Ministry of Education and Science of the Republic of KazakhstanL.N. Gumilyov Eurasian National University

Zh.Z. Orazbayev, T.Y. Yermekov, M.V. Dolgov

RESEARCH AND FEASIBILITY OF PARAMETERS OF CONSUMPTION AND PRODUCTION WASTES UTILIZATION

Astana, 2013

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Ministry of Education and Science of the Republic of KazakhstanL.N. Gumilyov Eurasian National University

Zh.Z. Orazbayev, T.Y. Yermekov, M.V. Dolgov

RESEARCH AND FEASIBILITY OF PARAMETERS OF CONSUMPTION AND PRODUCTION WASTES UTILIZATION

(Recommended by Scientific-methods Council, minute#4 dated December 25, 2012, and Board of Academics of L.N. Gumilyov ENU, minute #4 dated December 27, 2012, as a monograph)

Astana 2013

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UDK 628.4 (0758)BBK 30.60I 88

Reviewers:

N.A. Gatzenko – doctor of sciences in engineering , professor of the “Thermoenergetics” department of L.N. Gumilyov ENU, ISA academician, IASR, Member of science academy of

high school, expert of international award “Gold fire of Berlin Gana ”;Sh.A. Tulegenov - doctor of sciences in engineering , professor of the “Thermoenergetics”

department of agro-technical university named after S. Seifullin;Yu.D. Obukhov – candidate of sciences in engineering , professor of Ecology department of

Karaganda state technical university.I-88 RESEARCH AND FEASIBILITY OF PARAMETERS OF CONSUMPTION

AND PRODUCTION WASTES UTILIZATION./ Zh.Z. Orazbayev, T.Y. Yermekov, M.V. Dolgov/ L.N. Gumilyov ENU. Astaana: 2013 -232p.

ISBN 978-601-7400-99-6 In this monograph the technology of solid domestic and liquid wastes as well as production technology, i.e. development of feasibility study by means of substantiation of technological, constructive, energetic, physical-and-chemical and chemical parameters of the processes aimed at fragmenting, degradation and chemization of solid and liquid wastes which provides and facilitates realization of processes by means of pressing, shaping , extruding and so on. This monograph is intended for the scientific professional and students specialized in ecology, students of engineering and ecology specialties.Ill. 44, Bibl. 176UDK 628.4 (0758)BBK 30.60.ya73Considered and approved as a monograph by Scientific-methods Council, minute # 4 dated December 25, 2012, and Board of Academics of L.N. Gumilyov ENU, minute # 4 dated December 27, 2012ISBN 978-601-7400-99-6

© L.N. Gumilyov Eurasian National University, 2013

© Zh.Z. Orazbayev, T.Y. Yermekov, M.V. Dolgov

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INTRODUCTION

The process of interaction of society-man-environment system should be considered as the creator of consumption waste in an unlimited amount and this consumption waste is endless, as there can be the run out of the Earth reserves of raw materials, it should be noted that raw material waste is connected with the existence of mankind.

Waste is materials and substances produced as a result of human activity being the evidence of human existence from ancient times.

At the beginning of the XX-th century academician V.I. Vernadskiy formulated rules about chemical, physical, anatomical and morphological principles of waste production.

In recent years the problems of waste utilization that is the product of our daily life activity has become one of the most serious environmental problems.

With the development of civilization the amount of waste discharged into the environment is increasing. The modern society is often called “the society of mass production, consumption and waste discharge” where consumption brings the next consumption [1-3].

Once in Europe, the USA, Japan, Australia and other countries waste utilization has become an evident and serious problem as a result of soil contamination by hazardous substances and the increasing number of town’s landfills, huge amounts of money were allocated for the restoration of the disrupted balance of the environment, prevention of emission of harmful substances, development of recycling or waste sorting.

In urban areas there is the most intense accumulation of household waste and liquid industrial waste which if not removed improperly or untimely can heavily pollute the environment.

No less serious environmental problem is the processing and storage of industrial and household waste which accumulated on the territory of Kazakhstan in the amount of more than 20 billion tons, including 6.7 billion tons of liquid and toxic waste. Each year the number is increasing by one billion, which directly threatens human health.

This is explained by the fact that 95% of waste is transported and stored in open dumps which do not meet the requirements of the environmental and health legislation of the Republic of Kazakhstan. Their disposal and arrangement is carried out without projects and evaluation of the impact on the environment. Only 5% of household waste in the Republic of Kazakhstan is utilized or incinerated.

The society increases the consumer satisfaction through the nature and the nature itself serves as a resource and material and special basis for the society.

On the global scale the direction of civilization has led to its degradation. The development of production has reached the level where social and economic

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development of states is considered in a close relation with the quality of the environment. First of all the urgency of the problem is determined by the need to minimize the negative effects of a man-made process.

Environmental problems have moved into the sphere of global strategic goals of mankind survival. The concept of the conquest of the nature has led to the destructive kind of development of scientific and technical progress and economic activity[4-9].

At present promising direction of household waste processing is a chemical method proposed by the scientists of L.N. Gumilyov Eurasian National University, who received more than 20 innovative patents of the Republic of Kazakhstan.

The purpose of the proposed development and research project of production technology and consumption of solid and liquid household waste (PTCSLHW) is the development of feasibility study (FS) of technological, technical, climatic, structural, energy, chemical and physical and chemical parameters of the processes of crushing, grinding and chemicalization of solid and liquid waste, which will ensure and help to implement the processes by compacting, shaping and extruding etc.

The result is threading of technological processes of crushing all components of solid household waste (SHW) to dimensions of 10 mm, without involvement of a person at all stages of the operation. As an analyzing measuring device, with the end result of crushing all morphological solid household waste, there was accepted serial mineral processing equipment [10-17].

Released from the major components by extracting and dissolving on the scraper conveyors SHW goes both though washing and drying, which releases it from excess moisture. Washings fluid (emulsifiers) saturated with odors and gases is put into a mixer, where it goes through chemicalization produced and then is used to generate electricity.The dried SHW is put into a storage bin, which "smooths" the SHW cycles, then by portions it goes into pre-crushing machine. Cargo electromagnetic device takes out iron materials, waste, etc. Thereafter SHW with dimensions of 80 mm goes into pre-crushing machine, where it crushes to a size of 40 mm, and then it went through the second crushing and grinding to a size of 10 mm. At this stage the operation of crushing SHW by carried by gear and foot crushing devices.Then chemical method of SHW processing by mixing with chemical waste, such as sludge of galvanic production, acidic resin, coke fust, petroleum products waste, paints, lacquers, enamels, resins, and liquid waste of engineering industry. Chemical mixing processes are carried out by the following operations: a common mixer receives the crushed SHW as well as liquid mixed chemical waste from special tanks, as well as the polymer component, which allows you to receive chemical compounds of all components of solid and liquid wastes.

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In order to speed up chemical reactions the mixer equipped with a special construction of rotating diamond-shaped screws which are regulated and reversed depending on the content of SHW and components of chemical compounds in the mixer which if necessity will be equipped with special devices for monitoring and controlling chemical processes in the mixer. Waste after the processing in the form of slurry and gas moving away from the mixer to the treatment system for the further addition of various industrial waste of mining and steel plants, electricity and district heating, etc.

With the help of chemical additives they are prepared as a slurry to the next stage of extruding, pressing and shaping, at which it is necessary to determine the composition of the binding elements, such as sand, silt, ash, building grinded waste and others with dyes that allow you to get a variety of colors and glitter . For safety of the processes of waste recycling it is not allowed to use special hazardous, radioactive, medical, explosive, flammable liquids and soil, pyrophoric substances, flammable, dead animals and industrial waste water, wash water, etc.The processes of extruding, pressing and shaping are conducted on the basis of the existing technological equipment needed, depending on the products, goods and materials to determine the correlation of chemical additives and binding elements. For example, for the production of materials, such as boards, poles, fences, railway snow-retaining fences by means of extruding it is necessary: chemical additives - 10% sand - 30%, ash 8%, silt - 5%, dyes - 5% and the remaining 42% is chemical slurry from the mixer-blender.

As investment projects there will be determined technologies of food waste processing, used household and electronic appliances, used batteries, batteries of mobile and cameras. Development of technology for production of new materials from phosphoric industry waste for the use in various industries, environmentally safe technologies for complex processing of mineral chemical production waste, that will be carried out with the help of technological lines of the waste utilization factory for solid and liquid household waste(SLHW).

Design of the construction of a special device for waste processing by cutting various polymer tires, information technology waste for the purpose of grinding it to a size of 1-3 mm for chemical compounds in the mixer, which leads to new types of environmentally friendly materials.

Development of methods to neutralize harmful substances and hazardous toxic waste for the use in the chemical compounds with different industrial and consumer waste.It should be noted that the waste utilization factory for solid and liquid household waste provides the technology of complex processing of oil sludge, which eliminates pollution of environment.

Waste utilization factory for solid and liquid household waste allows to use technology to obtain a product from bulk waste taking into account the peculiarities of the construction industry of the country.

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Laboratory studies have shown that from one ton of chemical compounds of SHW and liquid industrial waste there can be obtained up to 20 m3 of different gases (methane, propane, etc.), from which you can obtain 100 million kilowatts of electricity per shift.

Innovative technological project of one line of oil and gas industry waste recycling allows producing new materials by using with chemical compounds with production and consumer waste and allows you to recycle sludge without pollution of the environment.

As a result there were obtained new materials thorough chemical compounds of SHW and production waste and there were studied their physical and mechanical properties to determine conditions of application. It should be noted that waste utilization factory reduces greenhouse effect in the atmosphere.

Relevancy and usefulness:Environmental safety is the compulsory condition of development in the

urban areas in advocates prerequisite for development in urban areas in the context of sustainable development. The process of interaction of society-man-environment system should be considered as the creator of consumption waste in an unlimited amount and this consumption waste is endless, as there can be the run out of the Earth reserves of raw materials, it should be noted that raw material waste is connected with the existence of mankind.

Method of utilization of household waste and liquid household waste allows to design a new generation factory in which all production processes are automated on the basis of modern technologies.

The advantages of the waste utilization factory for household and liquid waste are the following: [21-24]

1. There is no physical or manual work;2.There is no need in landfills for waste disposal as there is conducted

chemicalization of solid household and liquid industrial waste recycling;3.Occurring gases during waste chemicalization are used for heat and

electricity generation; 4. All kinds of solid and liquid waste (excluding metal and concrete) are

recycled into useful, import-substituting products and products for power supply, and used also for the production of adult and children's shoe bottoms;

5. The abovementioned recycled products are sterile, inert, non-degradable, non-combustible, durable, reliable materials with service time of over 50 years.

On the subject of the study there were conducted the following work: 1. There has been developed innovative technology for utilization of

production and consumer waste through chemicalization with the help of which you can get more than 100 items of new products and products for various industries;

2. There has been developed special innovative technology line for disposal of chemical waste through chemicalization;

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3. There have been developed specific recommendations on environmental, health and epidemiological safety of technology line work with all operations for obtaining new materials through chemicalization;

4. There has been developed a special instruction and standard that meet international requirements in order to attract investment projects on utilization of production and consumer waste in the CIS countries and abroad;

5. There has been developed an innovative industrial project on utilization of production and consumer waste by the chemical method, instead of urban landfills, waste sorting plants, which are widely used in the United States of America, Japan, France, Germany, Italy, Russia, and others;

6. There has formulated a conception of public administration in the field of waste management and environmental safety;

7. There has been composed a glossary on waste;8. There was provided a conception of public administration;9. There was developed an innovative method of utilization of production

and consumer waste by chemical and physical method, which allows you to get innovative materials for various industries, and also provides heat and electricity generated by released gases:

а) Method of thermal pressing from polyethylene and polyethylene regenerator;

b) Method of outer wrapping of worn-out metal pipes with thermoplastic and device for its implementation;

c) Method of applying a plastic coating on the inner surface of the worn-out metal pipes;

d) Indication of the position of hydrocylinder with reception of different materials as well as waste utilization management;

e) adaptive computer control of utilization of consumer and industrial waste;f) automatic control of utilization processes of technological line;g) design of device for grinding waste to a size of 1-3 mm. The strategy of the President of the Republic of Kazakhstan on ranking

among 50 most competitive countries of the world encourages the society to develop innovative technologies. Kazakhstan joined the Stockholm Convention on persistent organic pollutants, so it is necessary to work through the law on waste management.

