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Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka3. Project Description3.1 Type of projectA Common Hazardous Waste and Bio-Medical Waste Treatment Facility is required forthe treatment of Hazardous Waste and Bio-Medical waste to reduce the adverse effectsof these waste that may pose. The proposed Common Hazardous Waste and Bio-MedicalWaste Treatment Facility includes Incinerator, Autoclave, Shredder, etc.3.2 Location of the SiteThe proposed Common Hazardous Waste and Bio-Medical Waste Treatment Facility willbe established in an area of 2.43 Acre (9835 Sq. m) at Plot no. 312-A2 & 312-A2 (Part), 2ndPhase, Harohalli Industrial Area, Sy no. parts of 799 & 800, Village Harohalli, HarohalliHobli, Kanakapura Taluk, Ramanagara District, Karnataka. The location of site along withproject boundary in google map and project site layout is given below in Figure 1 & 2.3.3 Details of Alternate sitesNo alternative sites have been considered for the proposed Common Hazardous Waste andBio-Medical Waste Treatment Facility as the facility will be established in a notifiedindustrial area and also it covers good range of medical facilities in Bengaluru Urban,Bengaluru Rural, Mandya and Ramanagara Districts.3.4 Size and Magnitude of ProjectThe proposed Common Hazardous Waste and Bio-Medical Waste Treatment Facility shall bedeveloped in an area of 2.43 acre. The total cost of the proposed project is Rs. 15 Crores.The proposed facility shall have the following key components: (a) Incinerators fortreatment of both hazardous and bio-medical waste – 1 x 500 kg/hr rotary kiln incineratorand 2 x 250 kg/hr static incinerators, (b) Autoclave – 5 TPD, (c) Shredder – 1000 kg/hr and(d) D.G Set – 375 kVA. In addition to bio-medical waste, Maridi proposes to manage(through incineration) different kinds of non-hazardous waste streams including: (a)commercial and institutional waste (b) expired/rejected branded and packaged products (c)narcotics/drugs from customs/police department etc. Plastic recycling unit will also beestablished for recycling of shredded plastic after autoclave.5

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at Harohalli Industrial Area, Harohalli (V), Ramanagara (D), KarnatakaFigure 1Google Map of Project Site6

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at Harohalli Industrial Area, Harohalli (V), Ramanagara (D), KarnatakaFigure 2Layout of the Proposed Facility7

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka3.5 Project Description with Process DetailsM/s. Maridi Eco Industries Private Limited, proposes to setup a Common HazardousWaste and Bio-Medical Waste Treatment Facility that includes Incinerator withappropriate APCDs, Autoclave, Shredder and Effluent Treatment Plant.The treatment technology adapted at the facility is described below:3.5.1. Incineration: This is a high temperature thermal process employing combustion ofthe waste under controlled condition for converting it into inert material and gases.Incinerators can be oil fired or electrically powered or a combination of both. Broadly,three types of incinerators are used for treatment of waste: multiple hearth type, rotarykiln and controlled air types. All the types have primary and secondary combustionchambers to ensure optimal combustion. These are refractory lined.Combustion takes place in the primary chamber whereas the secondary chamber is forgas phase combustion. These are referred to as excess air incinerators because excess airis present in both the chambers .Thus the waste is incinerated in two stages i.e. theprimary chamber and the secondary combustion chamber which is positioned adjacent toeach other. The flue gases then passes through the high pressure drop Venturi Scrubber,droplet separator and are let out to atmosphere via ID fan and chimney. The PrimaryCombustion Chamber operates under near pyrolytic condition where the waste isdecomposed and all volatiles are released. The substrate remained, gets converted intosterile ash. The volatiles released from the Primary Combustion Chamber are thencompletely burnt in the Secondary Combustion Chamber under high temperature &excess air.3.5.1.1. Rotary Kiln IncineratorRotary kiln incinerators are designed with a primary chamber, where the waste is heatedand volatilized, and a secondary chamber, where combustion of the volatile fraction iscompleted. The primary chamber consists of a slightly inclined, rotating kiln in whichwaste materials migrate from the feed end to the ash discharge end.Volatiles and combustion gases pass from the primary chamber to the secondarychamber. The secondary chamber operates at excess air. Combustion of the volatiles iscompleted in the secondary chamber. Due to the turbulent motion of the waste in theprimary chamber, solids burnout rates and particulate entrainment in the flue gas arehigher for rotary kiln incinerators than for other incinerator designs. As a result, rotarykiln incinerators generally have add-on gas cleaning devices. The components areproposed to setup along with incinerator given in Table 1.8

