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Hyderabad Integrated MSW

Limited(A wholly owned subsidiary of REEL)

2nd International Conference on

ENHANCED USAGE OF ALTERNATE FUELS ANDRAW MATERIALS IN CEMENT INDUSTRY: RDF UTILIZATION IN CEMENT PLANTS WITH ISSUES AND CONCERNS ON RAMP UP

ByVarun Dilip Boralkar, Head (Processing & Disposal)

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Hyderabad Integrated MSW Ltd. (Ramky Enviro Engineers Ltd.)

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Hyderabad Integrated MSW Project Background

Hyderabad City

• State Capital of Telangana

• 400 Years Old

• 6th largest metropolis in country.

• Population of around ~8.5 million

• Area of ~ 625 Sq.Kms

Greater Hyderabad Municipal Corporation

• Formed in 2007

• 5 Zones, 18 Circles, 150 Wards,

• Present waste generation in GHMC limits is > 4000 TPD

Project Details• India’s Largest IMSWM Project in PPP Mode (Brownfield Project)

• Duration of CA is for 25 years

• Design Capacity of 4000TPD

• 3200TPD of MSW Processed & Disposed

• Post-Closure maintenance for another 15 years after completion

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Project Scope (*Major)

Door to Door collection

Secondary collection and Transportation

Transfer station Management &

Tertiary Transportation

Processing & Disposal

of MSW

Remediation and closure of Existing

dumpsite

Initially

in East and West Zone

and

later cover the entire

GHMC area

Remediation, closure

of the existing 4

dumpsites

Upgrade 3 existing

transfer stations

and

construct 5 new transfer

stations

And transportation of

waste from

Transfer station to P&D

Facility

Initially

in East and West Zone

and

later cover the entire

GHMC area

Integrated MSW

Management Project

To establish 4 integrated

waste

P&D facilities

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Main Entrance Gate Weighbridges

Admin block

Cafeteria

Plastic Recyclable plant

Material Stores

Pre sorting section Monsoon & Curing Shed

RDF Plant

Leachate Treatment Plant

Landfill Solar PondRDF Storage

Dump Capping Plantation & Greenbelt

Conformance Hall

INFRASTRUCTURE AT JAWAHANAGAR PLANT

Windrow Platform

D.G. Room & T. Yard

Service Workshop

Laboratory

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waste received in tipping floor 100 mm Screening

Recyclables

Removal

Windrow Composting

Primary Screening

35mm

Secondary Screens

16mmCuring

Screening

(4mm)

Rejects RejectsGas &

MoistureRejects

Moisture and Gaseous loss

RDF

Sand

Separation

Sand

Sanitary Landfill

COMPOST

Current Operations

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• Abrupt end to the RDF based waste to energy plant at Timarpur,

Delhi gave birth to India’s RDF research

• The Dept of Science & Technology , GoI had taken up the task of

developing a prototype facility of RDF out of MSW to add value

addition to the SWM operations

• A pilot plant at a cost of Rs 40 Mn was set up in Deonar land fill

site in Mumbai with Govt funding for making out RDF in Fluff &

Pellet form which became functional in 1992 and was dismantled

in 2000.

• The pelletization technology was transferred to RDF based

Power plants at Vijayawada & Hyderabad .

• The two power plants are built with soft loans from Government of

India {and concluded OTS on 29/7/2011}

Refuse Derived Fuel – Indian Perspective

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RDF Specifications ASTM E 856-83 (2006)

RDF 1 Waste in as discarded form

RDF 2 Waste separated to coarse size with or without Fe separation and 95% by wt% passing through 150 MM

RDF 3 Waste processed to separate glass/metals and shredded to pass through 50 Mm Screen (Fluff)

RDF 4 Combustible waste processed into powder passing through 10 MM screen

RDF 5 Combustible powder processed into pellets/briquettes

RDF 6 Processed into Liquid form Slurry

RDF 7 Processed into gaseous fuel

Feasible

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RDF in Cement Industry

• Cement is high Energy intensive industry.

• RDF is the best Alternative Fuel option for Cement Industries in terms of

volume & quality.

• To achieve any significant TSR, RDF will have play paramount role in India

• MSW and RDF generation is a sustainable and consistent alternate fuel

source

• Cement Industries pose as a partial MSW disposal option however pre-

processing and economic viability for manufacturer a must

• Advantages

1. High temp & residence time for destruction of fugitive emissions

2. Alkaline environment to neutralize HCL

3. Pre-calcination zone temp ranges up to 1000 Deg C

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HIMSW RDF Plant Pictorial Representation

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RDF Quality Specifications

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RDF Parameters Specifications

Calorific Value NCV : 2700-3100 Kcal/Kg

Moisture Content <20-25%

Chlorine Content < 1% by Wt

1212

Aug Sep Oct Nov Dec Jan Feb

RDF Despatch in MT 30 532 521 1052 1310 1350 2000

30

532

521

1052

1310

1350

2000*

0

500

1000

1500

2000

2500

RDF Despatches from HIMSW for FY 15

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Issues in Ramp Up: Our experience

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• Different Feeding mechanisms size sensitive and require different size of material

• Pneumatic System: Fine shredded with 30-50mm sieves

• MultiFlex System: <75-150mm Pre-shredded

• Hot Disc System: Size not a restriction; preferably pre-shredded

• Biomass Feeding Systems: Fine shredded 30-50mm sieves

• Level of shredding defines variation in product (not CV)

• Each system needs different processing line

• Can RDF manufacturer afford it?

• Who should put a process line first?

• RDF Manufacturer or Cement Plant?

• RDF manufacturer is not assured of off take by cement plant after establishing a

process line

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Issues in Ramp up: Our experience

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• Process stabilisation a major aspect

• Both at MSW Processing and Cement plants

• Heterogeneous nature of waste causes inconsistent quality of

RDF (Size and Moisture): Cement and Waste Management both

have to support each other

• Social stigma attached to waste a deterrent for cement industries

in handling the final output

• Clarity required on RDF usage and trans-boundary movement in

Co-processing guidelines

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Issues in Ramp up: Economical

• HIMSW despatches RDF at a financial loss on operating level

• Requirement of customised product for each cement industry,

economically not feasible

• Product specific capex needs to be shared by cement industries

• Multilevel shredding increases opex without value addition

• Size reduction does not add value CV wise; increases logistics

cost as density is lower

• Drying Mechanism capex and opex intensive

• Air density based segregation for removing HDR such as stones is

a high energy consuming process

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Conclusions and Way Forward

• Technology Platform: Cement and Waste management companies

need to partner for sustainable RDF production and consumption

• By minimum off take agreement

• Financial partnership preferable

• Market Development: Synergy between Waste management

companies and Cement industries for better market prospects of RDF

• Perseverance is required to achieve required quality of RDF, ~ 6 months

• Regulators Facilitation: ULB’s & cement industries in proximity of

each other to implement RDF production & consumption systems,

respectively. Facilitation between ULB, Cement Industry and

Operator.

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Opportunities

• Delhi MSW Solutions Ltd., NDMC, Narela Bawana (1500TPD)

• Hyderabad Integrated MSW Ltd. (3300TPD)

• Belgaum and Shimoga, Karnataka (300TPD)

• Katni & Sagar, Madhya Pradesh (300TPD)

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Ramky willing to partner with prospective RDF

consumers

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