In the Republic of Kazakhstan there was established Higher Technical Committee (HTC), which will determine key priorities for the development of science. At the Astana Innovation Forum on May 28, 2010 Parasat holding there was considered an innovative industrial project titled “Utilization of solid household waste and liquid industrial waste instead of town landfills and waste sorting plants"; in the laboratory there have been obtained new import-substituting materials.According to the letter No. 57-3 dated March 5, 2010 titled “Department of natural resources and control of Astana city" there is provided the possibility of building a

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pilot plant for utilization of household and liquid waste in 2012.For the first time in the world practice there is carried out a research of technological processes of solid household and liquid industrial wastes recycling by chemical method.

Scientific and practical significance of the research as well as research objectives:

The main advantage of technological processes of solid household and liquid industrial waste recycling (SHLIW) is the exclusion of solid household waste sorting operations and the abandonment of the town landfill;

The essence of technological processes of solid household and liquid waste is to ensure threading of technological processes of solid household waste utilization of all morphological structures by drying then crushing and grinding with minimum technological operations;

Increase of productivity and efficiency of crushing processes of all solid household waste components by means of chemicalization of solid and liquid waste for which it is necessary to conduct scientific and research and experimental works;

Theoretical and experimental parameter researches of chemicalization of solid household and liquid industrial waste taking into accounts environmental and production safety requirements and environmental purity of the products.

Expected results:– produced gases through chemicalization (methane, propane, butane, etc.)

is used to produce heat and electricity;– all types of waste are recycled into new useful products and import-

substituting products for various industries, which account for more than 40 names;

–there is no need in sorting and disposal of solid household waste on landfills;

– the process is not accompanied by harmful emissions into the atmosphere, and is not harmful for water resources and earth surface;

– full health and labor safety through automation of all production processes is ensured;

– all products are environmentally friendly;– there is no need the preliminary selection and separation of waste. New innovative project on recycling and utilization of solid household waste

by chemical method is included in the program of scientific and research and development works of the Ministry of environmental protection of the Republic of Kazakhstan for the years 2012-2015 [25-26, 66-76].

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1 STUDY OF PARAMETERS AND SELECTION OF TECHNOLOGICAL EQUIPMENT FOR CRUSHING PROCESSES AND GRINDING OF SOLID HOUSEHOLD WASTE OF ALL MORPHOLOGICAL COMPOSITIONS

1.1 Review and analysis of recycling and utilization of solid household and liquid industrial waste in the CIS countries and abroad.

Currently in Almaty, Astana, Karaganda and other cities of the Republic of Kazakhstan the entire amount of produced solid household waste (further SHW) is transported and stored without sorting and processing on landfills [8, 27].

According to the regional department of environmental protection as of January 1, 2003 about 4.4 tons of solid household waste is disposed on landfills, and in 2004 it is planned to transport about 900 tons.

This amount of waste causes insanitary, environmentally dangerous situation in the area. It was therefore necessary to design and construct waste recycling plant with sorting, recycling and utilization of waste.

The analysis of morphological composition shows (Table 1.1) that one cubic meter of solid household waste contains: 36% of paper, 14% of food waste, 6% of textiles, 4% of metal, 4% of glass, 9% of plastic and polymer containing waste. Moreover the proportions of polymer waste in the total mass increases.

Table 1.1 – Morphological composition of solid household waste as of 01.01.2010

Solid household waste classification

% of the total amount of SHW Europe CIS

countriesUSA RK Karaganda

cityPaper 24,7 20-36 38,0 36,0 36,0Food waste 37,8 20-38 25,0 13,0 14,0Wood - 1-4 - 4,0 3,0Textile 7,8 3-6 - 6,0 6,0Bones - 2,5 - 4,0 4,0Scrap metals 2,8 2-4 8,0 4,0 4,0Glass 2,8 5-7 7,0 4,0 4,0Plastic 8,0 8,9 8,0 9,0 9,0Other (oversized items, chemical and construction waste, rubbers, tires, etc )

16,1 10-35,5 15,0 24,0 20,0

TOTAL 100 100 100 100 100

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Damage to the population and the national economy of the Republic of Kazakhstan is growing both because of unsanitary conditions of landfills, and because of the corrosion of utility pipes (heating, water supply and sewerage) and reaches a billion tenge per year. Corrosion of utilities (heating, water supply and sewerage) creates overrun of water and heating, the response contamination of water supplied through the pipe and ground water, chemical activation of the protection of soil, which destroys the pipes from the outside. Waste and ground water contaminated as a result of contact with industrial and household waste, adversely affects the chemical composition of the soil, and utility network construction, buildings and facilities placed in it. There was the increase in products from virgin polymers and their compositions, produced in the form of packaging and containers for various purposes, household items, appliances, and technical parts. According to Karaganda public transport management every month more than 180 tons of polymer, plastic, industrial and household waste is transported on landfills that pollutes the environment as the duration of its resolution is more than 200 years. Laboratory experiments have shown that recycling of polyethylene changes the mechanical properties by 17-21% in the direction of reduction (Table 2.3), the other properties remain unchanged. Solid household waste of plastics can be recycled to produce products that do not require high mechanical load: window and door frames, boxes, plates, panels, automobile parts (bumpers, handles) and snow retaining fences for railway transport, the outer shell for metal pipes to protect from corrosion by groundwater, inner lining of heating water and sewage pipes. [26]

Theoretical and experimental studies show that technological processes of sorting, cleaning, separation and recycling are conducted by mechanical, hydrostatic operations of division in the electrostatic field and the operation magnetohydrostatic division in the paramagnetic fluid composition of which neutralizes the biological contamination of waste, especially polymer waste.

In CIS countries (Russia, Ukraine, Belorussia and other), in the countries of far abroad (the USA, Japan, Germany) there is no complex processing of solid household waste with the purpose of extracting the polymer components of solid household waste with the subsequent use for polymer products and coatings . In these countries there is prevailing tendency to burn solid household waste to produce heat and electricity.

Table 1.2 – Value of main operating parameters of plastic waste during extrusion

ParametersGOST 18599-83PNP PVP

Heater temperatureТн, 0С 200+10 230+10

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Pressure during the melting of the ends of blank parts Рпр, MPа

0,03-0,05 0,06-0,08

Depth of penetration of pipe material, mm 1-2 1-0 Duration of the melting tн with wall thickness, mm up to 4 5-10 10-15 16 and more

3550-8585-160160

5070-110110-200200

Duration of technological break, с 3 2 Welding pressure Рос, MPа 0,1 0,2Holding time under welding pressure tос, with blank parts wall thickness, мм Up to 45-1010-1516 and more

180240-480480-720900

240300-540540-720900

Table 1.3 – Main physical and mechanical properties of polyethylene before and after extrusion GOST 18599-83

Indicators PVP PNPDensity, g/sm3 0,945-0,965

0,756-0,7870,918-0,9330,886-0,897

Tensile yield stress, MPа, no less than 20,0/18,9 9,5/7,2Elongation at failure, %, no less 200/186 210/197Modulus of flexibility, MPа, не менее 800/735 200/189Melting range, 0С 127-135

120-128105-112101-106

Environment temperature, 0С from-30 to +60 from-30 to+60Heat coefficient of linear expansion, 1/ 0С 2*10-4 2*10-4

Thermal conductivity, vt/(m 0С) 0,42 0,34Thermal capacity, kJ 2,5

2,32,52,3

Brinnel Hardness, Н/mm2 45-5438-46

14-2512-23

Vicat softening temperature, 0С 30 60

Surface resistivity, Оhm*m 1,2*10145*1013

Volume resistivity, Ohm*m 8,2*1014 7,8*1014

Note: the numerator with primary properties of polyethylene, the denominator - the secondary extrusion.

Table1.4 – Comparative analysis of alternative solutions to technical and value characteristics

# Indicator Indicator value in US dollarsThe best in the world practice

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Proposed sample (Solid

household waste sorting and recycling

factory)

USA NSLHYNDROM

EX

ASTAnlagen Berlin GBH

Version 1 Version 2

1. Construction works 1200000 2391000 2704500 2000500 2. Equipment 2300000 22200000 5041000 4551700

3. Packaging, transportation,

insurance

25000 796400 282100 348800

4. Erection supervision works, check out and start up and training

400000 1600000 1122400 949500

5. TOTAL 3925500 27000000 9250000 7850500

6. Production capacity per year

210000 300000 60000 60000

7. Annual output $ USA 6800000 8700000 1600000 1160000

By extruding the various components of the waste (plastics, cardboard, paper, textile, rubber, glass, etc.), you can receive the following types of railway and construction of snow-retaining fences according to the instructions on the snow control on railways of the RK No. CP-751/1, 2001.

There was carried out theoretical and experimental researches of technological processes of sorting, cleaning, recycling waste in the electric field as well as researches of the magnetic hydrostatic separation in bioneutralizing paramagnetic liquid which is exposed to voltage controlled magnetic field , thus there is a deactivation of the selected components. By recycling plastic waste there can be produced:

- Railway products and signs;- External and internal coating of worn-out pipelines;- Road products and signs;- Window and door sets;- Agro-farming products building materials;- Finishing materials (plates, panels, fittings);- Machine and construction polymeric materials.The main consumers of such products can be automobile, construction,

wood-processing, textile factories, utilities. The main objective of this project is to develop a non-waste technology for processing household waste. Ferrous and non-ferrous metals can be supplied by steel companies.

Since 2002 JSC "Trunk rail road" is the customer of snow-retaining and snow-overblowing fences and also shields, road signs and the blow-up cards for

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railways from polymer waste. The annual volume of purchases of the above products is over 495 million tenge.

Plastic waste can be recycled, paper and cloth can be the raw material for the production of cardboard or components of products for railways. In addition to the above mentioned products for the railways by waste extruding you can obtain:

Portable lattice panels;- Markings for crossings of railways and roads.The raw material for the production of products will be the components of the waste: plastic products, paper, old clothes, plastic waste.

- portable latticed shields;- identification signs for railway and road crossings.The raw material for the production of products will be the components of

waste: plastic products, paper, old clothes, plastic waste.Waste will be sorted and then sent for recycling. The main component for

the coating of the used metal pipes is recycled polyethylene, derived from the mass of industrial and household waste.

Method of production depends on the nature of the surface pipe insulation, their diameter and length.For pipes coated on the inner surface or outer surface of the device there are used devices that allow simultaneously to apply a layer of material on the outer and inner surface of tube.

Metal pipes that were in use and which are necessary for covering the impact-resistant thermoplastic will be delivered from landfills and from interested parties or potential buyers. Delivered pipes will be reeled if necessary. The remained part will be prepared for the process of coating, after the ends are processed.

Production cycle of pipes with thermoplastic coating of surfaces include:1. Mechanical cleaning from foreign contaminants (dirt, a thick layer of rust), followed by processing with a turning lathe;

2. The surface processing to give high adhesion properties to the applied materials by using a special machine with reeling devices with the application of a polymeric tape;3. Introduction of the metal pipe in the coating zone for applying a black tape;4. Removal of the finished product from the coating zone;5. Preparation of finished products to be sent to consumers or shipment of the finished product in a stock.

