarding safe and hygienic disposal of solid waste INDENTIFICATION OF PROBLEMS & THEIR SOLUTION (Continues) Decided to go for Decentralized Disposal of Solid Waste to implement the waste segregation at source. Treatment of Bio degradable municipal solid waste to generate combustible gases (which can be used either as fuel in Kitchen or as fuel for generating power), was one of the early initiatives taken by the corporation. Opinion from various industry experts was taken METHODOLOGY DEPLOYED BIOMETHANATION The MAILHEM Way DECENTRALISED TREATMENT OF MUNICIPAL SOLID WASTE Finally, a tender was floated to treat the Municipal Solid Waste (MSW) 5 TPD, which was awarded to M/s Mailhem Engineers Private Limited. 3

QUALITY TESTS CONDUCTED DURING CONSTRUCTION Sr. No. NAME OF EQUIPMENT A) CIVIL EQUIPMENT TESTED AS PER STANDARDS 1. Geotechnical Soil Testing IS : 2386 1963 Part - I 2.

Index Properties of Soil IS: 2720 (Part 5) - 1985 IS: 2720 (Part 6) 1985 IS: 2720 (Part -3) -1980 IS: 2720 (Part 40) - 1977 IS: 1498-1970 Sr. No.

flow accepted in accordance with BS ISO 1217:1996 3 All pumps IS:9137 CLASS-C 4 All Motors Induction motor for 3 phase IS 325 / 1996 IS 325 / 1196 ISO 9001:2008 We have the rare distinction of being

4 QUALITY TESTS CONDUCTED DURING CONSTRUCTION Sr. No. NAME OF EQUIPMENT A) CIVIL EQUIPMENT TESTED AS PER STANDARDS 1. Geotechnical Soil Testing IS : Part - I 2. Cement IS: 1489 (Part 1) : Concrete Cube IS / / IS: Index Properties of Soil IS: 2720 (Part 5) IS: 2720 (Part 6) 1985 IS: 2720 (Part -3) IS: 2720 (Part 40) IS: Sr. No. QUALITY TESTS CONDUCTED FOR BOUGHT OUT ITEMS / EQUIPMENT NAME OF EQUIPMENT TESTED AS PER STANDARDS 1 TMT, Steel Bars IS 1608 : 2005, IS 1599 : 1985 (Reaffirmed 2002, IS 1786 : 1985) 2 All Blowers Air flow accepted in accordance with BS ISO 1217: All pumps IS:9137 CLASS-C 4 All Motors Induction motor for 3 phase IS 325 / 1996 IS 325 / 1196 ISO 9001:2008 We have the rare distinction of being ISO 9001 : 2008 and CRISIL rated specifically for Waste Management Projects. IMPLEMENTATION OF QUALITY POLICY 1. DAILY LOG SHEET 2. EQUIPMENT MAINTENANCE SHEET: Weekly, monthly and Annually 3. BREAKDOWN AND REPAIRS SHEETS 4. CUSTOMER SATISFACTION REPORT / VISITOR REPORTS 5. FEED BACK REPORTS 6. PERIODIC QUALITY INSPECTION REPORTS 7. ENVIRONMENT, HEALTH AND SAFETY AUDITS 8. PERIODIC SAMPLING FOR ALL PROCESS PARAMETERS MAILHEM S AUNDH BIOGAS PLANT IN THE NEWS!!! FINANCIAL BENEFITS 4

Sr. No. A RETURN ON INVESTMENT (ROI) considering 330 days DETAILS AMOUNT (` ) ANNUAL INCOME 1. Saving in electricity per annum 8,71,200 2. Savings by use of good quality organic manure 4,95,000 3.

