OUR MISSION
2005
CLEAN INDIA
GREEN INDIA




Presentation On

MUNICIPAL SOLID WASTE MANAGEMENT

September 18nd 2004


Organized by

The Clean Kerala Mission


At

Trivandrum


Title of paper:
A case study of low cost fully automatic
Eco Friendly MSW Composting/ Processing Plants
(Anaerobic & Aerobic)


By

M/s. The National Small Industries Corporation
(A Govt. of India enterprises),
S-67 G.C.D.A. Commercial Complex,
Cochin - 682 031




Workshop on eco friendly municipal solid waste management


Background:-

The rapid growth in urban population has caused tremendous increase in generation of Municipal Solid Waste (MSW) Disposal and Management of such a large amount of waste is a difficult task since the existing landfills are full up to their capacity and the new landfill sites far off the city are unaffordable due to increased transportation cost. Moreover, the landfill is responsible for land and water pollution besides creating the odour problem.

All the acts relating to the Municipal Solid Waste management all over the world declare solid waste as the ‘asset’ of the Municipal Secretaries. The term ‘asset’ has broad import because on using such term it becomes the responsibility of the Municipal Secretary to manage the same carefully. The primary duty of a person with regard to assets is to safeguard and utilize it economically. Thus although Municipal Waste is of no value to the public, it is of great value to the Municipality.

Unfortunately, some Municipalities of India and other low income countries evade their duties by encouraging the local public to process waste on their own who do not have the time and technology to do the same. As a result the wastes accumulate and remain unprocessed leading to further air, water pollution of residential areas, and wide spreading of diseases like Plague .

We find from our practical experience that processing msw is simpler compared to managing its living waste. Our humble suggestion to the Municipalities in this regard is that they change this attitude and take up their responsibilities themselves to create an unpolluted healthy environment. And we are happy to announce that, as promotional measure, We will be able to finance loan facility up to 50% of the project cost.

The thermal processes like incineration, Gasification, polarization are not permitted by the MSW act 2000 because of the formation of unwanted gases like dioxins etc, from plastic etc, which will damage the ozone layer. The external use of genetically modified bacteria’s (inoculums) are also not appreciated in the processing of compost as per the authoritative books on the subject (“Fundamentals of Compost”, “Manual for Quality Control of Bio Manures”, Bureau of Indian Standards). The Genetic Engineering Act 5th - Dec-1989 does not permit using inoculums slurry ( genetic bacteria) in compost processing.





The extent of risk factor involved in the external use of genetically modified bacteria is not yet confirmed and the marketing of such end-products will be a tedious task as it has happened in some of the already established 12 units in India including two units of Kerala.

As an industry, the solid waste processing to manufacture bio manure and allied products is an economically viable project at present. When all the Municipalities & Corporations in India get engaged in this modern method of conversion the bio-manure may become a surplus product in the market, if it happened, with in one or two years time. At that time this industry may not be attractive as it is now. So it is advised to take up this business by the concerned authorities themselves rather than giving it to private companies.

In our country the waste lands are scarce and the MSW processing is a must due to dense population state. In advanced foreign countries the MSW processing plants are installed at far away vacant lands. The nearby residents of the present Municipal Solid Waste processing plants in Kerala are facing very serious pollution problems due to the inappropriate selection of the processing technology, plants and storage procedure. For eg: storage of the MSW in the open place, implementation of wrong technology, chemicals, genetic bacteria (inoculums slurry) etc, not approved by the Bureau of Indian Standards Institution for production of compost from MSW and the crude methodology and mechanical mixing to accelerate composting process with in a period of 20 to 40 days.

Only the biological processes like composting, Vermi composting, Anaerobic Digestion and any other suitable biological processes are recommended by the MSW Act, 2000. Our plant and machinery could be used for all of the above processes












Workshop on eco friendly municipal solid waste management
Fully automatic Mechanical Compost Processing Plants( Aerobic)
For details ref: flow chart, Ref Bureau of Indian Standards: IS 9569


Introduction:-

Automated Management of Municipal Solid waste have been the subject of many researchers. From 1997 onwards as a tiny step, our company has come out with a novel idea of processing urban waste to manufacture bio-manure and better fuel, Finally we developed a plant & machinery. We have come out with Aerobic & Anaerobic composting plants approved by the Bureau of Indian Standards processes. The paper discusses about a machine and highlights salient features of the plant. Which automatically separate and remove the non-biodegradable materials like Plastic, Rubber, and Metal pieces etc, which are major threats to, the environment? The unique feature of our plant is that the plastic materials are separated by the machine itself (approx 99.5 %) The details of the plant are described in the following sections