The main raw material for the production of bumpers, air stripper for cars, window frames and door frames is recycled polyethylene. After obtaining the liquid mass of recycled polyethylene this mass will be filled out into special devices and then into special forms. After cooling the products will be transported in a stock.

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Metal pipes, which were in use, with certain surface damage and coating with thermoplastic which can be reused in the same operating conditions (except for the strong heating), as its surface is more resistant to corrosive nature of the environment during the exploitation due to high inertia of wrapping thermoplastic (polyethylene) to acid-alkali resistance, solutions, humid air. The internal metal frame increases the stability of the relatively thin plastic layer to mechanical loading. The layer of thermoplastic material on the surface of the metal pipe that was in use increases the operation time without repairs by 3-5 times. This will reduce the number of accidents occurring because of corrosion of pipes.

Collection of industrial and household waste will be carried out by special machines into specially equipped containers. This will improve the sanitary condition of the city and the region, and thus have a positive impact on the environment.

With the successful implementation of this project experience in production could be used in the other regions of Kazakhstan, as well as to establish mass production in the regions.Snow-retaining fences and other materials from plastics waste are two times cheaper than wood and concrete material and their service life is 50 years.

In urban areas there is the most intense accumulation of solid household waste (SHW) and liquid industrial waste (solutions of inorganic and organic substances, organic fluids in the form of oils, solvents, etc.), which, if improperly and untimely removed and disposal can heavily pollute the environment.

Countries of the world can be divided into several groups, depending on the solid waste management policy based on regional, climatic, geological, economic and political conditions.For example, in Japan, more than 70% of waste is burned by the city authorities. In countries such as Switzerland, Denmark, Luxembourg waste is also burned (about 70% of the total volume) due to the high population density, high GDP and the limited areas.

At the same time in the USA, Canada, Spain, Norway, Great Britain, Germany, Italy, Portugal and Finland 60-90% of waste is disposed on landfills of solid household waste. In Spain, Portugal and Finland about 10-20% of solid household waste is transported in the plants of complex processing. In Spain, Canada and German more than 10% of solid household waste is sorted at intermediate stations in order to obtain valuable materials from waste.

In France, Belgium and the Netherlands, more than a half of town waste is transported to landfills, 25-40% of the remaining solid household waste is burned, and the rest is cleared for composting or for obtaining useful materials.

The ground mass of solid household waste without separation (sorting) into components is transported and stored in open dumps, town landfills, 97% of which do not comply with environmental and health legislation of Kazakhstan. In many towns disposal of waste is carried out without projects and assessment of the

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impact on the environment. Only 5% of solid household waste in Kazakhstan is disposed or incinerated.

There are several technologies of intermediate cleaning in the world: burning, burning with heat regeneration (including electric power generation), burning with ash dust melting and gasification with solid materials melting, fuel waste regeneration, composting, crushing and sorting.

It should be noted that foreign investors LLP "Vtorma-ecology", JSC "Imabeiberika" (Spain), ASTA Anlagen (Berlin, Germany), AK "Altyn almas" (Spain partner from Kazakhstan), "Juventa-DV" (Germany) others, not sparing the funds are aiming at introducing in the cities (Astana, Almaty, Atyrau, Karaganda, Aktobe, etc.) the old technology on disposal, sorting and burning of solid household waste.

The main advantage of technology of solid household and liquid industrial waste recycling processes (SHLIW) is the exclusion of solid household waste sorting operations and the abandonment of landfills for urban household waste [27-41].

In recent years according to the report data for the years from 2006 through 2009 the amount of waste for disposal in Astana is the following (Table 1.5):

Table 1.5 – Data for the years from 2006 through 2009 the amount of waste for disposal in Astana

№ Waste input in landfills 2006 (m3) 2007 (m3) 2008 (m3) 2009 (m3)

1 Total waste input 553289,9 601449,0 678940,3 974962

2 Solid household waste disposed 5211253,6 574034,6 616050,3 906795,5

3Industrial, liquid and medical waste 32036,3 27414,5 62290 68166,5

During the development of Astana city there was a significant increase in accumulation and there was a change in the composition of waste from residential, industrial buildings, health institutions, business and industry.

From the standpoint of health and safety regulations and environmental protection, the current system of waste management in Astana will be developed in order to ensure minimal impact on the environment.

The ground mass of solid household waste without separation (sorting) into components is transported and stored in open dumps, town landfills, 97% of which do not comply with environmental and health legislation of Kazakhstan. In many towns disposal of waste is carried out without projects and assessment of the impact on the environment. Only 5% of solid household waste in Kazakhstan is disposed or incinerated.

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In order to choose alternative solutions of solid household waste recycling there was conducted an analysis of the World practice of using the options of waste recycling and sorting plants in terms of cost, technological and environmental factors which are shown in tables 1.6, 1.7, 1.8.

Table 1.6 – Comparative analysis of alternative solutions in terms of technical and cost characteristics

№ Indicators

Indicator value in US dollarsSolid

household waste

recycling and sorting

(Kazakhstan)

The best in the world practiceNSL

НYNDROMЕХ (the

USA)

ASTА AnlagenBerlin (Germany)

Ak-Altyn-almas

(Spain)

LLPVtorma-ecology (Spain)1 2

1 2 3 4 5 6 7 8

1 Construction works 1500000 2391000 2704500 2000500 9800000 7430667

2 Equipment 3000000 2220000 5041000 4551700 22600000 19466666

3 Packaging and transport 25000 796400 282100 348800 3200000 644835

4Erection supervision works, check out and start up

4000000 1600000 1122400 949500 5300001 2250169

5 Total in US dollars 5 000 000 27000000 9250000 7 850500 32300000 27272422

6 Production capacity per year (tons)

210000 (800 t per day) 300000 60000 60000 200000 420000

1 2 3 4 5 6 7 8

7Annual volume of production 6 800000 8 700000 1600000 1 160000 1 472000 1 000000

8 Payback period 1,5 8 6 4 5,3 7

9 Construction period (months) 11 28 14 16 1,4 1,2

10 Technology and equipment Domestic The USA Germany Germany Spain,

GermanySpain, Germany

11Area for location of the plant 4,2 6,8 5,6 5,2 5 5

12 Delivery of ancillary equipment

Domestic equipment

Imported equipment

Imported equipmen

t

Imported equipment

Imported equipment

Imported equipment

The poorly organized landfills located everywhere around the cities are the

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most serious polluters of surface and ground water. As a result of migration of chemical substances contained in the effluent of solid household waste from the territory of the existing and reclaimed landfills (dumps) into surface and ground water soil and water sources contamination.

Table 1.7 – Comparative analysis of types of waste recycling plants in terms of technological characteristics

№ Types of plants

Technological indicators of solid household waste

Waste disposal on

landfills

Direct transporta

tionSorting Storage

(dispatch)Intermediate stations

Solid household

waste recycling

Deactivation

1

Solid household waste sorting and recycling plant (Kazakhstan)

no yes yes no no completely completely

2

Solid house hold and liquid waste utilization(Kazakhstan)

no yes no no no completely completely

3USA NSLНYNDROMЕХ

no yes no no no completely completely

4 ASTAAnlagеn(Version 1) yes no yes yes yes partially partially

5

ASTAAnlagenBerlin(Version 2)

yes no yes yes yes partially partially

6Ak-Altynalmas yes no yes yes yes no partially

7“Vtorma-ecologiya” LLP

yes no yes yes yes no partially

Table 1.8 – Comparative analysis of types of waste recycling plants in terms of environmental indicators

№ Types of plants Environmental indicators

18

Absence of harmful

products for disposal

Absence of harmful

emissions into the

atmosphere and water resources

Imported equipment

Level of automation

of production processes

Presence of physical

and manual work

1SRSHW plant Completely

absent partially Kazakhstan yes no

2 SHLWU Completely absent absent Kazakhstan yes no

3 USA NSLHYNDROМEX

Completely absent absent From the

USA yes no

4 ASTA AnlagenBerlin (1 version) partially absent From

Germany no no

5AST А AnlagenBerlin (2 version) partially absent From

Germany no yes

6 Ak-Altynalmas partially absent From Spain no no

7

“Vtormaekologiya” LLP

Complete disposal of

solid household

waste

absent From Spain no yes

The results of the comparative analysis of types (Table 1.6, 1.7, 1.8)of solid household waste recycling plant show that the most promising indicators in terms of environmental, economic, technological, and other indicators of the world standards are the plants of NSL HYNDROMEX (USA) and solid household waste sorting and recycling and solid household and liquid waste utilization plant (Kazakhstan).

1.2 Economic problems of ecology in the transitional period of the Republic of Kazakhstan

Environmental issues have become one of the most important factors that have a direct impact not only on the development of the national economy, but also on people’s health and life in any region [42-51].

Giving priority to the solution of the main tasks of the day, to the implementation of the radical economic reform, which aims at creating the necessary economic conditions for solving social problems, which include ecological safety, as an integral and inseparable part of this task we must consider environmental protection issues and issues of rational use of natural resources. As

19

the most important means of achieving this goal there shall be accepted transition to the market regulators of development.

World experience shows that as environmental problems are aggravating and the quality of the environment is deteriorating in all countries with developed market economy there was created and strengthened centralized administrative systems of environmental management (command and control systems).

Initially these systems were based on the legal restrictions of the harmful impacts on the nature, its tightening and government regulation and control of such impacts and the use of various kinds of sanctions to violators of environmental laws.

There have been expanded the scope of gratuitous state funding of environment protection activity. Economic incentives played a secondary role.However, as the costs of environmental protection was increasing there has been identified their low efficiency compared with other areas of management, environmental management susceptibility to scientific and technical progress (STP), the lack of "power" methods of the nature protection and the need to reinforce them with a powerful system of economic incentives. There have come up a question of transformation of the existing administrative systems of environmental management into complex administrative and social economic systems. The distinctive feature of such systems is the use of economic (market) regulators of encouraging entrepreneurial initiatives in the rational use of natural resources while maintaining and strengthening the state and public control and regulation in the field of environmental protection. Obviously, we do not have other alternative.

Not so long ago in our country mechanism of regulation of the use of natural resources was based on the policy regulations and state standards that define the maximum allowable emissions of pollutants into the environment, health standards, etc., i.e. on the standards, which are not of cost and economic feature. Thus, in compliance with the prescribed "limits” the enterprise did not bear any costs on compensation of damage caused to the environment. These costs were covered by the territory as a whole or not covered at all.

Penalties for violations of sanitary regulations or occasionally received administrative sanctions could not significantly improve the situation, as used in extreme deviations, and not as an element of control of the enterprise activity. This environment protection policy is weakly connected with real economic interests of enterprises. It became obvious that the traditional administrative methods of environmental management are ineffective without economic ones.

It became clear that the market mechanism provides a more favorable environment for the rational use of natural resources rather than strict administrative measures. The market mechanism of pricing is not compatible with the artificial cheapness of natural resources or their free of charge basis, cultivated by the administrative-command system. The market laws dictate higher prices for natural raw materials in relation to the prices of final products. The market

20

mechanism expands the boundaries of profitable investments in the conservation of natural resources with the growth of their deficit.

To ensure the effectiveness of environment protection policy there is a need in orientation of the economic interests of the use of natural resources on nature conservation objectives and rational use of natural resources, the creation of the economic mechanism of environmental management and environmental protection (hereinafter: economic mechanism of the use of natural resources). The legal basis for creating and putting into operation this mechanism emerged with the introduction of the Law of the Republic of Kazakhstan “on environmental protection".

What is economic mechanism of the use of natural resources?The core of the mechanism focused on planning and funding environmental

protection measures is introduction of fees for the use of natural resources i.e. a special form of compensation of restoring expenses, which include:

- Fee for the use of natural resources;- Fee for the protection and restoration of natural resources;- Fee for environmental pollution.

