Nothing Should Go Waste
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1 Nothing Should Go Waste Mailhem Engineers Pvt. Ltd. Keywords: Biogas, Pune Municipal Corporation, Biomethanation, Power Generation, UASB, Waste to Energy, Renewable energy Ab s t r a c t Waste to Energy is a Renewable and Clean energy resource and it has very strong positive trait, "Healthy Environment". The paper concentrates on problem of Municipal Solid Waste generation and the dumping of the waste in landfill. Mailhem had always been with the philosophy of "Nothing Should Go Waste". Hence, waste is considered as resource rather than a problem. Problem is analyzed and all alternative solutions are taken in account, Biogas generation through Anaerobic Digestion found to be appropriate solution. Mailhem has set up Biogas Plants of different capacities based on various substrates all over India and few abroad. These Biogas Projects are based on Mailhem's "Modified UASB Anaerobic Digester" Technology and the biogas generated is used for several applications such as cooking, heating and power generation. Pune Municipal Corporation (PMC) has taken a lead in setting up of Decentralized Waste Treatment Projects all over the city. These decentralized waste treatment projects are biogas based power generation projects. Mailhem has been successfully operating such projects since 2010 and thus contributing to the Green Initiative taken by PMC for reducing Solid Waste Pollution & Green House Gas emission. Keywords: 1. Introduction We, Mailhem are pioneers in the Biomethanation field especially in Organic Waste Management for more than a decade and ISO Certified for Waste Management. Our philosophy is based on the dictum that "Nothing Should Go Waste" and that all organic waste products should be put to such a good use, so as to give you good returns in terms of Biogas and Organic Manure. We have extensive experience of installation and operations, having established large number of Waste Management plants throughout India. (Mailhem Brochure and Brief Company Profile are attached as Annexure I) Pune Municipal Corporation (PMC), an early mover in systematic and scientific treatment of solid waste generated in residential & commercial establishments, has implemented waste segregation at source and has implemented various treatment schemes for the solid waste thus collected. Treatment of bio - degradablcuse 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. PMC has got 3 such bio gas generation plants designed, supplied and installed by Mailhem Engineers Private Limited. Two of these plants (Aundh & Yerawada) have been commissioned and are being operated and maintained by Mailhem Engineers Private Limited. Third plant in the series is presently under commissioning at Katraj. Nothing Should Go Waste 1
2 Aundh Biogas Plant for Power Generation Biogas Power Generation Plant, Katraj 2 Mailhem Engineers Pvt. Ltd.
3 2. Tribulation Municipal Solid Waste generation in Pune is among the highest in Indian cities with average kg ( kg per person per day) of waste being generated per person per day. Currently, about metric tons solid waste is generated per day. In the recent years, the unhygienic and unscientific disposal of solid waste has led to garbage overflow, due to which an increase in the Environmental & Social nuisance has been noticed such as bad odour, stray animals, flies/ mosquitoes and outbreak of diseases such as Swine flu (H1N1), Malaria, which became a grievous concern / complaints for the local people residing in the Aundh area Analysis Everyday approximately 1200 tones of unsegregated solid waste made its way from Pune to Uruli Devachi. The basic operations can be divided into: Primary Collection Household collection by Waste pickers integrated into the Municipal system Ghanta Trucks system Secondary Collection Containers and Dumper Placers system Compactor Buckets and Compactors system Tertiary Transport to the garbage dumpsite at Uruli Devachi Transfer Stations and Bulk Refuse Carriers (BRCs) Hence, an effort was undertaken by local residents of Aundh area along with the Aundh mohalla committee and local NGO's parties (PPP -Public Private Partnership) to come under one roof and discuss the problems associated with the disposal of solid waste and their possible solutions. An awareness campaign was organized by the Pune Municipal Corporation, Aundh in which pamphlets / fliers (printed both in Vernacular and English language), Media (Radio and Television) to educate the common masses regarding safe, hygienic & scientific treatment and management of solid waste. 3. Tools and Techniques The source wise broad composition of solid waste generated in the city is Recyclable waste, Bio-medical waste and Biodegradable waste (Hotel & Restaurants, Vegetable Market, and Kitchen). Organic and bio-degradable Nothing Should Go Waste 3