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), KarnatakaTable -1Proposed Components for Incinerator setupS.NoList of ComponentsShell of IS : 2062 Grade “A”1.Rotary Kiln System with2.Inlet head with followinghandling arrangement3.Discharge Breeching with4.Single Drum Pyrolyser with the following5.Secondary Combustion Chamber with6.Spray Dryer with the following7.Multi CyclonesmaterialRiding rings with mountingsGirth gear with support bracketsand boltsKiln drive assembly with VVVFDriveSupport roller assemblyTrunion & thrust roller assemblySealing arrangementRefractory MaterialCart dumping systemCharging HopperRam feeding systemRefractory for Inlet HeadAsh ConveyorRefractory MaterialCS ShellEmergency VentsIsolation DamperRefractory MaterialCombustion systemDuctingEmergency stackRefractory MaterialCS VesselSS DistributorDisc Atomizer with motorRefractory MaterialEffluent Pumping UnitPipe Line ConnectionsCooling Air fanRotary valveShell of SS construction with CSSupportsRotary ValveLime Silo with discharge bin9

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka8.Reagent System which includes thefollowing9.Bag Filter modules10.Wet Scrubber With The Following11.Stack of 40 Mtrs. Height with thefollowing:Carbon storage hopper with bagholding mechanismScrew feeder for both Lime &Activated carbonVenturi Injection system withRoots blowerInterconnecting Pipe linesCS Housing, hopper and manifoldCompressed air header and blowtubesRotary air lockFilter bags of PTFE membrane onFiber glassBag cagesPulse valveTimer and sequence controllerInlet butterfly valve, Outletpoppet valves and bypass valveInternal coating,External insulation.Hopper Heaters & PneumaticVibratorsCS Packed Bed ChamberPre quenchPacking materialsScrubbing LiquidCirculationSystemCaustic dosing SystemRe-Circulation TankSampling PortsPlatform with LadderAviation LampLightning ArrestorDrain PointMan Holeas per layout with refractorymaterial.Kiln energetic liquid / waste oillance10

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka12.Interconnecting ducting13.Combustion System for Rotary kiln with14.Combustion System for SCC with15.Rotary Equipment’s includes16.Electrical panel as per drive list17.PLC System18.Day TanksKiln aqueous waste / water spraylanceKiln auxiliary clean fuel oil burnerwith supply trainBurner and lance supply getic liquid / waste oil lanceAuxiliary clean fuel oil burnerwith supply trainBurner and lance supply traincomponentsFuelsupplypipingtraincomponentsFuel pump with motorLiquid waste pump with motorAqueous waste pump with motorEvaporator cooler pumpScrubber recirculation pumpsCaustic dosing pumpsC.A. FanID FanLocal push buttonsElectrical cables and connectorsCable trays and supportsAllen Bradley makePower supply with cablePC Interface with PC and LaserPrinterAnalog Input and Output cardsFused digital input and outputcardsKT Interface cardI/O ChassisFuelHigh Energy Liquid WasteAqueous WasteCaustic Lye11

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka19.20.21.Instruments as per P& I DiagramsPiping within the Battery LimitPiping with fittings, valves, hard wares requiredConcept of IncinerationIncineration is an ultimate treatment process, applied to certain wastes that cannot berecycled, reused or safely deposited into a landfill. It is a high temperature, thermaldestruction oxidation process in which hazardous wastes are converted in the presence ofoxygen in air into gases and incombustible solid residue. The gases are vented into theatmosphere with cleaning as deemed necessary while the solid residue is sent to landfillfor disposal.The proposed incinerator would cater for the disposal/ destruction of the followingwastes: Spent SolventsWaste Oils, Oil Emulsions and Oil mixturesRefinery WastesExpired MedicinesPhenolic WastesGrease and Wax WastesSolid materials contaminated with oils.Soiled organics with high calorific valueThe Incineration system is designed to handle the following wastes from variousIndustries: Pumpable energetic liquid organic wastes free from suspended solidsPumpable aqueous wastes with limits as to T.D.S. & free from suspended solidsAdvantages of IncinerationThe following advantages of incineration of hazardous wastes Ability to handle heterogeneous wasteHigh efficiency due toVigorous mixing in the bedHigh retention timeLow NOx formation due toLower operating temperature &12