Fees for the use of natural resources are the main sources of forming targeted economic foundations through which you can finance environment protection activities of state, cross-sectoral and regional type.

But it would be absolutely wrong to think that economic mechanism of the use of natural resources only consists of a system of environmental charges. This fee system is very important, but only a single component of the overall integrated economic mechanism of the use of natural resources.

How do we environmental specialists see the whole process of creating and putting into operation the economic mechanism of the use of natural resources? This work consists of two composite directions and should be carried out at two stages.

For this purpose at the first stage it is planned for the whole country to introduce all of the above fees for the use of natural resources with building systems of environmental restrictions within the territory and the ecosystems in which productive forces should be developed and distributed. In addition, to create a legal and regulatory and methodological base to ensure the economic responsibility for violation of environmental laws. In the same period it is necessary to create a multilevel system of environmental foundations. Economic mechanism of the use of natural resources cannot and should not include only the "repressive measures". Therefore, at the second stage of implementation of general economic mechanism of the use of natural resources in certain moments in parallel with the first stage should be developed and implemented a powerful system of economic incentives for environmental protection activities with changes in the tax, credit and depreciation policy.

21

Under this system of economic incentive it is suggested the creation of right sales and purchase market for emission of pollutants into the environment, the introduction of a number of benefits to abolish the tax with the parallel introduction of a special tax on environmentally harmful products manufactured with the use of environmentally dangerous technologies. It is necessary to plan the introduction of accelerated depreciation of environmental facilities and structures, as well as concessional lending and funding of enterprises to carry out effectively tasks of environmental programs. All this provides the inclusion of environmental indicators in the system of planning calculations and economic incentives and economic activities of production and territory. The environmental funds created at the first stage are converted into environmental banks.

And, of course, the tasks of the second stage cannot be implemented without parallel improvement of pricing on products of nature-exploiting industries. With the transition to the market of wholesale taking into account of the changes in the economy of the use of natural resources it is necessary to regulate stimulation of cost-effective use of resources, production of environmentally friendly products and reduction of environmental pollution. Today all of this set of measures to create a single economic mechanism of the use of natural resources, which is the basis for the creation of the new market economy of the use of natural resources there was introduced one of the tasks of the first stage i.e. charges for environmental pollution with the partial introduction of environmental restrictions, although in this section additional developments are needed.

Unfortunately, after the introduction of payments for environmental pollution, the further creation of the economic mechanism of the use of natural resources is not implemented. The main articles of the Law of the Republic of Kazakhstan are not functioning, and consequently payment for the use of natural resources and the fee for the protection and restoration of natural resources is not applied because of the absence of regulatory and methodological basis for the implementation of the above-mentioned environmental charges.

In this case, we do not take into account specific economic groundless methods of payment for the use of natural resources.Unfortunately, little can be said about the tasks of the second stage of the economic mechanism of the use of natural resources. They are not completely finished.

The general trend of decline in production, the violation of economic relations and as a result, an increase of transition period to the market economy, obviously, has had an adverse effect on that there was not created regulatory and methodological basis, and at the second stage there was not created the legal basis for involving the economic mechanism of the use of natural resources i.e. the basis of the market economy of the use of natural resources.

The lack of real economic leverage of the efficient economic mechanism for the rational use of natural resources, well-grounded economic requirements of its full recovery and reasonable set of economic incentives do not motivate businesses and agencies for environmental friendliness.

22

Obviously, we have come to understanding that the ongoing organizational and structural changes of environmental authorities and the solution of very important, but still certain economic problems without creating a single economic mechanism of the use of natural resources cannot contribute to further improvement of environmental management, creation of a single, coherent management system of environmental safety in our country.

Here I would like to draw your attention to the fact that the economy of our country has a separate component i.e. the economy of ecology. But, unfortunately, the economy has not only "white spots", but also whole white fields. It should be borne in mind that it is not just about changing or putting into force certain economic indicators, but also the need to use a number of new economic concepts and categories, or changing the essence of some of the existing ones. The solution of all these economic problems is quite difficult, and in a number of new questions is new not only for us but also for a number of countries with a strong tradition of market economy. It is more important not to lose time and now as part of the overall transition to the market economy to address these important tasks. It is necessary to develop environmentally friendly industries that would correspond to the new technological and technical solutions on building a plant for sorting and recycling of solid household waste for cities with population of over 500,000 residents.

1.3 Selection and calculation of equipment parameters of technological line of waste utilization

Selection and calculation of equipment parameters for washing and drying solid household waste.

Cylinder drier is distinguished by high capacity, low energy consumption, low maintenance and operation safety [25, 26].

The length of cylinder drier is determined by the formula:

(1.1)

where W – the amount of evaporated moisture from SHW, kg/h; А –voltage of the cylinder drier on moisture, кg/m3· h.For slurry А = 120 kg/m3· hWith humidity of 6%, W = 600 kg/h, then Vб = 600/120 = 50 m3

With diameter of cylinder drier D = 2 m.

The selection of equipment for crushing and grinding solid waste.Gear double-roll crushers are designed for large and medium crushing of solid

23

household waste.Capacity of the gear double-roll crusher is taken from the catalog. It can also be calculated by the formula:

: Q = 188·D·n·L·S·δ·μ, t/h (1.2)

where Q – capacity of gear crushers, t/h; D – Diameter of rolls n –Rotating speed of rolls, rot./min; L – Length of rolls, m S –Width of the gap between the rolls, m d –Density of material, t/m3 m = 0,25+0,58 –disintegration coefficient of material;Diameter of rolls is determined by the formula D=(2+4)dmax, where dmax –

coarseness of the suppressed material. Based on the coarseness of the material we select a crusher (dmax = 200 mm), shaft diameter D=(2-4)dmax= =400-800 mm.

From the appendixes we select a gear crusher. The most suitable are the crushers DRO-577 and DRO-579. Their technical specification is given in Table 1.9.

Table 1.9 – Technical specification of the crusher DRO-577 and DRO-579

Indicators DRO-577 DRO-579Capacity ,t/h 125-180 150Maximum size of a piece of the crushed material, mm

800 600

Size of the crushed product, mm 0-150 0-125

Sizes of rolls, mm:

Diameter 900 630

Length 900 800

Rotating speed of rolls, rot./min 36 50

Motor power, kW 25,0 20

Mass of the crusher, kg 11400 12000Basic dimensions, mm

24

Length 4000 3600Width 3270 34450Hight 1215 1235

Selection and calculation of bins and the various vessels of technological line of waste utilization.

Loading bin, capacity of its daily rate when working in two shifts - 1600 tons from dump trucks:

(1.3)

where Q –bin capacity, t.;δ –bulk mass of the material, t/m3;φ – bin loading coefficient(0,8-0,85).The height of the pyramid part of the bin:

(1.4)

where L –bay of the building, m; В –Gape of the bin, м (в = 300 + 600 mm); α – angle of slope of the bin bottom, degree(α = 50+60)

(1.5)

The height of the prismatic part of the bin

Н2 = V-V1/φ1·L2, м (1.6)

where φ1 – coefficient of the filled up prismatic part of the bin φ1 = 0,4+0,7

Electric breaking machine – EKS 125 (SM-493B) «Drobmash», Russia. The technical specification is shown in table 1.10.

Table 1.10 – Technical specification of EKS 125 (SM-493B) «Drobmash»

Capacity, kg/h 2000Overall dimension

25

Length 2250Width 930Height 3053Height 3390Weight of the separator 2200Price including renewal, tenge 32600,0

Calculation of aerodynamic resistance of snow-retaining fences for railway and automobile roads made from waste.The calculation is made on the basis of snow-retaining fence of the built-up construction according to the instructions on snow-defense on the railways TSP/4390.

From the aerodynamic point of view snow-retaining shield shall be considered as a single fence that is without gaps with its constant thickness.The calculation is made for double-wide boards taking into account the vortex shedding of the air pressure at a movement speed.With a single board with dimensions of 40x160x3000 area of the resistance of paired boards to the air flow is determined by:

Sдоп.доски = 2 · 0,32 · 3 = 1,92m2

Dynamic pressure of air flow at the rate v = 30m/s,

(1.7)

where: ρnb –air density under normal conditions.

Value of 590 Н/m2 may be considered as a maximal voltage of air flow on the surface of the board of the rectangular cross section.

26

Picture 1.1 – The scheme of the voltage ob the board of counterforce fence

where f – maximum deflection; q –intensity of equal lateral load; А and В – bedding points on the board in the fence which are unsafe cross

section , where or .

Breakdown torque:

(1.8)

Allowable load:

(1.9)

Maximum deflection:

(1.10)

For boards with size h = 40 mm, h = 320 mm (from 2 strips to 160 mm strips) according to schemes of load moment resisting on axis:

(1.11)

Picture 1.2 – Scheme of load moment resisting on axis

Since the boards are perpendicular to the air flow by their widest part, their size is determined by the formula:

27

J

For polyethylenes strength under static bending after recycling under temperature of 160-180 degrees of high pressure polyethylene(HPP), low pressure polyethylene (LPP) has the following values:

Gн(HPP) = 12-14 mPa, Gн(LPP) =20-38 mPa.

Let us take the lowest value: Gн = 12 mPa.Calculation of allowable loads taken by the board from polymer waste:

The true load at the wind speed of 30 m/s,

F = ρ·S =590 ·2 ·0,16 ·3 =566,4 567Н

The level of strength under bending:

The weight of board from polymer waste:

Р = ρ · v · q = 0,16 - 0,04 · 3 ·108 · 10 192Н

Allowable load of its own weight for boards from waste polymer with dimensions 40х160х3000 mm:

(1.12)

Its own load from polyethylene Рс= 192НThe level of strength:

The weight of the polyethylene board is 2.2 times less than concrete board.

28

Selection and calculation of equipment parameters for drying solid waste.Cylinder drier is distinguished by high capacity, low energy consumption, low maintenance and operation safety.Cylinder drier speed is determined by the formula:

Vб = W/А , м3 (1.13)

whereW – the amount of evaporated moisture from SHW, kg/h;А – voltage of the cylinder drier on moisture, кg/m3· h.,

For slurry А = 120 kg/m3· hWith humidity of 6%, W = 600 kg/h, then Vб = 600/120 = 50 m3

With diameter of cylinder drier D = 2 m.

Selection and calculation of equipment for screen separation.Let us choose for calculation a double sieve sizing screen, considering the effective working area of the bottom sieve 0.7. Let us calculate for each screen hydration and vibrating screens of inline arrangementPerformance of vibrating screens is determined by the empirical formula:

Q= F·q·б·l·m·n·o·k (1.14)

where F – screen area, m2; q – specific capacity, its 1 m2 of the sieve surface, m3/h; б – bulk density of the material SHW t/m3; l,m,n,o,p,k - correction coefficients. Let us define the screen area of the first step: F= Q/(Q·б·l·m·n·o·p·k), m2 (1.15)

foe the sieve holes with diameter of 50 mm : q=42 m2/h, б=0,3 t/m3, к=0,5, l=2,0, m=2,1, n=1, o=0,3, p=1

F= 100/(42·0.3·0.5·2·2.1·1·0.3·1)=8 m2

Screen area shall be not less than 8 м2 .

