responsibilities of collection and dismantling centre · engineer,garc 20th july 2012 ....
TRANSCRIPT
Responsibilities of Collection and Dismantling centre
Presented by
M.PRAVEEN KUMAR,ENGINEER,GARC
20th July 2012
Today's discussion topics
Scenario of dismantling in unorganized sectors
Recycling demo unit at GARC
Our facility-overview
Highlights of Recycling Demo Unit
Details of vehicles provided for dismantling
Process flow of an ELV
Certificate of Destruction
Dismantling report
Current achievements
Code of practice for two wheelers(TVS Apache)
Cost details on dismantling a two wheeler
Code of practice for four wheelers(VW CAR)
Future activities at GARC
SCENARIO OF VEHICLES DISMANTLING IN UNORGANIZED SECTOR OF INDIA
• There are many vehicle dismantling centres in unorganized sector in India.
• Some of the places are Pudupet in Chennai, Mayapuri in Delhi,Lohar
Chawl and Chor Bazaar in Mumbai, Ukkadam in Coimbatore etc. • Dismantling of cars and bikes in these unorganised sector takes place in
a haphazard and unscientific manner.
• These were small units in the early days, when the cities weren't crowded, but their operations currently present significant health hazards to the citizens.
• In all, it is estimated that more than 100,000 people are employed in the unorganised sector, dismantling vehicles of various types and recovering parts and materials for sale/reuse/recycling.
DISMANTLING OF VEHICLES IN UNORGANIZED SECTOR IN INDIA
PUDUPET,CHENNAI
MAYAPURI,DELHI
The main ill-effects of these places of recycling are:
1.Air Pollution. 2.Contamination of ground water and land. 3.Highly unhygienic process posing threat to the workers handling it.
Recycling Demo Unit at GARC
The Recycling Demo Unit was setup by SIAM and NATRIP at GARC, Oragadam on 2th August 2011. A budget of 1.41 crores was allotted from the Auto R & D cess fund to establish this facility. The objective of this project is to study the process and establish the Code of Practice of dismantling and scrappage of selected automobile vehicles offered by OEM’S for the specific purpose, under Indian conditions without environmental degradation.
1.Arrangement of vehicles 2.Monitoring status of report 3.Technical support 4.Airbag neutralizing kit 5.Special tools
1.Dismantling facilities. 2. Cost estimation of scrap and labour. 3.Method of dismantling and disposing scrap 4.Cert of Destruction 5.Training/ Awareness programmes 6.Final project report
CLASS ROOM
BALING PRESS
PARTS STORAGE
DISMANTLING AREA
TIRE
STORAGE
ELECTRICAL PANEL
COMPRESSOR
OFFICE
RECEPTION
2/3 WHEELER DISMANTLING
AREA
Engine storage area
Gla
ss s
tora
ge
area
Fabric storage
PU storage
Details of Demo Unit Building Size 35mX25m Dismantling Area 16mX7m Parts Storage Area 16mX7m Total building area -510 sq m Vehicle body storage area-600 sq m
Our facility at GARC
Cost Break-up for Establishing RDU
S.No item Cost (Rs)
1. Bailing press 1677850
2. Air compressor 99800
3. Four wheeler scissor lift
215949
4. Two wheeler lift 65472
5. Fork lift 740940
6 Gantry crane 304594
S.No Item Cost(Rs)
7. Plastic crates for storage
119118
8. Material storage racks 134703
9. Dismantling tools 120060
10. Trolleys and jacks 44765
11. Oil collector 39236
12 Weighing machines 31700
Infrastructure cost :84 lakhs
Equipments and tools cost(only major items are displayed ):
The budget allotted for this project is 1.41 crores. The amount spent on various heads are displayed below.
Few equipments are now identified as stage two items which shall be procured from the remaining fund amount.
Highlights of our facility
Impermeable surface for appropriate areas with spillage collection crates to avoid land pollution.