4 portion of solid waste is 60-70% and therefore contributes significantly in solid waste generation. Different treatments methods used for waste degradation are: a. Vermi-composting - Suitable for Residential organic waste treatment. b. Organic Composting - Suitable for Garden waste treatment. c. Biogas - Suitable for Hotel & Restaurant waste treatment. 4. Implementation and Results 4.1 Project Description Pune Municipal Corporation is the pioneer in motivating the citizen for setting up scientific decentralized disposal of solid organic waste & thus the ward wise decentralized biogas plant was set up in Aundh. In this plant, 5 Tons of pre segregated organic (wet) garbage is shredded through mixers and converted into slurry. This slurry is then fed to the primary digester where it under goes hydrolysis for certain days. The hydrolyzed slurry internally travels from primary to secondary digester for further bio-methanation process. The two step digester (Primary + Secondary) is a compact construction in RCC. The gas generated is collected from top, the clear liquid over flow is used for slurry preparation and the small quantity of bottom sludge is dried & occasionally disposed off as organic manure. The gas generated at Aundh plant is fed to a generator to produce electricity for powering the street lights in the vicinity Benefits at User's end a. Reduces cost of transportation of wastes to the Landfill site, which is a normally located outskirt of the city. b. Waste Management - collection & transportation of segregated wastes in a decentralized manner can be achieved and monitored more effectively. c. Besides treatment of mix of organic wastes, it generates Biogas which can be utilized as source of energy and manure as a fertilizer. d. Decentralized Biogas plants require less, aesthetically good looking and completely air tight - thus reduction in odor, vermin, etc. e. Reduced greenhouse gas emissions, avoids the release of methane gas. f. Reduction of pathogens and weed seed in the waste applied to land. g. This will help in avoiding release of methane gas, from such uncontrolled open 4 Mailhem Engineers Pvt. Ltd.
5 Some Executed Projects 20 ton/day Potato waste based biogas plant at ITC Foods Ltd., Ranjangaon, Pune, Maharashtra, India. (Equivalent to 40 ton/day of food waste plant) Demonstration Power Generation Project for Municipal Corporation, Vijaywada Nothing Should Go Waste 5
6 Power generation project from treatment of 6TPD Segregated Organic Food/Canteen Waste Tata Motors Ltd., Pune, Maharashtra, India 3000 kg/day Biogas Plant at Wipro Technologies Ltd., Bangalore, Karnataka, India 6 Mailhem Engineers Pvt. Ltd.
7 4.1.2 Note a. Biogas generation is directly proportional to the input waste. The ROI has been calculated on the assumption that segregated organic waste will be fed to the biogas plant. b. 80% accelerated depreciation is available in the year of installation. The effect of this has not been taken into account while calculating ROI. c. Environmental impact due to neat and clean means of disposal cannot be quantified in terms of money. d. Government subsidies available (if any) have not been taken into account Block Diagram of Mailhem Biogas Plant Waste Management Capacity Water Organic Waste Sorting Table and Crusher Biogas Utilization System/ Biogas to flare R E C Y C L E Inlet cum Recycle Chamber Mailhem Digester Liquid Organic Overflow Discharge Biogas Storage Periodic Organic Manure Removal Waste Management Plant Capacity Minimum assured biogas generation Approx. 5 ton/day of segregated food/ Canteen waste Approx. 300 cum/day Equivalent Electricity Generation Equivalent to approx. 480 Electrical units / day (50 KW Engine for 8 to 10 hours). Organic Manure Generated Water Required Liquid Organic Overflow Approx. 165 Ton per annum Approx lit/day Approx lit/day Area Required For Waste Management Plant Approximately 300 sq. m. (20 x 15 m) Nothing Should Go Waste 7
8 4.1.5 ISO Implementation It has enhanced the Quality Policy of the plant. All the reports are documented and maintained effectively. Following records are maintained: a. Daily Log sheet b. Equipment maintenance sheet c. Breakdown and Repairs Sheet d. Yearly Preventive Maintenance Schedule Bar Code System A Bar Code System will be maintained to keep a track on segregation of waste. 4.2 Results (The detail data is attached as Annexure 2) Weeks Vs. Waste (Ton) Waste (Ton) Week 1 Waste (Ton) Week 3 Week 5 Week 7 Week 9 Week 11 Week 13 Week 15 Week 17 Week 19 Week 21 Week 23 Week 25 Week 27 Week 29 Week 31 Week 33 Week 35 Week 37 Week 39 Week 41 Week 43 Weeks The average of all the 43 weeks was 4.46 ton. Note: Week 1st starts at and Week 43rd ends at Mailhem Engineers Pvt. Ltd.