We consider it is a viable proposal as the transportation, space requirement, and pollution hazards are minimized. This sort of decentralized units have proved to be more efficient in operation. Discouraging the total collection and storage of MSW in one place, our units are meant to process the waste in restricted total enclosed small areas, in the town itself, thereby making it economically viable and profitable. At present such units are functioning at Angyang City, in Korea (Anaerobic Plant) Vadakara, Guruvayoor, Thaliparambu, (Our prototype Aerobic Plants. This shall be restarted shortly)






The processes

The incoming Municipal Solid Waste (MSW) collected in the dumping pit moves up through the elevator buckets, and reaches the Crushing system. Then the garbage is crushed, and water is sprinkled. After this, MSW moves down to the Wet-grinding system. During the wet grinding process the bigger size non bio-degradable materials such as plastic, rubber and metal pieces etc are cleaned and separated.

After wet grinding bio-degradable materials are de-watered and mechanically shifted to the composting yards, for composting. The composting time takes 60 to 90 days. After composting the compost is pulverized and balances non-degradable are separated, and the compost ready for sale.

Definitions of compost are:-

1. Composting is spontaneous in nature. (“Fundamentals of Compost”)

2. Composting – A natural process (“Manual for Quality Control of Bio Manures”)

3. Compost: - Relatively stable decomposed organic material. (as per Bureau of Indian Standards

4. Composting:- A controlled process involving microbial degradation of organic matter. (BIS)

5. Mechanical Composting: - The process of composting involving microbial degradation of organic matter (BIS)

Benefits of Aerobic Composting

1. Low investment.

2. Sophisticated technology & processes not required.








Workshop on eco friendly municipal solid waste management
Fully automatic Mechanical Compost Processing Plants( Anaerobic)
(As per Bureau of Indian standards Ref: IS 9569, IS 12986, IS 9478) Ref: flow chart

The main attraction of bio methanation technology is the energy-generating gas during process of treatment, which is a good source of revenue, so that they prove to be commercially viable.

Anaerobic decomposition (which occurs naturally) reduces the pollution, Anaerobic bacteria produce Methane and Carbon dioxide, both “greenhouse” gases. The mixture is often called “biogas” because of its biological origin.
Putrefactive breakdown of organic material takes place anaerobically. Organic compounds break down by the action of living anaerobic organisms. As in the aerobic process, the organisms use nitrogen, phosphorus, and other nutrients in developing cell protoplasm but reduce organic nitrogen to organic acids and ammonia. Carbon from organic compounds, which is not used in the cell protein, is liberated mainly in the reduced form of methane CH4. A small portion of carbon may be respired as CO2.
This process takes place in nature, such as decomposing organic mud at the bottom of marshes and in buried organic materials with no access to oxygen. Marsh gas, which rises, is largely CH4. Intensive reduction of organic matter by putrefaction is usually accompanied by odors of hydrogen sulfide and of reduced organic compounds which contain sulfur, such as mercaptans (any sulfur-containing organic compound).
Since anaerobic destruction of organic matter is a reduction process, the final product, humus, is subject to some aerobic oxidation when put on the soil. This oxidation is minor, takes place rapidly, and is of no adverse consequence in the utilization of the material on the soil.


Maturity of technology
Anaerobic digestion (AD) has been used to manage wastes and generate energy for centuries. It is widely used in Asian villages, where the climate is suitable for low technology designs, to produce biogas which is then used for heating and cooking. More recently AD has been developed into an industrial process for large scale waste treatment and energy recovery.
The organic garbage (Municipal Solid Waste) readily available from nature is a major source of energy. To utilize this free energy source, presently an eco-friendly process to manufacture manure and gas based power generation program is available in the market with 100 % indigenous machinery and plant. The mechanical separation of non-degradable materials like plastics is the specialty of this process, which makes it highly feasible comparing the other existing projects.
Benefits of Anaerobic Digestion / Bio - methanation

1.Generation of gaseous fuel.
2. Can be done on a small – scale or large - scale.
3. Free from bad odor, rodent and fly menace, visible pollution and social resistance.
4. No external power requirement unlike Aerobic treatment.
5. Enclosed system enables all the gas produced to be collected for use. Green house gases emission to the atmosphere is avoided.
6. Modular construction of plant and closed treatment needs less area.
7. Production of bio-gas and high grade soil conditioner.
8. Methane is a gaseous fuel (natural gas), which can be burnt directly or used to generate electricity.
9. Digestion improves the fertilizer value of the waste.
10. Treated effluent is less obnoxious and easier to handle.
11. The out put waste (partly treated) can be used.




The processes

The incoming Municipal Solid Waste (MSW) collected in the dumping pit moves up through the elevator buckets, and reaches the Crushing system. Then the garbage is crushed, and water is sprinkled. After this, MSW moves down to the Wet-grinding system. During the wet grinding process the bigger size non bio-degradable materials such as plastic, rubber and metal pieces etc are cleaned and separated.


After wet grinding bio-degradable materials are mechanically shifted to the digester for methanation. The methanation time takes 10 to 20 days. The energy generating CH4 gas during the process, CH4 is good for power generation / heating. After mathanation the bio-degradable materials are de-watered and mechanically shifted to the composting yards, for composting. The composting time takes 5to 10 days. After composting the compost is pulverized, and balances non-degradable are separated, and the compost ready for sale. The balance processed water recycled and reuse.














Salient feature of our fully auto MSW processing plant
(suitable for Aerobic, Anaerobic & Vermi Compost)


1) This is the only available system in India to process the municipal waste on a day to day basis.

2) The machine automatically clean, separate and remove the non-biodegradable waste material such as Plastic, Rubber, Metal pieces etc with out creating any pollution.

3) As our Municipal Solid Waste (MSW) is not a homogeneous mixture, in our process we make it homogeneous to be fit enough for Aerobic composting, Vermi Composting and Anaerobic Digestion.

4) Only the machine capable of instantaneously separating the non bio-degradable (mainly plastic etc) and processing the organic matter to the compost able mixture after the removal of toxins. (machine and process are totally patented)

5) The only MSW processing plant and process as per by the Govt bodies – DGS & D and Bureau of Indian Standards.

6) The plant can be of stainless steel built as per DGS & D (Quality Assurance) direction and can get a warrantee of 10 years.

7) This plant and machinery is 100% indigenous and up to 5-5000 ton pd. capacity.

8) No chemicals or artificial bacteria are involving in our process.

9) This plant can process any solid waste containing heavy fibers, like tender coconut husks, elephant dung and branches of trees, etc.

10) Due to higher rate of oxygenation/aeration in a closed chamber, pollutants are minimized in this plant, hence reducing chances of contagious viral diseases.

11) There is no chance of water pollution. The excess water in the process is recycled and re used.

12) The average power consumption cost is not more than Rs/- 40 - 60 for processing 1 ton MSW in our aerobic process.

13) In this process the production cost for extracting 1 Kg of BMC (Bio Manure Compost) is approx Rs 0.75 only

14) In anaerobic process, the products are fuel and Bio Manure Compost. The fuel extracted from this process can be utilized for running the plant or the fuel can be sold.

15) The total production cost for extracting 1 Kg of BMC along with the fuel is approx Rs 0.45 only.
16) Solid waste from fish/meat markets etc can also be processed in this plant.




Workshop on eco friendly municipal solid waste management

Conclusion:-

The paper has discussed in brief about authors experience in handling and mechanizing the Municipal Solid Waste and treatment them at reasonable cost and converting in to eco-friendly products (Bio-manure Compost)

References:-

Bureau of Indian Standards. IS: 9569,
Bureau of Indian Standards. IS: 12986,
Bureau of Indian Standards. IS: 10158,




COMPARISON

ANAEROBIC DIGESTION & AEROBIC COMPOSTING








Characteristics Anaerobic Aerobic
1. Is Urban installation advisable Yes + No -
2. Land requirement Less + More -
3. Fly’s problem No + Yes -
4. Virus problem through air No + Yes -
5. Air pollution No + Yes -
6. Bio gas available for power production Yes + No -
7. Bio manure quality Very good + Good -
8. Inoculums slurry (artificial bacteria) No + Yes -
9. Subsidy from Govt: 30% + 10% -
10. Power consumption Same Same
11. Digestion tank requirement Yes - No +
12. High technology Yes - No +
13. Capital investment 25% more - 25% less +
14. Water requirement Same Same



THE NATIONAL SMALL INDUSTRIES CORPORATION LTD.
(A Govt. of India Enterprises)
S-67, G.C.D.A. Commercial Complex, Marine Drive
Shanmugham Road, Cochin – 682 031
REGISTERED MAIL Date: 5-06-04

To

The Secretary ,
Thirur Municipal Corporation.

Sir,

Sub: Installation of Total waste (Liquid & Solid Waste) processing plant proposal for the Thirur Municipal Corporation.
Ref:

We are highly thankful for your invitation to submit proposal regarding the liquid waste processing plants for Thirur Municipal Corporation. At the outset, we would like to introduce ourselves as M/s The National Small Industries Corporation Ltd., (A Govt of India Enterprise) engaged in the activity of assisting the Small Scale Industries in India. We have been in the field of offering assistance to the SSI’s since 1955 through our various schemes like Hire Purchase, Industrial Raw Materials Assistance, Govt. Stores Purchase Programme, Tender Marketing, Composite Term Loan etc.

