For a Zero Waste Future

© 2014 Holcim Technology Ltd

Geocycle Pre-processing facility – Wadi Cement Works

2016-07-20

Geocycle Pre-processing layout

Operation & control Building

Detarping & sampling station

Geocycle Laboratory

Elaborate Fire-fighting System

Mobile ATEX Equipment

Fire water retention basin & Leachate collection system

Odour control system

Dedicated Weigh-bridge & drivers rest room facilities

Best and safe practices

Geocycle facility- An Overview

Pre-processing layout

Preprocessing Shed

Fire water Tank Pump House

MCC Room

Security Office

Pre-processing Shed

Storage & Processing Shed – Built with high concrete walls & the entire floor has been embedded with geo-membrane sheets to prevent percolation of pollutants.

Separated into Inbound and Outbound area for incoming waste & pre-processed waste respectively.

Quarantine area earmarked for Non-conforming waste.

Pre-processing System - Geocycle

Star Screen

M&J

▪ Consists of Metso M&J 4000 S hook shredder,

REMA belt conveyors, Steinert Magnetic Separator & Eco-star screen.

▪ Capacity = 200 m3/hour

▪ Safety features provided : Emergency stops, Pull cords limit switches for screen cover & hopper access. Instant tripping of the entire system from IR

detector. MVWS system for BC-1, BC-2 & reject bins. Foam suppression for shredder hopper & pits.

▪ 1000 m3 water tank with level indicators.

▪ 1 Main Electric pump, 2 diesel pump of

capacity 410 m3/ hr each & 1 jockey pump

of capacity 25 m3/ hr.

▪ 14 hydrant points in pre-processing area.

▪ 5 hose reels inside the shed.

▪ 13 UV/IR detectors provided inside the shed

for fire detection.

▪ 560 sprinklers (ESFR type) provided at roof

inside shed.

▪ MVWS system, activation through LHS

cable provided at BC-1, BC-2 & reject bins.

▪ Low expansion foam system provided for

both the pits and for shredder hopper.

▪ IR detectors for BC-1 & BC-2 for instant

stopping of shredding line.

▪ Portable fire extinguishers provided inside

shed, MCC, Metso containers, Weigh-

bridge Porta cabin, pump house, security

room etc.

▪ Smoke sensors provided at MCC room.

▪ LHS cable provided at Electrical cables in

MCC room.

Fire fighting System at Pre-processing

Co-processing System – Wadi Cement Works

Police Screen &

Wind Shifter

Chain Belt Conveyor

BC-1BC-2

BC-3

Walking Floor

Multiflex Bin &

Screw

RAL

Shut Off gate

ILC

▪ Dosing, transportation and feeding system for accurate

feeding of pre-processed waste.

▪ Consists of Walking floor -150m3/hr, Multi-flex -200m3/hr,

Rotary airlock - 300m3/hr.

▪ Safety features provided : Emergency stops, Pull cords ,

MVWS system for Multi-flex & CBC, Sprinklers for Walking

Floor, Interlocks provided for safety shut-off gate.

▪ LHS cable provided for Multi-flex, CBC, BC-1, BC-2

& BCD

▪ UV/IR detectors provided in walking floor, BC-1, 2, 3

& BCD

▪ 8 Manual call points provided covering all locations.

▪ Booster pump of 273 m3/hr capacity provided to

cover BCD & Zone 2 of BC3

▪ 6 Deluge valve provided for MVWS system covering

Multi-flex, CBC, Police screen, BC-1, 3 & BCD

▪ 40 sprinklers (ESFR type) provided at roof of WF

▪ Fire alarm interlock taken for tripping of Co-

processing circuit.

▪ Hydrant posts provided at WF & Multi-flex

▪ Temperature scanner with display provided for Multi-

flex

▪ Chute level sensor for BC-1 and BC-3 discharge

▪ Interlocks for shut-off gate provided with tank water

level, temperature & pressure apart from general

interlocks.

Fire fighting System at Co-processing

Operation & Control Building

Operation & Control Building is meant for administrative work

Houses Laboratory , Sample preparation & sample storage room

Conference room for daily production meetings & conferences

Drivers rest room

Washrooms & changing rooms with lockers for shop floor personnel

Detarping & sampling station

Horizontal Anchorage Line system equipped with shock absorbers.

Safety belt provided for safe anchorage.

Provided with fall arrest system.

For safe detarping of vehicle.

For safe sample collection from incoming waste trucks.

Mobile Equipment

▪ Liebherr Hydraulic arm Handler

▪ Atex 22 compliant

▪ Rear view camera

▪ Liebherr Wheel Loader

▪ Atex 22 compliant

▪ Rear view camera

▪ Terex Skid steer Loader

▪ Sound proof ROPS/FOPS cabin.

▪ Rear Egress for an Emergency exit.

▪ Jungheinrich Fork-lift

▪ Drum handling & tilting attachment

▪ Engine Spark Arrester, Diesel Particulate Filter

▪ Anti Spark & Anti Static Forks

▪ Genie Scissor lift

▪ Maximum workable height = 12.2 meters

▪ Maximum load carrying capacity = 349 Kg

▪ TPS Road sweeping machine

▪ Fitted with spark arrestor

▪ Workplace monitoring

▪ Stockpile temperature▪ Illumination level▪ Noise level

▪ Radiation levels▪ VOCs

▪ Checklists for periodic monitoring

▪ Incoming Vehicle inspection at main gate▪ Pre-start checklist for arm-handler, loader etc.