Selection of the type of magnetic separator.As solid household waste has fat-containing items and presented in a concentrated form, the separation process can be seen as separation of highly magnetic of ores.For dry separation of highly magnetic ores the capacity is calculated by the formula:

29

Q=0,82n (L·0,1) v·б (lg(d2/d1))a·b (1.16)

where Q – capacity, t/h;n – the number of cylinder driers for main separation;L – the length of the cylinder drier;v – movement speed (taken as 1m/s);б – SHW density, t/m3;d2,d1 – the minimal diameter of SHW grains, mm (for rough materials=

0,01);а – empirical factorв – empirical factorWe have:Q = 100t/hL =1,2m (for electromagnetic cylinder drier BM 12/10)Б = 7,8 t/m3 (for iron);d1 =150 mm (size of preserve tin)d2 = 0,01 d1=1,5 mmFrom tables: а = 1, в = 1We find the number of cylinder driers for main separation: n=Q/ (0,82 (L-0,1) v(d1-d2/ lg d1/d2) a·b) (1.17)

For L= 2,5m (separator of magnetic cylinder driers BM/250, with capacity of 180 t/h).

n=100/0,82*(2,5-0,1)*1*7,8 (150-1,5/ lg (150/1,5)*1*1 1

Table 1.11 – Technical specification of electromagnetic cylinder drier BM12/10

Indicator BM 12/10The length of cylinder driers, mmInternal diameter, mm The length of the active part of the

cylinder drier, mmRotating speed of the cylinder drier,

rot./minDimensions, mmLengthWidthThe weight of the cylinder drier, kgPrice including renewal

1200010001330342265

120051505640,0

Table 1.12 – Technical specification of separator (magnetic cylinder drier) PBM 90/250

30

Indicator PBM 90/25Dimensions of the cylinder drier, mmThe lengthThe diameter Capacity, t/hDriving power, kWThe mass of the separator , kgPrice including renewal, tenge

90025001804318074,60

The selection of equipment for crushing.

Gear double roll crushers are designed for large and medium crushing solid household waste.Capacity of gear double roll crusher is taken from the catalog. It also can also be calculated by the formula:

Q = 188DnLSб, t/h (1.18)

where Q- capacity of gear crushers , t/h;D – diameter of rolls;n – rotating speed of rolls, rot./min;L – length of rolls, m; S – width of the gap between rolls , m; – material density, t/m3; = 0,25+0,58 –coefficient of material fragmentation.Diameter of the rolls is determined by the formula D = (2 +4) d max, where

dmax – is coarseness of the suppressed material. Based on the coarseness of the material from the appendixes we select a crusher (dmax = 200mm), select the diameter of rolls D = (2-4) d max = 400-800 mm.

From the appendixes we select a gear crusher. For the set tasks crushers DDZ-3m and DDZ-6 are most suitable. Their technical specifications are

specified in table 1.13.

Table 1.13 – Technical specifications of the crusher DDZ-3m and DDZ-6

Indicators DDZ-3м DDZ-6мCapacity , t/h 125-180 150Maximal size of the item

of the crushed material, mm800 600

Coarseness of the crushed material, mm

0-150 0-125

Dimensions of rolls, mm:Diameter 900 630Length 900 800Rotating speed of rolls, 36 50

31

rot./minMotor power, kW 25,0 20Mass of the crusher, kg 11400 12000Main dimensions, mm Length 4000 3600Width 3270 34450Height 1215 1235Price including renewal,

tenge6890,0 5960,0

The selection of equipment for enrichment.Through screen sizing the raw material of solid household waste has been divided into small and large, both free of heavy and light components. To separate the light and heavy components of SHW feedstock is subject to pneumatic cleaning. For the pneumatic cleaning there are used separators and pneumatic jig washers. Capacity of pneumatic separators depends on the size of the cleaned solid house waste. Since, the number of light components is 80% of the total, then with capacity of 100t / h there shall be used pneumatic separators (jigs) with a capacity of not less than 100 t / h

Table 1.14 – Technical specification of pneumatic separators of SP and SPB type

Indicator СП-12 СПБ-100Capacity, t/h 100 100-140

Maximal size of the cleaned, mm

756-50 (0-10)

Surface:Working area,m2 12,0 -

Pump rate per minute 310-400 -Electric motor power, kW 19,8 24,0

Separator mass, kg 14506 29500Dimensions, mm

Length 8150 15800Width 3590 5050Height 5000 2500

Price including renewal, tenge 19260,0 21760,0

Table 1.15 – Technical specification of pneumatic saddling machine POM-2А

Indicator POM-2АCapacity, t/h 100Surface are, M 4,5Pulsed-flow air rate 200-420Air-flow rate, m3 /h 15000-20000

32

Air drag, km/m 3,6Electric motor power, kW 4,5Machine mass, kg 6200Dimensions, mmLength 5712Width 1850Height 6000Price including renewal, tenge 12960,0

Sizing of auxiliary equipment.Selection and sizing of equipment for dust collection.Bag filters РФГ-У are used to clean the air after the pneumatic jig washers. Capacity of bag filter is determined by the formula:

V=F0 q, m3/h (1.19)

where F0 –Filtration of the filter surface,m2; q – specific capacity (180-200m3/h, m2).

Table 1.16 – Technical specification of auxiliary equipment

Indicator ШЭ-80 ШЭ-100-80 ШЭ-120-10 ШЭ-140-100Width of conveyer

belt, mm800 1000 1200 1400

Thickness of the rock layer no less

than mm

До 250 До 250 300 300

Power consumption, kW

4,8 4,8 6,4 8,65

pulley blockDiameter, mm 800 800 1000 1000

Mass, kg 3334 1000 4750 5658Price including renewal, tenge

6890,0 4750 7460,0 9880,0

Selection and sizing of the various bins and containers.Loading bin capacity of which at a daily work in two shifts is 1600t:

V = , m3

(1.20)where Q – bin capacity, t; б –bulk mass of the material, t/m3;

33

– bin volume coefficient(0,8-0,85).The height of pyramidic part of the bin:

Н1 = tg , m (1.21)

where L –column spacing of the building, m; В –gape of the bin, м (в=300+600mm); – angle of slope of the bin bottom, degree ( = 50+60).

V= , m3 (1.22)

The height of prismatic part of the bin H2 = V-V1/1L2, m (1.23)

where 1 – volume coefficient of the prismatic part of the bin

Electric separator EKS 125.

Table 1.17 – Technical specification of electric separator EKS 125

Capacity, kg/h 2000DimensionsLength 2250Width 930Height 3053Height 3390Separator weight 2200Price including renewal, tenge 32600,0

It is necessary either to increase the quality of the electrical separators to the required level, or to upgrade the separator by increasing its capacity.

Quantitative data on the raw materials and the extractive products (average values):Input of raw materials - 100 tons / hour;Extracted (separated fresh raw materials for re-use - 78-87 tons / hour;Paper - 18-20 tons / hour;Polymers - 5-12 tons / hour;Food waste - 35-45 tons / hour;Glass - 7-9 tons / hour;Bones - 6-8 tons / hour;Metal - Black - 5-12 tons / hour;            Color - 2-3 tons / hour.

34

СМDepending on the morphological composition of solid household waste

arriving at the sorting line, taking into account the varying composition of solid household waste, from 6 to 18-20% of sufficient volume of solid household waste is disposed.

2 STUDY OF THE PARAMETERS OF INDUSTRIAL WASTE CHEMICALIZATION TAKING INTO ACCOUNT ENVIRONMENTAL AND INDUSTRIAL SAFETY REQUIREMENTS

2.1 Laboratory studies of operational parameters and physical-mechanical properties of polymer wasteCurrently in Karaganda THE entire volume of solid household waste (further SHW) is transported and disposed without sorting and recycling on landfills [26,52-63].According to the Regional Department of Environmental Protection as of January 1, 2007 4.4 tons of solid household waste is disposed on landfills, and in 2008 about 900 thousand tons.This amount of waste causes unsanitary, environmentally dangerous situation in the region. Therefore, there is need for the design and construction of waste recycling plant, with sorting, recycling and utilization of waste.

The analysis of the morphological composition (Table 2.1) shows that one cubic meter of solid household waste in the city of Karaganda contains: 36% of paper, 14% of food waste, 6% of textiles, 4% of metal, 4% of glass, 9% of plastic and polymer containing waste. Moreover, the proportions of polymer waste in the total mass increases.

Table 2.1 – Morphological composition of SHW as of 01.01. 2007

SHW classification% of the total volume of SHW*

Europe CIS countries USA RK Karaganda city

Paper 24,7 20-36 38,0 36,0 36,0Food waste 37,8 20-38 25,0 13,0 14,0Wood - 1-4 - 4,0 3,0Textile 7,8 3-6 - 6,0 6,0

35

Bones - 2,5 - 4,0 4,0Scrap metals 2,8 2-4 8,0 4,0 4,0Glass 2,8 5-7 7,0 4,0 4,0Plastic 8,0 8,9 8,0 9,0 9,0Other (oversized products, chemical and construction waste, rubber, tyres and other)

16,1 10-35,5 15,0 24,0 20,0

Total 100 100 100 100 100

* According to the Environmental Service of JSC RMUKH of Oktyabrskiy district of Karaganda region

Damage to the population and the national economy of the Republic of Kazakhstan is growing, both because of unsanitary conditions of landfills and corrosion of utility pipes (heating, water supply and canalization) and reaches billions of tenge per year. Corrosion of utility pipes (heating, water supply and canalization) causes excess consumption of water and heat; pollution of water and ground water supplied through the pipe, chemical activation of soil, which destroys the pipes from the outside. Waste water and ground water contaminated through contact with industrial and household waste, adversely affect the chemical composition of soil and utilities placed on them and design in the construction of utilities, buildings and facilities.There was increased the production of materials from primary polymers and their compositions, produced in the form of packaging and containers for various purposes, household items, appliances, and technical spare parts. According to Karaganda municipal transport authority every month over 980 tons of plastic, plastic, industrial and household waste goes to the town’s landfills. This waste pollutes the environment as the period of its dissolution is more than 200 years.

The main tasks of the research:a) it is necessary to develop special construction of the mixer, which simulates the chemical compounds of all morphological compositions of solid household waste and liquid industrial waste;b) full description of waste according to its complete morphological compositions taking into account the weight in grams, temperature and pressure in the mixer, from which the product is obtained in the form of various compounds with the pulp;c) to obtain various pulps;г) From the pulp obtained from the mixer through combining different construction waste (shredded plaster waste, bricks, asphalt waste, sawdust, pressed tile, rubber, cotton fabric, polymers, polypropylene, polystyrene, sand, etc.) with chemical waste during extrusion, pressing to obtain new materials;e) to formalize the selected new materials with the purpose of certification in laboratory centers.

36

The CIS countries (Russia, Ukraine, Belarus, etc.), the non-CIS countries (the USA, Japan, Germany, etc.) do not conduct a complex recycling of solid household waste for the purpose of extracting the polymer components of solid household waste with the subsequent use for obtaining secondary polymeric materials and coatings. In these countries the prevailing trend is incineration of solid household waste to produce heat and electricity.To develop new solutions we have sent 18 applications for patent of the Republic of Kazakhstan concerning the abovementioned directions of works. We have received 10 innovative patents and six patents of the Republic of Kazakhstan.

Table 2.2 – Values of the main operating parameters of polymer waste during the extrusion

Parameters GOST 18599-83PNP PVP

Temperature of the heater TH°C 200±10 230±10The pressure during the melting process of the ends of blank parts Рпр, MPа.

0,03-0,05 0,06-0,08

Depth of penetration of pipes material, mm 1-2 1-0Duration of melting tн with wall thickness ofmm up to 4 5-10 10-15 16 and more

3550-8585-160

160

5070-110110-200

200

Duration of technological break, с 3 2Welding pressure Рос, MPа, 0,1 0,2Holding time under welding pressure tос. with wall thickness of blanks, mm Up to 4 5-10 10-15 16 and more

180240-480480-720

900

240300-540540-720

900

Table 2.3 – Main physical and mechanical properties of polyethylene before and after extrusion

Indicators PNP PIP

Density, g/sm3 0.945-0.9650,756-0,787

0.918-0.9330,886-0,897

Tensile yield stress, MPа no more 20,0/18,9 9,5/7 ,2Elongation at failure, %, no more 200/186 210/197Modulus of flexibility, MPа no more 800/735 200/189

Melting range, С 127-135120-128

105-112101-106

Environment temperature, °С from-30 to +60 from-30 to+60Heat coefficient of linear expansion, 1/ °С 2*10-4 2*10-4

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Thermal conductivity, W/(m°С) 0,42 0,34

Specific heat, kJ 2,52,3

2,52,3

Brinnel Hardness, H/mm2 45-5438-46

14-2512-23

Vicat softening temperature°С 30 60

Surface resistivity, Ohm *m 1,2*1014 5*1013

Volume resistivity,Ohm *m 8,2*1014 7,8*1014

Note: the numerator - with the primary properties of the polyethylene, the denominator – with the secondary extrusion.