9 PORTABLE ORGANIC WASTE TREATMENT PLANTS SEED, Nepal EPSM, Malaysia Nothing Should Go Waste 9
10 Interloop Ltd., Pakistan Hindustan Aeronautics Ltd., Bangalore 10 Mailhem Engineers Pvt. Ltd.
11 Weeks Vs. Biogas (Cum) Biogas (Cum) Week 1 Week 3 Week 5 Week 7 Week 9 Week 11 Week 13 Week 15 Week 17 Week 19 Week 21 Week 23 Week 25 Week 27 Week 29 Week 31 Week 33 Week 35 Week 37 Week 39 Week 41 Week 43 Biogas (Cum) Weeks The average of all 43 weeks was Cum. Note: Week 1st starts at and Week 43rd ends at Weeks Vs. Electrical Unit Electrical Unit Week 1 Week 3 Week 5 Week 7 Week 9 Week 11 Week 13 Week 15 Week 17 Week 19 Week 21 Week 23 Week 25 Week 27 Week 29 Week 31 Week 33 Week 35 Week 37 Week 39 Week 41 Week 43 Weeks Note: Week 1st starts at and Week 43rd ends at Significance of Solution 5.1 Transportation Due to the implementation of decentralized Biomethanation Plant, the organic waste generated in Aundh area is going to be processed and disposed off Nothing Should Go Waste 11
12 within the local area Considering the 500/- per ton of waste and operating period of 330 days, PMC has Rs Lakhs annually in transportation. 5.2 Electricity The produced biogas is used to generate electricity for lightening the street lights of Aundh vicinity & running the biogas plant. Considering the operating period 330 Rs. 5.5 per Electrical Units, about 1,58,400 Electrical Units, PMC has Rs Lakhs annually. 5.3 Organic Manure The settled sludge is used as Organic manure which is used as a fertilizer/soil conditioner for their public gardens. Considering the operating period 330 Rs. 3 per Kg, about 1,58,400 Electrical Units, PMC has Rs Lakhs annually.cost EFFECTIVENESS: (considering 330 days per year) for 5 TPD Biogas Plant, At Aundh. 5.4 Return of Investment Description Annual Income 1. Saving in electricity in lieu of biogas 1,58,400 Electrical Unit per Rs.5.5 per Electrical unit 2. Savings by use of 165,000 kg/annum of good quality organic Rs. 3/kg 3. Savings in transportation of 1650 ton per annum of waste Rs.500/ton In INR 8,71,200 /- 4,95,000 /- 8,25,000 /- Annual Expenditure 4. Expenses toward deployment of operator to operate biogas plant per annum - 4 operator A TOTAL INCOME per annum (approx.) 21, 91,200/- 4,32,000/- 6. Electricity estimated to be consumed 13,200 Electrical Rs.5.5 per Electrical Unit. 5. Consumables (including lubricants, etc.) per year 10,000/- 72,600/- B TOTAL EXPENDITURE per annum (approx.) 5,14,600/- C Total Investment including estimated civil cost but exclusive taxes / duties for biogas plant Payback period (approx.) A - B Total Income - Total Expenditure 16,76,600/- 49,32,720/- 2.9 years 6. Conclusions Treatment of mix of organic wastes, it generates Biogas - which can be utilized as source of energy and manure as a fertilizer Reduced greenhouse gas emissions. Reduction of pathogens and weed seed in the waste applied to land 12 Mailhem Engineers Pvt. Ltd.
13 Lessons Learnt Transportation Earlier all the solid waste generated in Pune was transported at Uruli Devachi which is about 20 km from Pune. The cost incurred for collection and transportation was more, but now the same has reduced to a considerable amount, after the successful installation of the Biogas plant. Waste Segregation Initially, unsegregated waste was received at biogas plant site, but since biogas plant can only accept organic waste, the segregation need to be done at plant site. Man power has to be employed to segregate the dry and wet waste. Now, PMC has made mandatory for all the residents to segregate the waste, as a result, cost incurred for segregation has decreased. Weekwise Data on Waste Week Waste (Ton) Average Biogas ( Cum) Average Electrical Unit Average Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Nothing Should Go Waste 13
14 Week Waste (Ton) Average Biogas ( Cum) Average Electrical Unit Average Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Week Maximum Minimum Mailhem Engineers Pvt. Ltd.
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