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NOTES ON VISIT MADE BY THE TEAM HEADED BY THE CHIEF
ENGINEER, COMMISSIONERATE OF MUNICIPAL
ADMINISTRATION TO STUDY THE RECYCLING OF PLASTIC
WASTE BY MK AUROMATICS, ALATHUR INDUSTRIAL ESTATE,
KANCHEEPURAM DISTRICT.
Date: 06.08.11
Team Members:
1.Thiru.R.Ragunathan, Chief Engineer, O/o the CMA
2.Thiru.K.Ravi, Regional Executive Engineer, Chengalpattu
3.Thiru.N.Manohar, Municipal Commissioner, Alandur
4.Thiru.ThiruchenthilVasan, Manure Officer, O/o the CMA
5.Thiru.Srinivasan,PA to CE,O/o the CMA
6,Thiru.V,Murugesan,Municipal Engineer, Tambaram
7.Thiru.N.Mahesan, Municipal Engineer, Alandur
8.Thiru.Srinivasan, Municipal Engineer, Pallavapuram
9.Thiru.A.Gurusami, Municipal Engineer, Avadi
10.Thiru.N.M.Krishnamurthi, Municipal Engineer, Madhavaram
11.Thiru.K.Seenuvasan, Municipal Engineer, Tiruvallur
12.Tmt.Jegatha,Assistant Engineer, O/o the CMA
13. Thiru.Babu, Assistant Engineer, Tambaram Municipality
The team visited MK Aromatics pvt Ltd, a plastic waste recycling
unit which is engaged in downstream refining of Petroleum
Hydrocarbon from Crude Oil feed stock derived out of Waste Plastics.
They manufacture various aromatic hydrocarbon solvents, aliphatic
hydrocarbon solvents, carbon and its by-products for various industrial
applications like agrochemicals, coating, specialty chemical etc.
Shri.Makesh K Merchant, the Managing Director, MK Aromatics Ltd
explained about the processing of plastic waste into fuel viz., diesel,
furnace oil, aromatic hydrocarbon solvents, carbon and its by products
carried out by the company.
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Recycling of Plastic Waste:-
Today the availability of the waste plastics is enormous, as the
plastic materials have become part and parcel of daily life. They get
mixed with Municipal Solid Waste and thrown over land area. Thinner
polythene/polypropylene carry bags are the most abundantly disposed
of wastes, which do not attract the attention of rag pickers for
collection for onward recycling for lesser value.
The dumping yards of the Urban Local Bodies are now piled up
with plastics. Though plastics have become inevitable in our day to day
life, this poses lots of problems. The ever increasing demand for
plastics, leads to generation of plastic waste. In India alone, about
6000 Tons of plastic waste is generated per day.
Presently, plastic wastes are disposed off by recycling, land filling
and incineration. The drawbacks of these methodologies are
incomplete degradation, high energy consumption, air pollutants
emissions and very high cost.
Plastic recycling is the process of recovering scrap or waste
plastics and reprocessing the material into useful products, sometimes
completely different in form from their original state
Disposal of plastic waste through co processing in Cement kiln
is a known and accepted process of Municipal Solid Waste
Management in many developed countries. This process of plastic
waste disposal was not practiced in India for want of statutory
clearances from appropriate authority. Co-processing is the use of
plastic waste as raw material, as a source of energy, or both to replace
natural mineral resources and fossil fuels such as coal, petroleum and
gas (energy recovery) in industrial processes, mainly in industries such
as cement, steel, glass.
With the limited availability of such industries in the
administrative limits of Urban Local Bodies in TamilNadu, the
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municipalities are not able to dispose the plastic waste through these
industries.
Plastic to Fuel:- Polymer Energy Technology
The manufacturing of aromatic solvents, aliphatic solvents,
waxes carbon etc., from the waste plastic being carried out by the
plant and machineries designed by M/s Harita NTI Ltd. The
manufacturing facility is based on Polymer Energy technology. Harita-
NTI is a joint venture between Harita (A TVS Group Associate) and
Northern Technologies International Corporation (NTIC, USA).