Laboratory experiments have shown that the secondary recycling of polyethylenes modifies the mechanical properties of polyethylene by 17-21% downward (Tables 2.2 and 2.3), the other properties remain unchanged. SHW of plastic can be recycled to produce new products that do not require high mechanical load: window and door frames and boxes, plates, panels, automobile parts (bumpers, handles); snow retaining fences for railway transport; outer shell for metal pipes to protect against corrosion by groundwater, internal lining of heating water pipes and sewer pipes.

Theoretical and experimental studies show that the technological process of sorting, cleaning, separation and recycling of waste is provided by mechanical, hydrostatic processes of separation, a separation process in the electrostatic field and processes of magnetohydrostatic division in the paramagnetic fluid composition of which neutralizes the biological contamination of waste especially polymer waste.

2.2 Design and operating principles of laboratory mixer

The picture shows a general view of a mixer for mixing and stirring chopped compositions of SHW and liquid industrial waste up to 0,5 mm, old equipment (internal combustion engines, tanks, brake devices, etc.), as well as waste of baking and wine producing plants and etc.

Laboratory mixer consists of a cylinder 1 with screws 4, hermetically closing lids 4 and manometers 2, thermometers 5, rubbers 6.Rubber tire serves as a reservoir for the gas produced.The cylinder 1 is connected to the electric motor 7 through the bearing. With the use of automatic switch made you can control the rotating process of the cylinder.

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Picture 2.1 - General view of a mixer with a mounted manometer, thermometer, and a rubber bladder for the accumulation of gas

Technical specification of the laboratory mixer:Volume – 5 litres;Diameter of the cylinder – 23 mm;Height – 35 mm;Rotation of the mixer – 35 rot/min;Power of motor – 1,5 kW;Motor rotation– 50-100 rot/min;Total mass of the mixer – 8 kg.

Picture 2.2 – Special lid for hermetic sealing of the device

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Table 2.4 shows the composition of waste obtained from the pulp 1

Table 2.4 – Composition of waste from the pulp 1

Numbers Type of waste Number Numbers Type of waste Number1 2 3 4 5 61. Polymer waste from low

pressure (tank of water)20 9. 80

1 2 3 4 5 62. Plastic waste from high

pressure(tank of drugs)140 10. Wine and vodka

waste15

3. Paper waste from the tank 25 11. Oil waste 204. Multicolored rubber waste 25 12. Oil waste of reservoir 455. Saw dust from pressed

wood boards50 13. Wine waste 45

6. Gypsum waste 65 14. Saw dust from wood 607. Rubbers from tubed tires 5 15. Painting waste 458. Colored polymers 15 16. Fabric waste 45

Total mass of waste, total: 860 g

Table 2.5 shows the composition of waste obtained from the pulp 2

Table 2.5 – Composition of waste of the pulp №2

Numbers Type of waste Weight in grams

Numbers Type of waste Weight in grams

1. Chemical waste 160 9. Bone waste 602. Polymer waste 60 10. Meat waste 603. Wine and Vodka waste 60 11. Drugs waste 604. Rubbers from tires 80 12. KCl 1205. Food waste 80 13. NaCl 1206. Fruit waste 80 14. Azotic acid 1207. Vegetable waste 80 15. Vegetable oil 1208. Potato waste 80 16. Animal oil 809. Krasin waste 80 17. Medical waste 60

Total mass of waste: 1560 g

Let us connect the obtained pulps 1 and 2 to each other by placing them in a mixer with a total weight of 2420 grams, and as a result we will obtain the pulp 3.Obtainment of new materials based on the pulp 3 with the other compositions of materials (cement, sand, plaster solution, paint, asphalt coating, crushed bricks and other building materials).Table 2.6 shows the different types of materials obtained in laboratory conditions, which are shown in pictures 2.5 - 2.6.

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Table 2.6 – Type of materials obtained in laboratory conditions

Numbers Composition of the new material Weight in grams

New material brand

1 2 3 41. 1. Pulp №3

2. Sand3. Cement

555040

А

2. 1. Pulp №32. Cement3. Sand4. Plaster

65216565

Б

1 2 3 43. 1. Pulp №3

2. Brick3. Cement

454545

В

4. 1. Pulp №32. Plaster waste3. Cement4. Paint

50302515

Г

5. 1. Pulp №32. Plastic3. Saw dust4. Vegetable oil

65202525

Д

6. 1. Pulp №32. Solution3. Dye

5050100

Е

7. 1. Pulp №32. Plaster3. Solution

553510

Ж

8. 1. Pulp №32. Polymer3. Phosphor

502275

З

9. 1. Pulps №32. Polymer3. Saw dust

623030

И

10. 1. Pulp №32. Polymer3. Plaster

653025

К

11. 1. Pulp №32. Cement3. Brick

603022

Л

12. 1. Pulp №32. Polymer3. Asphalt

503030

М

13. 1.Pulp №3 55

41

2. Talc3. Pepperidge

2020

Н

14. Н+Д composition 40+50 О15. 1. Pulp №3

2. Polymer3. Cement

503535

П

16. 1. Pulp №32. Plastic3. Saw dust

654030

Р

17. 1. Pulp №32. Polymer

4845

В1

18. 1. Pulp №32. Plaster waste3. Polymer

654030

Д1

19. 1. Pulp №32. Polymer3. Dye

503010

Ж1

20. 1. Pulp №32. Polymer3. Phosphor

503025

З1

21. 1. Pulp №32. Polymer3. Asphalt

653525

И1

22. 1. Pulp №32. Polymer3. Glass

654030

К1

23. 1. Pulp №32. Polymer3. Gypsum

654030

М1

24. 1. Pulp №32. Polymer3. Plaster waste4. Gypsum

65402020

С1

25. 1. Pulp №32. Polymer3. Cement4. Solution

65402210

Т1

The obtained new materials can be used as wall and floor coverings, as well as areas for road and pavement, tiles for the roofs, borders for roads, etc.

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Picture 2.3 – Crushed waste up to 3-5 mm for blending in the mixer

The following picture shows the different chemicals for speeding up the processes of chemical reactions

Picture 2.4 – The different chemicals for speeding up the processes of chemical reactions

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After the crushed solid household waste the mixer receives various liquid industrial waste:a) from the convoys of bus depots liquid waste after the removal of internal combustion engines, braking systems, etc.;b) from the machine-building plants the similar liquid waste.

Continuation of chemical speeding processes occurring inside the mixer (Picture 2.5)

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Picture 2.5 – Electric box for drying different compositions, pulp for example

Picture 2.6 – The obtained new materials from the compositions of SHW and liquid waste

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2.3 The results of laboratory studies of chemical processes of solid and liquid industrial waste

Together with the conducted successive reactions - chemical transformations of polymers (polymer-similar transformations, intermolecular reactions, destructions) there can be modified polymer base of waste (paper, plastic bags, fabric, etc.) during the reaction there is obtained a new polymer material which possesses physical and chemical properties of the pulp.

To implement these reactions there can be used soap and powder waste as a emulsifier and petroleum products such as gas, kerosene as solvent, etc.

A chemical reaction occurs in the mixer at a higher temperature and pressure with release of gases (methane, propane, nitrogen, etc.) through controlling the release of gases in the furnace it is possible to adjust the pressure of the (blender) mixer.

The temperature is regulated by the supply of cold water into the outer casing of the mixer.In the mixer there is prepared a chemical mixture of crushed solid household waste and liquid chemical waste that requires special connecting elements in the form of chemical additives such as potassium chloride, sodium oxide, iron oxide, ferric chloride, chromium oxide, polymers, etc.

After combination of solid household waste with liquid chemical additives is is prepared as pulp to the next stage: extruding, pressing and shaping. For the occurrence of these processes it is necessary to determine the composition of the binding elements, such as sand, silt, ash, crushed construction waste, etc. with dyes. For safety purposes of waste utilization it is not allowed to use special hazardous, radioactive, medical, explosives, flammable liquids and soil, pyrophoric substances, combustible gases, dead animals and industrial waste water and washing water, etc.The processes of extrusion, pressing and shaping are conducted on the basis of the existing technological equipment needed to, depending on the products, goods and materials to determine the correlation of chemical additives and the binding elements. For example, for the production of boards and racks of railway snow-retaining fences by extruding it is necessary: chemical additives - waste pulp - 45%, construction waste - 20%, asphalt waste - 20%, steel - 10%, dyes - 5%.

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2.4 Provision of environmental and production safety of chemical waste utilization technology

A plant proposed to construction for solid household and liquid industrial waste recycling is developed on the basis of waste recycling plant «NSL-HYDROMEX» of NSL International Corporation, Trading, Inc, registered in Los Angeles, Californian, USA with implementation of Kazakhstan inventions indicated in application # 1.

According to proposed technology for liquid and solid wastes recycling the produced materials are environmentally safe for household and industrial usage. The great advantage of this technology is the extraction of heavy metals from the liquid medium such as strontium, mercury and many others.

This technology is improved for recycling of solid and liquid waste, chemicals, packaging materials made up from polymeric products (various containers, bags, food and alcoholic products and etc.), contaminated soils, municipal waste, hospital waste, textile materials, plastic, tires, paints, solvents, spent oils and others in a mixture in different ratios (excluding iron and reinforced concrete waste). According to present technology it is carried out the recycling of solid and liquid waste by chemical recycling that allows to get following types of new products (goods) inside the shop floor:

• road and railway signs, plates, cross sleepers, poles, separators, curb stones;• parking guard, roofing and etc.;• electrical and thermal insulation materials, belts and etc.;• building materials (tiles, paving slabs and etc.).

2.4.1 Technological processes of SHW and liquid industrial waste utilization and disposal

1. Separation and classification: all types of solid waste are acceptable; no need for preliminary separation.

2. Crashing: unloading from a garbage truck into a special SHW bunker; preliminary cleaning and separation of iron and reinforced concrete oversize materials; initial crushing of SHW considering industrial waste; milling of mixed solid waste and conveying transportation to storage bunker.

3. Liquid waste mixing: liquid waste unloading into bunker; liquid wastes are mixed in a special tank for the neutralization and detoxification.

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4. Solid and liquid waste mixing: milled and mixed solid waste are transported by the conveyor to the solid and liquid waste (SLW) mixer; preliminary mixed liquid waste is pumped under pressure from the tank to the mixer (SLW); liquid and solid waste are mixed in SLW mixer.

5. Polymerization and chemicalization: chemical polymeric components (CPC) are inserted under the pressure into SLW mixer; solid and liquid waste are mixed in (SLW) mixer and wet pulp is prepared for extrusion processes at elevated temperature.

6. Moulding: Wet pulp comes to the special compression mold, extruder or any moulding appliance; The pressure is mechanically increased up to 100 tons; The density of the final product is g/sm³ 0,78-0,897; During the reaction the polymer are expanded and generates the heat and as a result the temperature can reach 200-230 С0; All the chemical reactions are finished at this stage.

7. The final products with environmental and industrial safety: The full range of molecular processes is occurred as a result of chemical reactions, high temperatures and increased pressure where all living microrgerm existed in the waste such as bacteria, fungus and others completely die; The final products are becoming sterile, durable, non-toxic, with required fire-resistant and moisture resistant properties; The final product (mixed SLW) can be modified in countless number of construction materials for extruding and forming.