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnataka Low excess airIn bed neutralization possible for removing acid gassesQuick restart due to heat stored in the bedAbsence of moving parts hence low maintenanceFlexibility to handle diverse fuelsResidence time can be adjusted by varying kiln speedWaste feeding without much preparationWaste heat recovery is possibleGas cooling systems can be fixedWell Scrubbing systems can be addedTemperature control for constant efficientlyAir control for adequate excess airInterlocks for safe operational shut downIncineration System DesignAn incinerator consists of a burner which ignites the supplied fuel and combustibles in thewaste feed in a combustion chamber. Thermal destructions of most organic compoundsoccur at a temperature between 850 oC to 1100 oC. To achieve thermal destruction,residence time usually ranges from 30 to 90 minutes for solid waste and 0.5 to 2.0seconds for liquid waste. Turbulent mixing is important because the waste and fuel mustcontact the combustion gases if complete combustion is to occur. Sufficient oxygen mustbe present and is supplied as ambient air or as pure oxygen through an injection system.A typical incineration system consists of several distinct units. The first unit is the kiln orprimary combustion chamber, in to which waste is fed and in which initial volatilizationand destruction of contaminants take place. Gases formed during incineration in the kilninclude un combustible organics or combustion by-products, which are generally referredas Products of Incomplete Combustion (PIC). These PICs' are drawn to a secondarycombustion chamber to inverse the efficiency of destruction of PIC's. Residual bottom ashproduced typically exist the kiln through a gravity drop and then cooled before disposal into landfill.The off-gases from secondary chamber is routed through an air pollution control systemin which gases are cooled and removes particulate matter and final flue gases are emittedthrough a stack.The installed capacity details of incinerator are given in Table 2.13

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), KarnatakaS. No.1234Table-2Technical Details of Incinerator setupDetailsIncinerator capacity1.5 Million Kcal/HrQuantity of Hazardous Waste500 kg/HrCalorific Value3000 - 5500 Kcal/kgHSD: 30Litres/ Hour,Fuel RequirementFurnace Oil: 90 Litres/ HourThe Rotary Kiln is designed for ashing mode operation only.Incineration Feed Rate: Due to non-homogeneous nature of the waste, characteristicsincluding the required Calorific Value and the feed rate through the kiln and system heatof combustion, moisture and ash content, bulk density will vary. All these factors willaffect I influence the feed rate and auxiliary fuel requirement.The possibility of variations in liquid wastes feed rate to be incinerated due to its CalorificValues. Required heating value liquids are to be fed at Rotary Kiln and that of high to be inSecondary Combustion Chamber (SCC). The net LCV of the liquid waste should be such asto help sustain flame at the lances.The incinerable wastes shall be pre-processed in case of necessary for making it uniformcalorific value and maintain the norms of halogen concentrations less than 1% and all.Wastes are fed through cart dumper and ram feeder into the rotary kiln and the hot gasesare sent to the secondary combustion chamber. Temperature at SCC will be min. 11000Cfor wastes with a gas residence time of 2 seconds. The residence time and the desiredtemperatures are maintained at both primary and secondary combustion chambers forcomplete combustion as per CPCB guidelines for hazardous waste incineration. The gasesafter complete combustion shall be sent to spray drier I evaporative cooler for coolingfollowed by Gas cleaning equipment. The Schematic Diagram of Incineration process isshown in Figure 3.The gases are passed through multi cyclones for removal of particulates. Then dry limeand activated carbon are injected for neutralization of acidic gases and removal of organicconstituents if any. The flue gases then passed through bag filters for complete removalparticulates and then through wet alkaline scrubber for neutralization. The flue gasesafter completely cleaned in all respects shall be sent out through a 30 m stack. EmissionStandards for common hazardous waste incinerator is presented in Annexure - IV.14