The Polymer Energy Technology i.e., Transverse Flow of Catalytic
Reactor for conversion of waste plastic, converting plastic wastes into
fractions of hydrocarbons (PE-oil) was invented by M/s. T.Technology in
Poland to provide a needy solution for plastic waste disposal.
Polymer Energy is a technology for converting waste plastics into
fractions of hydrocarbon / crude oil range, using Transverse Flow
Catalytic Conversion methodology. The raw materials used in this
process includes many Polyolefins such as Polyethylene (PE),
Polypropylene (PP) etc; which can be used in any mixed proportions,
thus help reducing of municipal wastes and finally form an eco-friendly
environment.
The technology is free of emission, effluents thus meeting air
quality; Fractions of hydrocarbons are formed as the result of thermo-
catalytic transformation process, which takes place in the presence of
catalyst.
Raw Material for processing:Polyethylene (PE), Polypropylene (PP), Polystyrene (PS),
Laminates depending upon the nature of plastics etc from plastic
waste in the Municipal Solid Waste stream are used as raw material for
processing. The main source of raw material is from the
agents/dealers, vendors for old and used material.
Process:
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Waste plastic is fed into the reactor through a loading press with
sliding door. Waste plastics are depolymerised inside the reactor in the
presence of the catalyst, and converted into hydrocarbon vapors. The
vapor is then carried through the cooling system to the pipeline (the
hydrocarbon cooling subsystem works at atmospheric pressure). Upon
cooling, the vapor gets condensed, as a slightly heated blend of
hydrocarbon with viscous fluid flows into the intermediate tank. The
product is further chilled in the intermediate tank and the resulting
liquid hydrocarbons are pumped into the storage tank. If any
uncondensed vapor enters the intermediate tank, they have the
possibility of becoming condensed in the additional cooler mounted
behind the intermediate tank and connected to the hydraulic back-
pressure valve. The water cooling subsystem of the unit works in a
closed cycle.
Waste in the raw form along with the catalyst is fed in to the unit
through two stage hydraulic driven press. The waste is carried from the
press to the processing reactor through the reducer. The burner fed
with furnace oil, biomass & gas maintains the reaction temperature.
The high temperature splits the raw material into hydrocarbons.
Hydrocarbon vapours move towards the cooling system (water is the
cooling medium) and then to the intermediate tank to the storage
tank.
All plastics are polymers mostly containing carbon and hydrogen.
Polymers are made up of small molecules called monomers.
Degradation of polymers occurs when this long chain of monomers
breaks at certain points. If the division of bonds occurs randomly, it is
known as Random De-Polymerisation.
Plastic waste is converted into liquid hydrocarbons by random de-
polymerisation. The process is carried out in a specially designed
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reactor in the absence of oxygen and with zeolite based catalytic
additive.
Maximum reaction temperature is 350C and there is total conversion
of waste plastic into value-added fuel products.
Plastic Waste collected from ULBs supplied to site
Segregation for better quality of product
Shredding of plastic waste
Feed into Trommel and then through Hydraulic press
The baled waste plastic fed into Reactor with High Temperature
the degradation of the of the polymers Depolymerisation
Final products viz., furnace oil, grease, carbon etc.,
Polymer Energy Unit at Alathur, Kancheepuram
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The environmental clearance has been issued by the State
Environmental Impact Assessment Authority (SEIAA),TamilNadu vide lr
No. SEIAA/TN/EC/S(f)/002/F-106/2008 dated.4.11.2008 for manufacture
of fuel from waste plastic.
Plastic recycling unit at Porur:
The team also visited M/s Rama Plastics, a plastic recycling unit
in Porur and studied the process of waste plastic into raw material for
recycled plastic. They collected plastic waste mainly carry bags, trash
Products made out of plastic
Visit by team of officials from Municipal Administration
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bags and shredded the same suitable for processing. The shredded
plastic waste, called flakes is then feed into the reactor which has a
high temperature of about 500C for melting. The molten material
from the reactor extruded into a thin wire like material. The granules
made out of this wire will be used as a raw material for recycled plastic
goods viz. toys, baskets, car parts,. The plastic waste material which
would be free from impurities can only be used for this process and
whereas the soiled plasticcarry bags in the Municipal Solid Waste
stream contain lot of impurities.
