Vibhar Enviro Care Pvt has developed an cost effective and affordable solution for safe disposal of all sorts of wastes converting wastes in to Renewable energy , there by reducing the Co2 emissions and creating a safer environment for better living conditions.
Wastes have been co-processed in cement kilns since long and this practice is prevalent in developed countries. Many developing countries are also taking initiatives for co- processing of waste in cement industry. There are few attempts in India on Co-processing in cement plants, by different cities but the system is still to be fully established.
The dry fractions of MSW are sent for reuse and recycling while the rejects from the compost as well as the non-recyclable products, are sent to co processing in to Cement sector.
The Recycling of plastics happens to the commercial concept only , mainly Recycling principally refers to Recovery . After collection of the portions that can be recycled by mechanical recycling, there remain numerous fractions in the rejected stream like plastics (heavily contaminated articles, multi layered composites, pouches, etc), jute rubber, leather, rags, coconut shells, etc., which are mostly unattended and allowed to remain in the waste stream, thus forming the large bulk of the municipal solid waste problem. References are available that developed countries are disposing these otherwise difficult to recycle wastes, through co-processing in Cement Kilns (Energy Recovery) in a scientific and environmental friendly manner.
The cement industry consumes a significant amount of natural resources and energy. It also contributes worldwide to the development and modernization of cities and infrastructure. The cement industry and its associations continuously try to improve environmental performance by optimizing the use of natural resources and reducing its overall energy consumption and carbon footprint. The use of wastes as fuels and raw materials in cement kilns can help manage wastes while contributing to the sustainable development of our world.
To demonstrate the Co-processing methodology, ACC had conducted co-processing trial runs of the hazardous waste, including plastic waste at its Kymore Cement plant, with the support and guidance from Indian Centre for the Plastics in the Environment (ICPE) and the results of trial burn demonstrated that there are no negative influences on the stack emissions due to presence of high temperature and long residence time of the kiln and also there was no impact on the product quality. After the successful trial burns, the process received legal sanction as part of the Guidelines for Co-processing of Hazardous waste in Cement Plants published by the Central Pollution Control Board in 2010.
The main objective of co-processing is the substitution of primary fuel and raw material by waste. It is a recovery of energy and material from refuse.
Co-processing of wastes in properly controlled cement kilns provides energy and materials recovery while cement is being produced, offering an environmentally sound recovery option for many waste materials. In general, co-processing of waste in resource-intensive processes can be an important element in a more sustainable system of managing raw materials and energy.
The transformation of waste into Alternative Fuels and Raw materials (AFR/ RDF) must meet certain requirements. Some types of waste cannot be used directly as Alternative fuels and Materials (AFR) or Refuse derived Fuels ( RDF). This step produces a waste product with defined characteristics that complies with the technical specifications of cement production and guarantees that the environmental standards are met.
After the sorting of waste, it was found that the moisture content of dry fractions of waste was higher than 20%, and that there would be the need to sun-dry or Mechanical drying the waste before further processing and making it ready for sending to the cement plant.
This material typically comprised of jute, leather, plastic, cloth rags, wood, coconut shells, paper, paper plates & cups and any other material with calorific value, which are the rejects after the different level of formal and informal recycling mechanism. the same ( Alternative Fuel) was used for reducing the moisture content to below 20%, as desired by the cement plant. The pre-segregated dry waste was kept for sun drying for 5-6 days. After significant reduction in moisture content , the waste was transported for baleing and bagging at a suitable location within the plant. Some waste was also sent to the RDF facility for preparation of RDF Fluff( which we are planning at Down Tirupathi).
RDF Fluff that had been prepared from the dry sorted MSW rejects was also packed in bags. about one truck load of bagged RDF Fluff and Dry sorted waste rejects was prepared. After baleing and bagging of the required quantity of waste ( truck load), the waste was transported to the down Tirupathi , where huge volumes are loaded in to bigger Trucks for Transportation of RDF Fluff for co-processing in to Cement Industries.
Key benefits: Environmentally sound utilization of dry sorted rejects of MSW as well as material produced from RDF plants leading to an increase in the life of the Sanitary Landfill, thereby decreasing pressures on land .
Cement Industry :
• Co-processing is location specific for each cement plant. The closer the distance between the waste generator and a Cement Plant the more economically viable it is for co-processing. • Additional investments are required by the cement plant to manage the waste streams. • The better the quality of segregated material sent to the industry, the easier it is for the plant to come up with a homogeneous fuel mix that can be used for cement manufacture.
Key benefits to Society & Environment : Co-processing leaves no residue to be land-filled and it helps conserve non-renewable resources and contributes to reduced global environmental footprint. It represents a sustainable solution for many waste streams including dry rejects of MSW that cannot be recycled and ideally should not be land filled or incinerated. It offers significant potential for reducing pollution and landfill space caused by the waste disposal.
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