From the available data, we understand that , Thirur Municipal Corporation 16 km2 and have a daily collection of 8 tones of MSW & 30000 litters waste water flow. We propose to process a total Project for the liquid & solid waste. We consider it is a viable proposal as the Capital is minimized, space requirement is minimized and pollution hazardous are minimized, this sort of combined units have proved to be more efficient in operation. We propose one 10 ton msw processing plant with 30 KL waste water processing capacity. This proposal mainly a solid waste processing unites and an waste water recycling is included. The collection of msw in trucks and the waste water in tankers can be practical, and whole system can be work feasibly. The separated bio-solid waste from the waste water will be processed along with the collected MSW to convert to a manure form. The recycled Waste water is drained out to the drainage system after utilizing the required quantity of it in the msw processing plant.


2




As our Municipal Solid Waste (MSW) is not a homogeneous mixture, in our process we make it homogeneous to be fit enough for Anaerobic Digestion composting technologies, as per Bureau of Indian Standards process.

The prototype machineries, which we had installed at the plant established at Vadakara, in Kerala. (not stainless steel) At present the machine is made by stainless steel, as per direction from DGS & D (Quality Assurance wing) to avoid corrosion, we shall offer a performance guarantee for ten years .The samples of the bio manure produced at Vadakara plant, project report & Fully automatic Anaerobic MSW Stainless steel plant quotations with this letter.

You are requested to look into the matter and arrive at a decision at the earliest enabling us to serve you.

Let this beginning may lead us to mutual benefits.

Thanks with regards,

Yours faithfully,


(K.P. Kamalakaran)
Sr. Branch Manager



















3

QUOTATION

Eco-friendly fully automatic low cost 10 ton/day Anaerobic msw briquetting plant


No Details Qty Amount

1














2
3
4
5


6















7
Machinery details (2 ton / hr MSW)
(As per project report)

a) Stainless steel MSW feeding system
b) Stainless Steel MSW Plastic separating and
size reduction plant 1 ton / hr capacity
c) Stainless steel dewatering system
d) Stainless steel water recycling system
e) Stainless steel slurry pump
f) Electric turning machine
g) Size reduced MSW pulverizing and plastic
separating machine 300 Kg / hr capacity
h) Size reduced MSW (Compost) machine 300 Kg / hr i) Excavator or loader


Cost of electrical instrumentation
Cost of erection and completion
Technology transfer & consultation charge
KEL/ other 75 Kva gas with diesel Generators

Civil works
(As per project report)

a) 175 sqm totally enclosed electrified G I sheet or fiberglass shed for installation of plant & machinery with water heaters & Stainless Steel filters, tanks, Etc.

b) 600 sqm RCC floor, G I sheet roof, electrified shed,
office room, workers rest room, toilet, Etc.

c) Land development & basic infrastructure cost,
green belt Etc.

d) 800 m3 RCC digestion tank, water heaters,
Stainless steel water filters & tanks Etc


Waste Water Recycling

a) waste water collection stainless steel tanker trailer

b)_Stainless Steel On Line Bio-Solid Waste Filters,
500 Cm Height. 142Cm Dia. . 5 Stage stainless steel Net, Including stainless steel valves, stainless steel Structure,5 HP, 2880 RPM,440 V Bharath Bijjelee Submersible Motors Pump/air compressor pump With Auto Controls Etc:




c) 32,000.litter RCC water tank with
stainless steel Net, Including stainless steel valves, . . stainless steel Stretcher,5 HP, 2880 RPM, 440 V Bharath Bijjelee Submersible Motors Pump With Auto Controls Etc:


project cost

DBOT (Design Build Operate & Transfer) or
Turn key project cost
(10 % above on project cost as pre operative expenses)



Total project cost


2


2
2
2
2

2

2
1




1



















2


3











3














66,00,000,00


1,50,000,00.
2,50,000,00.
3,00,000,00.
6,00,000,00.





7.5,00,000.00.


10,00,000,00.


3,00,000,00.


7.5,00,000,00.



16,000,00.00.


27,000,00.00.









6,00,000.00.



1,56,00,000,00



15,000,00,00

1,71,00,000,00







Net Quotation Amount

Price basis Price at site after 180 days with 100% Advance Tax & Duties
Net project cost – 171 lakh
(Rupees one seven one lakh only)
Nil

Terms & Conditions: Copy of Kunnamkulam Municipal corporation agreement attached for discussion




(K.P. Kamalakaran)
Sr. Branch Manager structure