5 Sr. No. A RETURN ON INVESTMENT (ROI) considering 330 days DETAILS AMOUNT (` ) ANNUAL INCOME 1. Saving in electricity per annum 8,71, Savings by use of good quality organic manure 4,95, Savings in transportation of 1650 ton per annum of waste 8,25,000 TOTAL INCOME per annum (A) 21,91,200 B ANNUAL EXPENDITURE 1. Operation & Maintenance cost 5,42, Captive electricity consumption 72,600 TOTAL EXPENDITURE per annum (B) 6,14,600 TOTAL INCOME TOTAL EXPENDITURE (A - B) 15,76,600 C Total Investment including PMC Dept work 70,00,000 D PAYBACK PERIOD 4.5 Years Additional Financial Benefits to PMC.. 80% accelerated depreciation is available in the year of installation. Environmental impact due to neat and clean means of disposal s cannot be quantified in terms of money. Impact of Subsidy by MNRE (GOI) and Carbon Credits has not been taken into account BENEFITS FOR PUNE MUNICIPAL CORPORATION Generated wastes can be treated and disposed off locally and therefore increase operating life of Sanitary Land Fill site. Reduces cost of transportation of wastes to the Landfill site, which is a normally located on outskirt of the city. SUSTAINABILTY & APPLICABILITY IN OTHER AREAS Waste Management collection & transportation of segregated wastes in a decentralized d manner can be achieved and monitored more effectively. The treatment of mixed wastes results in bi-products biogas and fertilizer. Decentralized Biomethanation plants require less space and are aesthetically good looking. SUSTAINABILITY OF THE PROJECT DUE TO Good returns on investment for PMC open dumping of waste is avoided Reduced transportation cost to PMC Scientific and hygienic disposal of waste at its source of generation 5 years O & M contract with penalty clauses built into the contract document ensures continuous functioning Pune Municipal Corporation (PMC) has already got 3 such Biogas Generation plants designed, supplied and installed by M/s MAILHEM ENGINEERS PRIVATE LIMITED: Pune Municipal Corporation, Aundh Ward Pune Municipal Corporation, Yerawada Ward Pune Municipal Corporation, Katraj Ward Applicability in Other Areas (Contd ) Seeing the success of PMC (Aundh, Yerawada & Katraj) biogas plants, PMC has now floated another tender for setting up 15 more biogas plants. Mailhem has bagged 8 out of these 15 projects and they are in various stages of execution. This decentralized model will soon be replicated in Bangalore, Kolkatta, Kerela and Gujrat in the near future. 5

Sustainability and Applicability in Other Areas (Contd ) Sustainability and Applicability in Other Areas (Contd ) Pune Municipal Corporation Plant Katraj, Pune Pune Municipal Corporation Plant

6 Sustainability and Applicability in Other Areas (Contd ) Sustainability and Applicability in Other Areas (Contd ) Pune Municipal Corporation Plant Katraj, Pune Pune Municipal Corporation Plant Katraj, Pune Sustainability and Applicability in Other Areas (contd ) The same technology has been successfully implemented for treatment of : Canteen Waste Slaughter house Waste Hotel Waste Starch Effluent Waste Vegetable & Market Yard Dairy Effluent Waste Waste Leather Shaving Waste Fruit & Flower Market Yard Sewage Grey Water Sludge Food Processing Waste from STP Combined Sewage (Grey Unique Combined Sewage & Water) & Canteen Waste MSW Treatment for Municipal Bodies Poultry Waste EXISTING PLANT LOCATIONS Faisalabad, Pakistan Sirohi Kinnaur, HP Delhi Mundra Ahmedabad Surat Nashik Mumbai Pune Belgaum Goa Vaishnav Devi, J & K More than 250 plants installed and many more in pipeline. Kathmandu, Nepal Ranchi Dewas Rewa Bela Rajnandgoan Bhubaneswar Waste Management Plants Vijayawada Mailhem Head Office Hyderabad Mailhem Export Orders Mangalore Bangalore Mandya Dijibouti, Africa Cochin Chennai Thiruvanthapuram Malaysia *Map not to scale Mailhem Engineers (P) Limited 14, Vishrambaug Society, 2 nd Floor, Opposite International ti Convention Centre, Senapati Bapat Road, Pune, Maharashtra, INDIA Tel : , , Fax : marketing@mailhem.com URL : 6

Municipal Solid & Liquid

Municipal Solid & Liquid Waste Management by Lt. Col. Suresh Rege (Retd.) Executive Director Mailhem Ikos Environment Pvt. Ltd. Delivering Sustainable Solution for Generating Green Energy Since 1995 MAILHEM