Appropriate storage for dismantled spare parts, including impermeable storage for oil contaminated spare parts
Appropriate containers for storage of batteries. Appropriate storage tanks for the segregated storage of end-of-life vehicle
fluids like brake oil, power steering oil, engine oil, transmission oil, engine coolant, wiper washer fluid, left-out fuel, etc
Appropriate storage for used tyres, including the prevention of fire hazards. SEDA Airbag neutralizing kit with universal adapter for bursting of airbags
and seat belt pretensioners. Exposure and hands-on experience on dismantling of 60 two wheelers and
15 four wheelers. Fork lift capable of handling breakdown vehicles and vehicle white bodies Bailing press with a capacity to handle bales of size 16”x16” weighing 60 to
100 kgs. Oxy-acetelene gas cutting for cutting the car white body. Weighing machines to handle various weights to a maximum of 500 kgs.
Vehicles were provided to RDU from OEM’s for dismantling
Sl.No OEM No of Vehicles Type
1 Tvs motors 15 Un registered
2 Bajaj 36 Un registered
3 Hero honda 5 registered
4 Yamaha 4 Un registered
Four wheelers
Sl.No OEM No of Vehicles Type
1 Maruti Suzuki 7 Registered
2 Volkswagen 7 Un registered
3 Toyota 1 registered
4 General motors 1 registered
5 Mahindra 2 Un registered
6. Renault Nissan 1 Un registered
7 Tata motors 2 Un registered
Vehicles provided for dismantling to RDU
End of life vehicle
• Willful donation
• Vehicle details
Documentation
• Acknowledgement
• Undertaking
• Photos
• Registration details
Process flow for an ELV
Dismantling
• Pretreatment
• Operation
Planning
• Tentative date of dismantling
• Vehicle parked in safe location
Process flow for an ELV cont..
Segregation
•Ferrous, non- ferrous, plastics, rubber
•Weighment
•Storage at marked location
Process flow for an ELV cont..
COD
•Preparation of certificate of destruction
•Report on parts recovered.
Certificate of Destruction- specimen copy
The Certificate of Destruction are issued to vehicles which are dismantled a our facility.
For
un
-reg
iste
red
veh
icle
s
For
regi
ster
ed v
ehic
les
Dismantling Report - Contents
The dismantling report will be made for vehicles which were dismantled in recycling demo unit.
S.No Item Data
1 Registration No.
2 Model
3 Manufacturer
Name
4 Year of Make
5 Last owner's
name
6 Odometer
reading
7 No. of reusable
parts taken out
For studying
the trend of
reusable parts
8 List of reusable
parts (with
quantity)
9 Weight of
metals
10 Weight of
plastics
S.No Item Data
11 Weight of glass
12 Photos of Chassis no.
13 Photos of white body for rusting
pattern
14 Photos of
suspension/steering
parts
for rusting
pattern & weld
condition
15 Photos of PP/PU
interior parts - I/P,
steering wheel, steering
column, gear knob etc.
for color fading
pattern
16 Photos of rubber parts for cracking
pattern
17 Oil fluid drained
18 Battery removed
19 Tyre removed
The recycling demo unit has dismantled 60 two wheelers which were provided by OEM’s.The following results were obtained.
Type of vehicle
Ferrous scrap(Kg)
Non ferrous scrap(Kg)
Plastics(Kg)
Rubber(Kg) Time taken for dismantling (man-hours)
Moped 32.09 1.65 14.84 8 2
Bike 68.26 2.8 7 10 4
scooter 84.84 1.56 6.72 8.2 3
Current achievements
Code of Practice for Two Wheelers
OIL 2. OIL DRAININGDRAINING 3. BATTERY REMOVAL
4. SEAT REMOVALDRAINING 5. FUEL DRAINING/TANK
REMOVAL 6. FUEL DRAINING/TANK
REMOVAL
OIL 1. MOUNTINGDRAINING
11. AIR FILTER
8. ELECTRICAL REMOVAL 7. HEADLAMP REMOVALRAINING OIL 9. MUD GUARDDRAINING
OIL 10. CLUSTER REMOVALDRAINING OI 12. SHOCK ABSORBERDRAINING
Code of Practice for Two Wheelers contd..