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), KarnatakaFigure-3 Schematic Diagram of Incineration ProcessStorage of lncinerable Hazardous WasteAn lncinerable waste storage shed with adequate capacity as per CPCB guidelines will alsobe established as a necessary infrastructure. The design of storage shed will beconsidered as per following requirements. Minimum of 15m distance between storage shedFire break of at least 4m between two blocks of stacked drumsMaximum of 300 T incinerable waste storage limit in a block of drumsAt least 1m clear space between two adjacent rows of drums in a pair for routineinspection purposesSpillage or leakage control measures to be adopted in the event of any leakage orspillagesRecord keeping and maintenance of shedFire detection, protection and safety measures as well as performing safety auditsevery year by the operator of a facility and externally once in two years by areputed expert agency.Storage area shall be designed in such a way that the floor level is at least 150mabove the maximum flood level.Signboards showing precautionary measures to be taken, in case of normal andemergency situations shall be displayed at appropriate locations.15

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), KarnatakaLaboratory FacilitiesThe existing laboratory facility will be used for tests to be conducted at incinerationfacility with an objective to study the followingStorage and Feeding requirements: physical form of waste, pH, hazardous wasteproperties such as inflammability, reactivity, compatibility with other wastes etc. forsegregating the waste and to store accordingly, in order to suit feeding mechanism.Operating conditions of the furnaces: viscosity, moisture content, total organic carbon,calorific value, volatility of the waste, special incompatible wastes, inorganic salts, metalsetc.Air pollution control devices: chlorides & other halogens, sulphur, nitrates, mercury &other heavy metals etc. The laboratory of the TSDF facility shall be capable of monitoringall the parameters prior to disposal.Waste FeedingWaste-feeding plays an important role to achieve desired combustion efficiencies.Continuous feeding of homogeneous waste having same/similar calorific value to thecombustion chambers is the desired option. However, often maintaining homogeneousfeed of waste is not feasible due to incompatibility of different wastes for mixing.Conventionally, hazardous wastes in solid form are fed through a hydraulic system, whichwill have automatic two gates i.e. once the outside plate is closed, inner side plate isopened and solid waste mass is hydraulically pushed inside the Kiln and once the innerside plate is closed, outer plate is opened for next batch of solid waste. This system,besides negative pressure in the combustion chambers is required to ensure safety and toprevent workmen exposure to thermal radiation.Combustion ChambersIncineration plant shall be designed, equipped, built and operated in such a way that thegas resulting from the process is raised, after the last injection of combustion air, in acontrolled and homogenous fashion.Incineration plant will be equipped with one auxiliary burner which would be switched onautomatically with the temperature of the combustion gases after the last injection ofcombustion air falls below specified temperature. It will also be used during plant startupand shut-down operations in order to maintain the minimum specified temperature at alltimes during operations and as long as unburnt waste is in the combustion chamber.The burners will be pressure-atomized type with approved certification from the Bureau16

Establishment of Common Hazardous Waste and Bio-Medical Waste Treatment Facility at HarohalliIndustrial Area, Harohalli (V), Ramanagara (D), Karnatakaof Indian Standards or equivalent.Kiln and secondary combustion chamber of the incinerator will be made of mild steelconforming to IS: 2062 and of suitable thickness lined with high-grade refractory andinsulation, so as not to buckle in or bulge out.Combustion chambers (Kiln & secondary combustion chamber) will be designed to supplywith excessive air to ensure complete burning of wastes. The blower will provided withappropriate capability to supply of combustion air. Incinerator facility will have a windowfitted with safety view glass to view the kiln (a

A Common Hazardous Waste and Bio-Medical Waste Treatment Facility is required for the treatment of Hazardous Waste and Bio-Medical waste to reduce the adverse effects of these waste that may pose. The proposed Common Hazardous Waste and Bio-Medical Waste Treatment Facility includes Incinerator, Autoclave, Shredder, etc. 3.2 Location of the Site