Provision of bitumenous surface using bitumen with plastics is
also one of the options for disposal of plastics. In this process theresource fuel can not be derived and the consumption of natural
resources also increased for production of these materials
In order to ensure the compliance with the Municipal Solid
Waste (Management &Handling) Rules 2000, under the provisions of
Environmental Protection Act 1986 and making the ISWM mandatory
for all the municipalities, the Plastic Waste Management is very much
essential as it poses various problems while producing organic manure
from waste.
The land requirement for a 5 to 7 tons per day plant will be about
5 acres in which 2 acres would be used for landscaping as PCB norms.
The cost involved will be around Rs. 9 crore. At present the plastic
waste is purchased at Rs. 5 per kg at the plant.
Alternately, the company can take plastic waste at the collection
centers of the Municipal garbage yards free of cost within 25 kms.
Conclusion:
Under article 6(d) of the Plastic waste (Management & Handling)
Rules,2011, the municipal authority may ask the manufactures,
either collectively or individually in line with the principle of
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Extended Producers Responsibility (EPR) to provide the required
finance to set up plastic waste collection centres. TamilNadu
Plastic Manufacturers Association (TAPMA) who arranged the visit
may be asked to set up plastic waste collection centres to
receive the plastic waste from the municipalities.
Normally under the Extended Producers Responsibility
manufacturers must take responsibility to take back their
products from end users at the end of the products useful life.
Hence the manufacturers ie TAPMA may be requested to set up
Plastic waste collection centres in selected municipalities by
clustering nearby Urban Local Bodies. They shall arrange for the
transportation of the waste from the respective municipalities to
the collection centre for onward transmission to their processing
facility.
The recycling units viz., Plastic Waste to Fuel through
Polymer technology may be set up in selected municipalities all
over Tamil Nadu under BOOT basis with proper concession
agreement and the plastic waste be supplied by the municipality
for their process.
The processing facility shall also be set up through Public Private
Partnership (PPP) mode with a portion of amount may be
provided as financial assistance for setting up of the facilty
The TAPMA may also be requested to carry out awareness
programme on separation of plastic waste and motivate the
public on segregation. Mass cleaning and collection of
segregated plastic waste shall be arranged in selected areas ofthe municipality with the coordination of Residential Welfare
Associations.
With Corporate Social Responsibility made as mandate to all
Industries, CII may be called for a discussion to take part in
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creating awareness among various stake holders regarding
source segregation in SWM, throwing prohibited materials like
plastic and other solid items into the toilets and drains causing
choking in drains and sewers, beautifying city water ways and
maintaining them, creating and maintaining them for
sustainability.
This effort would pave industry and public cooperation as well as
solving certain environmental issues.
K.Ravi,
Regional Executive Engineer,
Chengalpattu
N.Manohar,
Municipal Commissioner, Alandur
ThiruchenthilVasan,
Manure Officer, O/o the CMA
Srinivasan,
PA to CE,O/o the CMA
V,Murugesan,
Municipal Engineer, Tambaram
Thiru.N.Mahesan,
Municipal Engineer, Alandur
Thiru.Srinivasan,
Municipal Engineer, Pallavapuram
Thiru.A.Gurusami,
Municipal Engineer, Avadi
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Thiru.N.M.Krishnamurthi, Municipal
Engineer, Madhavaram
Thiru.K.Seenuvasan,
Municipal Engineer, Tiruvallur
Tmt.Jegatha,Assistant Engineer, O/o
the CMA
Thiru.Babu, Assistant Engineer,
Tambaram Municipality
R.Ragunathan,
Chief Engineer, O/o the CMARama Plastics, Plastic Recycling unit at
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Rama Plastics, Plastic Recycling unit at
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