13. SWITCHES & CONTROLS
17. HANDLEBAR
15. CARBURETTOR
16. BRAKE FLUID DRAINING 18.EXHAUST SYSTEM REMOVAL
14. BRAKE REMOVAL
Code of Practice for Two Wheelers contd..
21. ENGINE REMOVAL 20. BRAKE SHOE
24. PARTS SEGREGATION&STORAGE 22. BRAKE DISC
OIL 19. HORNRAINING
23. FRAME REMOVAL
Code of Practice for Two Wheelers contd..
Cost details of dismantling a two wheeler
From earlier slides the amount of scrap generated from dismantling a two-wheeler is shown.
Market rate for two wheeler scrap
Ferrous Non ferrous Plastic Rubber
30 Rs/kg Al-100Rs/kg,Cu-300Rs/kg 10 Rs/kg 1 Rs/kg
Moped Bike Scooter
1650 Rs 3350 Rs 3800 Rs
Considering the above mentioned rates the cost which can be recovered from dismantling a two wheeler and selling the scrap
Cost incurred at GARC-Recycling demo unit for dismantling a two-wheeler
considering manpower ,infrastructure and other expenses is 450 Rs.
Note : The scrap rate said above are subject to vary on day-to-day basis.
1. AIRBAGS 2. BATTERY REMOVAL
3. AC GAS 4. FLUID DRAINING
Code of Practice for Four Wheelers
5. BONNET 6. HEAD LIGHT
7. DOORS 8. DOOR TRIMS
Code of Practice for Four Wheelers contd..
9. WIPERS 10. TYRES
11. BUMPER OIL 12. FENDERDRAINING
Code of Practice for Four Wheelers contd..
13. CRASH BAR 14. RADIATOR REMOVAL
OIL 16. ENGINE & DRIVESHAFTDRAINING
Code of Practice for Four Wheelers contd..
15. CAT-CON REMOVALRAINING
19. INSULATION MATS
17. BOOT DOOR 18. SEAT
20. ROOF COVER
Code of Practice for Four Wheelers contd..
24. REAR AXLE
O21. BRAKE CYLINDERDRAINING OIL 22. SUSPENSIONDRAINING
OIL 23. STEERING COLUMNDRAINING
Code of Practice for Four Wheelers contd..
25. DASH BOARD OIL 26. FUEL TANKDRAINING
OIL 27. WHITE BODY REMOVALRAINING
Code of Practice for Four Wheelers contd..
OIL 28. BAILING OF BODY AND DOOR PANELS
Code of Practice for segregation
1.Ferrous and non ferrous parts 2.Plastic,Fabric,wiring harness
3.Engine ,PU, Rubber, Pyro, Battery 4.Fluids in separate barrels
Future activities of RDU-GARC
• The cost estimation of four wheeler scrap is to be carried out.
• ELV take-back responsibility needs to be assigned.
• The license for authorization and operation of waste management generated at
dismantling facility need to processed.
• The disposal of four wheeler scrap has to be carried out.
• RDU shall be able to handle premature End-of-life vehicles.
• To make and fine tune a road map which can guide a dismantler to sell the scrap
and the same material shall be used by OEM’S in their newer models.
• To upgrade the existing facility by adding few items to the already available facility
1. Freon capturing kit (approx-75,000 Rs)
2. Auto glass removal kit (approx-75000 Rs)
3. Fluid extraction kit
• To analyse the market for dismantled parts taken from ELV’S and to effectively
conserve the energy which is utilised for making the same part.
• To suggest a business model which shall be inline with the ELV regulation to be made
effective in India.
Thank you
Visit our facility for more information
We are available at: