DRAFT CONCEPT REPORT

TABLE OF CONTENTS

Sr. No. DESCRIPTION PAGE

1 GENERAL 1
1.1 Existing Solid Waste Management System 1

2 RECOVERY OF MATERIAL FROM SOLID WASTE 2

3 TECHNICAL CONSIDERATIONS FOR PLANNING AND DESIGN OF MRF 3

4 METHODOLOGY 4
4.1 Activities Of MRF 4
4.2 Methods and Equipment used for Processing and Recovery 4
4.3 Process Flow diagram 5

5 EQUIPMENT SELECTION AND CRITERIA 7
5.1 Material Handling 8
5.2 Manual Sorting 8
5.3 Size Separation 9

6 LAYOUT OF MRF 10


ANNEXURE-1 (Concept Design Figures) 11




1

MATERIAL RECOVERY FACILITY FOR SAHIWAL CITY

1. GENERAL
Sahiwal town is situated at a distance of about 18 miles from the left bank of the
river Ravi,187 Km west of Lahore and 200 km east of Multan. The Grand Trunk
Road and the main railway line connecting Peshawar-Lahore with Karachi pass
through the town. The Lower Bari Doab Canal separates the town into two
parts.Its approximate height above sea level in 500 feet. Sahiwal lies
3039'52.16" N latitude and 73630.54"E longitude.Present population of
Sahiwal is 406,681 and Estimated population is 482,775.
1.1 Existing Solid Waste Management System
The existing solid waste management system of Sahiwal is being managed by
the Tehsil Municipal Administration (TMA). Presently there is no proper disposal
facility in Sahiwal. Waste generated is disposed off into the designated dump site
at Ratti Tibbi without making any arrangements for environmental safeguards.
By adopting the 0.35 kg/person/day generation ate the present waste generated
in Sahiwal comes out to be 140 tons/day which requires an area of approximately
28 Acres approximately for landfill facility. However, by installing a Material
Recovery Facility, the landfill area will be decreased by 70 to 80%.
The waste composition adopted for Saihwal has been taken as same concluded
by recent waste characterization survey carried out by GHK for Sialkot which are
given below.
Table: Composition of MSW of Sialkot, Solid Waste Management Strategy and Action Plan (PCIIP), 2010

















Component
Glass 0.16
Metals 0.07
Paper/Cardboard 0.36
Plastics 0.33
Food/Organic 1.02
Wood 0.11
Leather/Rubber 0.10
Electronics 0.04
Other 0.27
Average (Per
Household)
2.46
Average (Per Capita) 0.35
2

Municipal Waste Composition
Source: GHK Sialkot Waste Assessment Survey. 2010


2. RECOVERY OF MATERIAL FROM SOLID WASTE
There are three main methods that can be used to recover recyclable materials
from Municipal Solid Waste (MSW):
i. Collection of source-separated recyclable materials by either the
generator or the collector, with and without subsequent processing
ii. Commingled/Mixed recyclables collection with processing at centralized
materials recovery facilities (MRFs)
iii. Mixed MSW collection with processing for recovery of the recyclable
materials from the waste stream at (MRFs)
In Sahiwal city, mixed-waste collection is being practiced, that requires no extra
effort by the generator and results in no incremental collection costs. Therefore, a
much complex system is required for the processing and recovery of different
materials from solid waste.
The different recyclable materials that will be recovered from the mixed MSW are
as under:
Bulky Items
Cardboards
3

Plastics (PETE, HDPE and other mixed plastic)

Glass (clear and mixed)
Aluminium cans, Tin cans
Ferrous Materials
Paper/Rags
By the recovery of the above recyclable materials, the mixed MSW eventually
prepared, will be used as feedstock for composting.

3. TECHNICAL CONSIDERATIONS FOR PLANNING AND DESIGN OF MRF
For the planning and design of MRF, following technical considerations are
followed:
The coordination of the MRF with the integrated waste management plan
for the community and clear explanation of the role and function of the
MRF in achieving landfill waste diversion and recycling goals.

What type of MRF should be built, which materials will be processed now
and in the future, and what should be the design capacity of the MRF.

While it has been possible to build and operate MRF in close proximity to
both residential and industrial developments, extreme care is taken in their
operation if they are to be environmentally and aesthetically acceptable.
Ideally, to minimize the impact of the operation of MRF, it is sited in more
remote location where adequate buffer zone surrounding the facility is
maintained.

In the design and selection of equipment for MRF, a materials balance
analysis to determine the quantities of materials that can be recovered
and the appropriate loading rates for the unit operations and processes
used in the MRF is prepared.

MRF layout will include: (1) sizing of the unloading areas for mixed MSW
(2) sizing of presorting areas where oversized or undesirable materials are
removed, (3) placement of conveyor lines, screens and other unit
operations, (4) sizing of storage and outloading areas for recovered
4

materials, and (5) sizing and design of parking areas and traffic flow
patterns in and out of the MRF.

Staffing depending upon the degree of mechanization of MRF.


4. METHODOLOGY

4.1 Activities Of MRF
The different activities performed in an MRF depend upon the functions of MRF
i.e (1) The role that the MRF is to serve in the waste management system (2)
The types of material to be recovered (3) The form in which the materials to be
recovered will be delivered to the MRF (4) The containerization and storage of
processed materials for the buyer

In view of the above mentioned functions, the following processing and recovery
activities are being formulated for the MRF receiving mixed MSW of Sahiwal City:

Material Handling (Transport and transfer of solid waste)
Size Separation (Separation of dust and Stones from the solid waste)
Manual Sorting (Recovery of recyclable materials from solid waste)
Size Reduction (Removal of bulky items)
Densification (Compaction of recovered materials)

4.2 Methods and Equipment used for Processing and Recovery
Following are the general methods and equipments with respect to the activities
of MRF defined in section 4.1:

Material Handling


Unit operations used for the transport and storage of MSW
and recovered materials. Typical applications include: (1)
conveyors for the transport of MSW and recovered
materials, (2) storage bins for recovered materials, and (3)
rolling stock such as fork lifts, front-end loaders, and various
types of trucks for the movement of MSW and recovered
materials.
Size Separation


Unit operation in which materials are separated by size and
5

shape characteristics, most commonly by the use of

screens. Several types of screens are in common use
including: (1) reciprocating screens for sizing shredded yard
wastes, (2) trommel screens used for preparing commingled
MSW prior to shredding, and (3) disc screens used for
removing glass from shredded MSW.
Manual Sorting


Unit operation in which personnel physically remove items
from the waste stream.Typical examples include: (1)
removal of bulky items that would interfere with other
processes, and (2) sorting material off an elevated conveyor
into large bins located below the conveyor.

4.3 Process Flow diagram
The different operations to be carried out in MRF are best described with the help
of the following Process Flow Diagram.

Moreover, two schematic process diagrams i.e Fig. 2 & 3 are attached in
annexure-1 that further elaborates the concept of process of MRF.




















6

TippingFloor
Receiving
Area
Inclined
ConveyorBelt
Trommel
Screen
C
o
n
v
e
y
o
r

B
e
l
t

FerrousMetals
Plastic&Rubber
Paper&Rags
Glass
Wood
MainlyOrganic
Fraction
MixedMSW
Recovered
Recyclables
BulkyItems
Cardboards
OpeningBags
Dirt
Contaminants
Landfill
ToComposting
Plant
7

5. EQUIPMENT SELECTION AND CRITERIA

Following factors are kept in mind for the selection of equipment and physical
facilities:

Capabilities
What will the device or mechanism do? Will its use be an improvement over
conventional practices?

Reliability
Will the equipment perform its designated functions with little attention beyond
preventive maintenance? Has the effectiveness of the equipment been
demonstrated in use over a reasonable period of time or merely predicted?

Service
Will servicing capabilities beyond those of the local maintenance staff be required
occasionally? Are properly trained service personnel available through the
manufacturer or the local distributor?

Safety of operation
Is the proposed equipment reasonably foolproof so that it may be operated by
personnel with limited mechanical knowledge or abilities? Does it have adequate
safeguards to discourage careless use?

Efficiency
Does the equipment perform efficiently?

Environmental effect
Does the equipment pollute or contaminate the environment?

Health hazards
Does the device, mechanism, or equipment create or amplify health hazards?

Economics
What are the economics involved? Both first and annual costs must be
considered. Full operation and maintenance costs must be assessed carefully.
All factors being equal, equipment produced by well-established companies and
having a proven history of satisfactory operation should be given appropriate
consideration.

8

Following are the Equipments selected with respect to the activity to be
performed for processing and recovery of materials from the mixed MSW of
Sahiwal City.

5.1 Material Handling

Transport of waste materials between the various separation and processing
operations requires a reliable and effective conveyor system. Conveyor systems
include the horizontal and inclined belt.
Inclined belt conveyors will be used to transport waste from mixed waste hoppers
or the tipping floor to elevated materials sorting lines. Materials will then be
removed from the conveyor by manual or mechanical methods and deposited
into their respective bins located below the conveyor. For manual separation
processes, conveyors will be sized to enable sorters to comfortably reach items
on the belt.

5.2 Manual Sorting

The most common system for the manual sorting of material is the elevated sorting
belt with storage bins located beneath. Materials to be sorted are transported to the
elevated sorting conveyor with an inclined conveyor. In this system, sorters will be
located at stations on one or both sides of the elevated, moving conveyor.
Sorting stations are placed so that sorters are not interfering with other sorters. In
other words, if sorting occurs only on one side of the conveyor, sufficient spacing is
provided; if sorting occurs on both sides of a conveyor belt, the stations are
staggered.

Typically, each sorter is responsible for a specific material, and controls are in place
so that the conveyor speed can be adjusted or stopped. In some cases, reducing the
speed of the conveyor may result in a higher-quality product and not significantly
reduce overall processing rates. Other factors that affect the efficiency of sorting
operations include the skill and training of the sorter, the presentation of the
materials to be sorted (e.g., burden depth, time varying distribution of materials), and
worker fatigue. Fatigue is reduced by adjustment of environmental variables such as
temperature control, lighting, and ventilation.

Materials will be removed from the mixed-waste stream moving on the conveyor and
pitched forward or pulled back and deposited into collection chutes. The collection
chutes lead to bulk storage bins for the separated materials. Waste containers may
also be present for the storage of contaminants.
9

Conveyor Belt
Design of Conveyor Belts for the above mentioned activities will be done according
to the following design criteria:

Value
Parameter Unit Range Typical

Belt speed ft/s 01.6 0.5
Belt width
Stations on one side in 3042 36.5
Stations on both sides in 4872 60.5
Belt height in 3642 42.5
Material depth in 06 4.5

5.3 Size Separation

The most common type of size separation process is screening, in which items are
given the opportunity to pass through (underflow) a certain size opening.
The most common types of screens in recycling applications is the trommel screen
which is adopted for the MRF of Sahiwal City.

Factors that are considered in the design of vibratory screen include the following:
Particle size, particle size distribution, bulk density, moisture content, particle
shape, and potential for the material to stick together or entangle
Screen design characteristics, including materials of construction, size of screen
openings, shape of screen openings, total surface screening area, rotational
speed for rotary drum screens and length and diameter for rotary screens
Separation efficiency and overall effectiveness
Operational characteristics (e.g., energy requirements, routine maintenance,
simplicity of operation, reliability, noise and vibration, potential for plugging)

Trommel Screen
Material to be separated will be fed into one end of a tubular, rotating screen with a
downward slope (around 5), so that the material will flow down the screen as it is
dropped and tumbled. Lifters will be placed within the screen to increase the degree
of lifting and dropping of material. Blades or prongs will be included on the inlet end
to open bags.



10

6. LAYOUT OF MRF
A schematic layout plan is attached in annexure-1 as Fig. 1, developed to
highlight the following principle unit operations and equipment employed in
processing materials at MRF:

Manual sorting facilities
Equipment and facilities for materials transport
Equipment for component separation
Weighing facilities
Movable equipment
Storage facilities
Administrative buildings

























* The detailed layout of MRF will be designed on the basis of solid waste loading
rate formulated according to the soild waste generation of Sahiwal city.
11

ANNEXURE-1
(Concept Design Figures)