▪ Shredding line walk-by inspection▪ Fire-fighting inspection▪ Waste Profile forms

▪ OH&S compliance▪ Daily tool box talk▪ Alert sharing & implementation of learning

▪ Work permit system▪ Fire-fighting drills

▪ Incident reporting▪ Safety Observation tour (SOT)

Systems in place for safe operation

Practices in place

Daily safety talk & alert sharing sessions

Best practices implementation

Monthly tool box talks

Use of dedicated uniforms for operators & workers

Mandatory use of half face canister masks

All Mandatory PPEs to be adhered to at the workplace

Adequately trained on fire-fighting & safe handling methods

Best and safe practices- Geocycle

Safety signage display at all identified locations

Emergency contact numbers

Mandatory PPEs adherence

H&S policy of the group company

Provision of Emergency Eye Wash

Safety shower provided for accidental spills over body

Spill kits for arresting accidental spills on the floor

Best and safe practices- Geocycle

Fire Water Retention & Leachate Collection

1200 m3 fire water retention basin for capturing residual fire-fighting water.

Provided with a layer of Geo-membrane sheet to prevent percolation of water.

50 m3 Leachate collection sump provided at 2 locations.

Drains separating storm water with potentially contaminated water.

Drains are epoxy coated for prevention of percolates.

Submersible pumps provided for reuse of contaminated water through co-processing.

2015 2016 2017 YTD Sep 2018

Achieved TSR% 4.16 6.23 9.65 10.92

4.16

6.23

9.65

10.92

0

2

4

6

8

10

12

Thermal substitution rate

%T

SR

Thermal Substitution rates are on an increasing trend YOY basis

In 2019 post expansion of its Pre & Co-processing facilities, Wadi aspires to achieve 20% TSR

2015 2016 2017 YTD Sep 2018

Achieved 31720 45678 67197 58167

31720

45678

67197

58167

0

10000

20000

30000

40000

50000

60000

70000

80000

AF V

olu

me

s -

MT

AF & AR Volumes for Wadi

AF includes Haz & Non- Haz Industrial wastes, Biomass, Sorted Municipal Waste etc..

AR includes Red Mud, Fly-ash, Iron slag etc..

2015 2016 2017 YTD Sep 2018

Achieved 66343 97448 87732 66026

66343

97448

87732

66026

0

20000

40000

60000

80000

100000

120000

AR

Vo

lum

es

-M

T

Safety Promotional Activities - Training and assessment

Fire fighting training to Geocycle team

Training

Assessment

Class room Training for drivers

On Roa

Class room Training on Fire fighting

Certification training for drivers Rewarding Safety man for the month

Safety Promotional Activities

Laboratory & quality assurance at Wadi facility

Only pre-analyzed and approved waste materials are allowed to be received at our pre-processing facility

The materials received in closed trucks are tested for properties in line with WAC before pre-processing – Waste Characteristics Evaluation.

The samples of pre processed material ready for dispatch are tested for requirements for co-processing at our cement plant.

Any non-conforming material will be rejected and send back to respective waste generator

Geocycle Laboratory

• ICP : Used for spectroscopic analysis of elemental

composition of waste.

• GC : Used for the determination of PCB

(Poly Chlorinate Biphenyl) in the sample.

Lab is equipped with14 ultra modern instruments which are used for analysis of waste samples for finger Print & Comprehensive analysis.

• CHN&S ANALYZER : Determination of Carbon, Hydrogen,

Nitrogen & Sulphur content in the waste.

• BOMB CALORIMETER : Used for measuring the Calorific

value of the sample .

• PROXIMATE ANALYZER : Used for determination of

moisture, volatile matter, ash and fixed carbon in the sample.

Geocycle Laboratory

• AUTO-TITRATER: Used for titration of colored solution whose

end point cannot be detected properly by visual observation.

• KARL FISHER ANALYZER: Used to determine moisture

content in the organic samples.

• SUPRA PURE WATER SYSTEM: Ultra pure water is used in

sample preparation elemental analysis on ICP spectrometer

and Chloride analysis in Autotitrator.

Geocycle Laboratory

• MICROWAVE DIGESTER: Used for sample preparation for

analyzing them on ICP spectrometer.

• PH METER & ISE: Quick simple and accurate measurement

of pH of the solution & to determine the Fluoride content.

• RADIATION SURVEY METER: Used to detect the presence of

radioactive material in the sample.

Geocycle Laboratory

• MOISTURE ANALYZER: Used to determine the moisture

content by weight loss method.

• VISCOMETER: Used to determine the viscosity of the liquid

samples.

• FLASH POINT ANALYZER: Used to determine the flash

point of the liquid samples.

Geocycle Laboratory

Geocycle Awareness cum Personality Development: April 2018

Program organised at Disha Wadi Center Wadi

Geocycle Awareness:

Video presentation on Clean and Green Wadi

Corporate Video Presentation of Geocycle India

Basic Introduction presentation on Geocycle India

Personality Development:

Factor enhancing Personality

Improve communication Skills

Leadership Quality

Group presentation on Beat Plastic Pollution: DAV School

The Group Competition was organised at DAV

Public School Wadi

● Four different group of student were presented

the studies of four different designated area of

India.

● The Problem of plastics pollution were identified

by the Groups.

● All Groups were presented the solution of

plastics pollution in there respective presented

area.

● The presentation were evaluated by the faculty

and Geocycle employee

● The winner group was recognised with a gift

Geocycle Awareness cum Road Safety Training: July 2018

Road Safety Training for two wheeler rider was

organised at Government High School Wadi

● Equipments and controls of motor bike

● Personal Protective Gear

● Language of Road sign

● Braking to stop distance

● Brainstorming session on Road safety violation

through Videos