8. Lack of emission that provides environmentally clean products and goods: All gases and liquids as a result recycling are processed in gas-cleaning system in order to receive electric and heat power; Almost no harmful hazardous substances are released into environment and chemical processes of recycling have no secondary products for utilization as all chemical and technological processes (crushing, milling, washing, drying), SLW chemicalization and liquid processes are carried out in a closed circuit of technological processes and recycling operations.

2.5 The main targets and objectives of (solid household waste and liquid industrial waste Utilization) SLWU

The main target of SLW utilization is the stable improvement of ecological situation in the cities and the protection of public health by creation of a modern system of SHW management on the basis of advanced technologies application for

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waste management, the establishment of industrial infrastructure for waste neutralization and utilization.

Upon SLWU development it is used the experience of the Russian Federation, Ukraine, the USA, Spain, Germany and other countries successfully solving the waste management problem on the basis of Kazakhstan regulatory documents in waste management field.

Implementation of SLWU directly related to the processes of economic and social development of the city. The application of modern technical achievements and technologies require capital intensive equipment for the neutralization and utilization of household waste. Therefore the proposed solutions for waste management improving should be adequate to financial capacity of the city.

One of SLWU objectives is to concentrate financial material-technical resources, industrial and scientific potential of the city for maximum involvement of such kind of waste (solid household waste and liquid industrial waste) into the economy turnover through recycling.The following objectives are established by technical query for SLWU development:

definition of a set of interrelated organizational, economic, environmental, financial, technical measures forwarded to reducing of SHW volume and decreasing of SHW production, its negative impact on the environment;

development of a waste management system that provides recycling, utilization, accounting and control;

development of measures to eliminate unauthorized (natural) waste dumps, prevention of their occurrence;

development of methods for indicated works organization, calculation of their cost, performance of most economic and optimal SLWU option on the basis of comparison method and innovative solutions of this problem in the world.

However SLWU realization effectiveness and solution of assigned tasks directly depend on the social-economic development of Astana city in planning period, the growth of welfare.

Therefore to achieve SLWU effectiveness on realization stages the following are required: studying and implementation of progressive experience and methods for SHW

management; rationale for choosing of basic technologies for waste management; using of economic mechanisms for business entities stimulation in waste

recycling field; Identification of priority objects for the neutralization and utilization of SHW

and their disposal on the basis of waste generation recording in Astana city; infrastructure formation and development for SHW recycling; the implementation of projects for treatment, neutralization and utilization of

waste on the initial phase;

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establishment of recording system for SHW generation, utilization, neutralization and disposal;

High-quality and full implementation of SLWU mostly depends on the responsibility of government bodies at all levels for a positive solution of SHW existing problems, overcoming of administrative barriers in this field.

At the same time it requires stimulating of investment for the development of waste neutralization and utilization industry including the involvement of micro and medium entrepreneurship. It corresponds to the strategic development plan of the Republic of Kazakhstan 2030 whose task among others is stimulation of business entities activity for recycling and the worldwide waste utilization through the introduction of a resource and energy conservation technologies.

This problem proposes the necessity of creation the conditions for non-hazardous technological processes implementation for SHW recycling and utilization in Astana city.

The analysis of the existing SLWM problems (solid household and liquid waste management) in Astana city. Solid waste utilization is a part of SLWM economic system.

Its purpose is to ensure the minimization of waste generation, SHW maximum involvement as a raw material into the economy turnover, reducing the negative waste impact on the environment.

SLWM in Astana city as in other aspects of management activity is foreseen by the functions of acting system of legislative and executive power of the Republic of Kazakhstan, government bodies of administrative areas.

SLWM main functions are organization, coordination, planning, promotion, financing, accounting, control of waste management activity and information providing in this field. Due to this the waste management is an integrated complex of measures that covers SHW collection, recycling, utilization, treatment and disposal stages.

The study and analysis of SLWM organization in Astana city show that currently used waste management methods are obviously behind time requirements; do not contribute to the stability of the environment quality and the sanitary-epidemiological situation of the territory. Currently the methods of SHW collection and disposal are directly connected to settlement status. Therefore the solution of existing problems is in systematic approach to the modernization of the existed methods, organization style and execution of SHW management, implementation and using of developed countries experience.

The volumes of SHW generation in Astana city have a constant upward trend. It requires SLWM improvement, generation process analysis, waste collection and disposal, and technical their recycling methods, the possibility of using SHW secondary raw materials.

Weak mechanical equipment and technical backwardness of production facilities of municipal sector entities, the lack of necessary infrastructure for SHW neutralization and recycling in Astana city, lack of production facilities

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development for recycling of waste commercial components have an obvious effect on the difficulty of current SLWM situation.

A specific concernment is the condition of illegal waste dump in Astana city.For example according to the sanitary-epidemiological service data as of

01.04.06 year 46 streets of Saryarka district and 22 streets of Almaty district have illegal dumps.

SHW landfill located at the range of Astana city on the 6th km of Astana Pavlodar highway. The landfill is operated since 1974 year. Since 20.09.99 year it is under JSC "Astana Gorkommunkhoz" jurisdiction, site area is 65.6 hectares including the quarry of 35 m. depth and approximately 6 hectares area in the center of the site. Indicated landfill does not meet environmental and sanitary standards, protection zones are not organized; in some places waste is disposed not only on waste landfills but also on the surrounding areas

Officially SHW amount is determined only at the landfill on the basis of the number of trucks record and the volume of imported waste to the waste dump by them accordingly.

According to reporting data the total amount of waste disposed at the landfill for the entire period of its operation since 1972 year was over than 16 million mЗ including not only SHW but also manufacturing (industry) and construction waste.

SHW consists of four main components - paper, food waste, heating oil waste (ash, slag), plastic waste. These four components form over than 80% of all content in volume. According to JSC "Astana Gorkommunkhoz" data the rate of plastic waste in overall composition increased significantly last time.

Humidity content of solid waste is at the range of 30-58% and their bulk density is 0,18-0,3 t/m³.

Considering the difference of bulk densities for each individual type of waste the ratio of food waste in overall composition will be bigger by its weight due to the high humidity content in comparison with other types of waste.

Table 2.7 – Volume ratio of waste types

№ Waste type Volume ration, %1 Paper waste 25,852 Food waste 24,603 Plastic waste 14,754 Wood 4,355 Textile 3,856 Glass 3,307 Metal 4,358 Bones -

9 Heating oil waste (ash, slag) 20,35 10 Leather, rubber piece - 11 Stone, brick rubber - 12 Others -

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TOTAL 100

A system of glass bottles reception-delivery is established in Astana city. For example the glassware receiving station near the central market takes glass bottles of different types: beer, vodka, soft drinks which can be reused. Reception value ranges are from 3 up to 30 tenge depending on the type of bottle. This is the reason of very low glass content in SHW composition. On the other hand due to the lack of such a system for plastic bottles made up of polyethylene terephthalate (PET) common enough for soft drinks bottling such empty bottles are easy getting into waste.

The increase of paper waste in SHW overall composition is predicted on the basis of the capital status of Astana city with a variety of government buildings accordingly producing a large amount of paper waste due to administrative work. The level of heating oil waste such as ash will be significantly reduced due to the expansion of district heating systems as well as gas or power supply systems for household purposes. Expected changes in waste content are shown in Table 2.8.

Table 2.8 – Expected changes in waste content

# Waste type Expected changes in content

1 Paper waste Increase2 Food waste Insignificant 3 Plastic waste Increase4 Wood Almost absent 5 Textile Almost absent 6 Glass Almost absent7 Metal Almost absent8 Bones9 Heating oil waste (ash, slag) Decrease10 Leather, rubber piece Almost absent11 Stone, brick rubber Almost absent

According to the report the amount of solid production (industrial) waste taken to the city landfill is approximately 5-10% of total SHW amount.

In accordance with to the same landfill data of SHW management JSC "Astana Gorkommunkhoz" for 2006 the industrial waste was 68,166.5 m³ of the total amount of 974962 m³ of SHW that is 6%.

That industrial waste does not include coal ash from HPP and dewatered sludge from water treatment facilities.

Most part of the production (industrial) waste (related to V Class) are construction and demolition waste generated from the demolition of buildings, concrete, ceramic waste, sawdust and splinters.

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There is a special designated plot at the existing waste dump for the storage of construction waste, metal scrap and used automobile tires. Wood waste is disposed along with the used automobile tires on the plot. Last time this plot is almost empty because the rubber tires were distributed to private organizations for subsequent sale. This event was held under the campaign for waste recycling and reuse.

Scrap metal is also regularly taken out of the waste dump by metal recycling companies.

In accordance with SNiP the industrial waste of I and II hazardous classes are prohibited to accept in SHW landfill. The maximum amount of III and IV hazardous class of industrial waste permitted for acceptance and storage together with other non-hazardous solid waste was defined.

The following table shows the results of the analysis of solid industrial waste content excluding ash coal from HPP and dewatered sludge from water treatment facilities.

Table 2.9 – The results of the analysis of solid industrial waste

# of items Type of industrial waste Volume ratio, %

1 2 31 Construction waste 42,82 Black metal 23,03 Nonferrous metals 0,54 Slags 12,85 Reinforced concrete waste 12,86 Rubber waste 5,57 Wood waste 2,58 Ceramic and clay bars 3,01 2 39 Glass 0,510 Others 2,5

Initially the responsibility for collection, transportation, treatment and disposal of solid industrial waste is assigned to each company individually. Therefore the hazardous waste will be recycled up to non-hazardous level by the origin producers of waste. Considering the fact that Astana city has only one permitted landfill some of industrial waste are allowed to be disposed there.

The ticket system is practiced regarding the construction waste. "Ticket" is a permission that gives the right to unload the garbage to waste dump. There are 2 types of tickets: ticket for 3 m³ and ticket for 5 m³ of waste. Trucks drivers buy tickets from the controllers and then unload the waste at the landfill. The cost of 1 mЗ of construction waste disposal is 91 tenge (according to 2006 year data).

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Collection of medical waste generated by health-care institutions activity is carried out by the same organizations that are engaged in SHW management. Their disposal is carried out in the same way as non-hazardous waste that includes SHW.

According to Gorkommunkhoz data the waste generated by health-care institutions are considered as non-hazardous and subjected to disposal or mixed with other SHW.

As a result of modern conditions analysis for waste management in Astana city it is necessary to mark the following issues that require solutions nowadays and in future:

- correction of the existing waste landfill problems;- maintenance of existing and acquisition of a sufficient number of new

machinery for waste collection;- control of illegal waste dumps;- the establishment of hazardous waste management system of both

industrial and hospital.The most serious issue that requires urgent solution is the condition of

existing waste dump. According to the city Environmental Protection Agency waste dump is the source of groundwater contamination.

Waste dump can be not only the source of groundwater contamination but also a source of air pollution caused by uncontrolled spontaneous waste combustion. It is recommended to conduct daily filling up of waste with insulating soil layer to avoid spontaneous combustion.

According to Gorkommunhoz opinion some of construction waste can be used as an insulating layer but the works are performed irregularly. The insulating layer of soil is laid only when the plot is full.

According to the standards of the RoK "Landfills for solid household waste" the estimated area of landfill disposal for 15 years of calculated period for cities with 500-700 thousand of population should be allocated at the range of 41-61 he at 20 meters of height of SHW disposal.

Currently a new 50.4 hectares landfill consist of 4 cells is constructed according to Spanish technology for solving of indicated problem. At the present time a new 300x400 m cell is built with foreseen waterproofing to exclude water flow filtering of cell content.

The landfill maintenance is provided for SHW receiving only by special trucks to avoid damage of geotextiles base and geomembrane.

Gas withdrawal on gas flaring installation is foreseen on a new landfill and waste water will be sent to the treatment facilities through sewage tanks. After purification water is used for technical purposes of landfill but Spanish landfill experience does not comply with the requirements of international standard.

The justified tariff is a necessary tool for providing of SHW effective management. The changes of the structure and approval of a new tariff that considers all expenses, investments return and profit are required for the effective management of waste. However the problem for waste management providing

54

should be solved only on the basis of population interests consideration related to the family budget expenses of poor people on waste disposal service.

Analysis of foreign and local experience has shown that the development of effective waste management system requires not only considering the local socio-economic, demographic, geographic and other conditions but the corresponding state budget and tax policies forwarded to the formation of service rendering system in waste disposal field.

The modern waste management system in Astana city is a consequence of fragmentation, weakness and limitation of capacity of state public utilities.

The body responsible for SHW in Astana city is the Department of Energy and Utilities of Astana city akimat. Administrator of programs that execute work financing for urban improvement and sanitation cleaning of the city are regional akimats. However JSC "Astana Gorkommunkhoz" is the directly responsible body for the implementation of solid household waste management including waste collection, transportation and dumping.

Along with JSC "Astana Gorkommunkhoz" there is administration of urban improvement of Astana city that carries out street cleaning, collection of street and park estimates. This organization bears responsibility for the supply and maintenance of such facilities as waste bins installed over the whole territory of the city as well as wheeled plastic containers, brooms and other items used for streets cleaning.

SHW collection and transportation are under responsibility of a number of entities that operate in accordance with boundary delimitation scheme for SHW removal in Astana city approved by the supervising deputy akim agreed with the Department of State Sanitary and Epidemiological Supervision, the Department of Energy and Utilities and akimats of city districts: JSC “Astana Gorkommunkhoz”, “Astana Techservice” LLP, MUS “ Turmys” and “Banu” LLP.

The powers of city coordinating body should ensure the formation and cooperation, coordination of local authorities activity involved in management process, organizations involved in waste disposal field on the following directions: Development of territorial programs; Development of regulations, instructions and guidance documents and

regulations on waste disposal within its competence; Implementation of the regulation and limitation in the of waste disposal field; State control execution;

Therefore the basis of the waste disposal problems in Astana city is a number of reasons inherited from the recent past of the country and arising from the current situation: The weak material and technical equipment of public utilities affecting on the

provision of planning and regular SHW collection and disposal; Lack of SHW regular collection and disposal from surrounding areas of Astana

city; Lack of production capacity for waste recovery and usage at recycling and

55

utilization; Lack of measures and actions to reduce the generation of solid industrial and

household waste; The situation of waste management in Astana requires the implementation of

modern methods, organizational and material-technical transformation of the industry, the introduction of measures to reduce SHW generation in the residential sector, social objects and in enterprises through the training of Astana city inhabitants by modern approaches of SHW collection

Conceptual foundation of SHW generation reduction and its negative environmental impact reduction.

One of the most important aspects of waste management organization is closely related to the objectives of maximum reduction of SHW amount generation, limitation of negative environmental impact by available methods. It is very important for today conditions with a steady growth trend of waste generation volume, the lack of appropriate dumping facilities, weak waste recycling.

While choosing the approaches for waste generation reduction, reduction of its negative environmental impact the following actions become priority: Prevention and minimization of waste generation; Maximum possible reduction of hazardous substances content in waste; Maximum secondary using of waste components; Environmentally sound removal (disposal) of remain part of waste.

Targets of waste reduction in Astana city, its negative environmental impact reduction require increasing of waste treatment level, determination of the conditions, methods and measures for its quantitative and qualitative reduction.

Experience of some western countries that successfully solve the problem of waste amount reduction and its disposal volume shows that an important issue of this process is the method for primary SHW reduction whose consequence in a secondary SHW reduction is the implementation of sorting and secondary usage of waste commercial components. Reduction of total number of waste generation, reduction of its hazardous properties is achieved by implementing a number of sequential organizational and technical measures that can be applied in Astana city including the following:

1.Waste reduction at the "source" that means at the place of its generation through the implementation of SHW sorting for waste recover and its separate (selective) collection from population through the reorientation of producers and consumers on products and packaging that results to less amount of waste and organization of branched system of recyclable materials collection;

2. Secondary recycling and using (recycling) reduce the amount of waste dumping due to removal of commercial components from total SHW amount;

3. Incineration of waste reduces the amount of waste sent to dumping but requires the use of expensive air-cleaning equipment;

4. Landfill dumping is a necessary method for waste especially for not recyclable, noncombustible or combustible with toxic substances release;

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5. Chemicalization of solid household and liquid industrial waste without sorting and dumping, construction of new generation plant.

It is confirmed by practice that a significant SHW reduction can be achieved through regulatory actions and periodic review of SHW accumulation norms in the residential sector and on the social-household objects.

Approach to reduction of waste amount on the basis of the rationing is a fundamental condition for the creation of a full system of waste management, the main factor of reduction of SHW negative impact on environment and sanitary conditions of the city. Therefore the expected results on the reduction of waste amount especially municipal and domestic waste should be based on justified rationing of SHW accumulation at population.

Nowadays the establishment of reasonable standards of waste accumulation (generation) in the city, careful analysis of SHW morphological composition should precede to creation of capacities with advanced technology for the recycling and utilization of waste, reduction of SHW amount sent for dumping after utilization.

It is also important from the point of stabilization providing and then reduction of environmental pollution by solid industrial and municipal waste. Reasonable norms of SHW accumulation (generation) will ensure the accuracy of generating waste record in the city generally, will allow to make economic calculations related to the provision of management and development of the waste treatment system with the definition of capital investment for the creation of required infrastructure.

Research for establishment of justified norms of waste accumulation is required in the city.

Revision of norms for waste accumulation for Astana city population that were approved in 2000 year is required for obtaining of a true representation on SHW generating amount in the city. In such a way the temporary “SHW accumulation norms” in Astana city for developped housing as annual average norm has been tablished in amount of 1,1 m³ that is not confirmed by annual volume of actual waste income from city population to SHW landfill.

Analysis on SHW data of the Ministry of Environmental Protection of the RoK in Kazakhstan cities shows that the average annual rate of SHW accumulation in big cities is average from 1.3 up to 2.2 mᵌ per inhabitant.

It is expected to conduct works on establishment of SHW accumulation standards for Astana city during the period of SHLWM implementation. At the initial stage it is expected to determine accumulation standards for developed and private sectors of Astana city and adjacent villages (Koktal, Ilyinka, Promyshlenniy and others).

Establishment of SHW accumulation standards in accordance with the Law of the Republic of Kazakhstan "On local self-government in the Republic of Kazakhstan" is under responsibility of the local executive body. The establishment of SHW accumulation standards in Kazakhstan is regulated by the Government

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decree of the Republic of Kazakhstan dated November 2, 1998 year № 1118 on the issue.

SHLWM strategy in the city for long term prospect on SHW amount reduction, reduction its negative impact on the environment should be based not only on the study and usage of advanced methods for waste management but also on implementation of methods focused on waste amount reduction, change its morphological structure, implementation of technologies for its full recycling or destruction that means to refuse from dumping landfills and waste sorting plants.

It is very important not to lose time and start to solve these important issues right now as part of the common transition to a market economy.

It is required the development of environmentally sound industries that meet proposed new technological and technical solutions for construction of a plant for solid household waste sorting and recycling.

Development of SHLWM system that provides recycling, utilization, registration and control of waste by type.

A steady tendency of SHW amount increasing in Astana city, the importance of solving problems with waste collection, processing, disposal, development of material and technical base and improvement of industry technical equipment defines the necessity of ensuring the proper system for SHW accounting. Currently the assessment of waste streams and its amount accounting is the foundation of proper arrangement of SHW management.

Public accounting functions in waste management field suppose the establishment of accounting procedures and rules for all types of waste, compilation, data analysis and evaluation, providing of relevant information to the executive authorities.

The availability of reliable data on SHW generation amount especially municipal waste will allow reasonably plan and implement measures on waste management and introduction of modern methods on waste treatment.

Advanced technologies for waste utilization and neutralization are expensive. Data of waste generation accounting are required to plan the infrastructure development while determination or selection of technology and equipment for landfills, determination of landfills size, selection of vehicles brands and types and required mechanisms.

However currently providing of reports on waste generation are not ensured and SHW accounting in location areas is poor organized all that facts discredit data reliability on amount of waste subjected to recycling. In a certain extent it is related to the lack of state forms of primary accounting, a single form of statistical reporting on household waste generation, removal and accumulation in Kazakhstan.

Static reporting on wastes according to the Order of the Statistics Agency of the RoK # 43-g dated 04.11.05 was introduced for the first time this year.

- form # 1 “Report on municipal waste within its public collection and disposal”;

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- form # 2 “Report on waste sorting and depositing”.Accounting of the collected and disposed waste in landfills/dumpsites is

executed in the city as usually by incoming waste volume depending on the transport type and by calculation with the accepted SHW density using.

This kind of situation on household waste reporting does not allow giving an exact forecast of SHW generation in coming years. Therefore the only way of theoretical estimate of household waste generation in settlements is multiplying the population size on the index of accumulation rate per capita.

According to data received from the utility companies the SHW generation dynamics in Astana city has an upward trend.

One of HW characteristics is the density. Accounting for incoming waste to landfills and dumpsites is executed by volume in uncompressed shape. According to the results of a number of studies the average annual values of SHW density in Russia cities are accepted in the range of 190 - 230 kg/m3. These values are close to Kazakhstan cities data for example in Astana city waste density is 0.21 t/mᵌ.

However there is no reliable data on the amount, composition and density of the waste that is generated in the adjacent area.

Studies that were conducted during the development of project “Improvement of solid household waste management system in Donetsk region of Ukraine” (financed by the European Union) showed that at a significant difference of waste collection and disposal rates in 28 cities of Donetsk region the rates are below 0.4 m3/per.year in all districts.

Considering the higher economic and industrial development of Donetsk region in comparison with the Astana city we believe that the rate 0.4 m3/per.year can be used for an approximate determination of the minimum average annual volume of SHW generation in settlements of the city.

At the same time it is an indication that the mechanism of activity regulation of city enterprises towards the introduction of low-waste technology is not developed. This situation gives a task for the development and implementation of measures focused on the reduction of industrial waste growth at all stages of life cycle. It requires improvement of production processes, secondary usage of generating waste as much as possible and reduction of SHW amount subjected to disposal.

“Methodology instructions on the development of draft standards for waste management by private and legal bodies” are approved by the Order of the Minister of Environment # 163-P dated 23 May 2006 and its providing for approval to the authorized body in environmental protection field of the Republic of Kazakhstan. According to the order all city companies that are the sources of waste generation, production and consumption should develop draft standards for waste management - both quantitative and qualitative limitations related to waste generation, collection, storage, usage, utilization, transportation and dumping considering its impact on the environment.

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The introduction of regulation for waste generation on factories and issuing permits for SHW disposal to a certain extent helps to organize control and account of waste generation and industrial waste incoming to landfills.

Development of measures for elimination of unauthorized (spontaneous) landfills and prevention its occurrence.

Unauthorized dumps and places with various waste accumulations are regularly detected in Astana city. Conducting of annual sanitary ecological months does not give the required effect since they are not supported with engineering and technical, organizational activities and administrative measures. According to the data of the sanitary and epidemiological surveillance Department there were 64 unauthorized dumps in 2005 year in Astana city.

The reason of their generation is in incomplete coverage of population and low level of regular planning of SHW disposal organization, in poor equipping of sites for waste collection, in shortage of transport and containers.

Such kind of situation is observed not only in the near station villages where regular planning collection and disposal of waste is not organized but also in Astana city.

Waste management methods that have been used up to present days in planned economy conditions have not changed according to modern requirements. The lack of effective economic instruments for solid waste management is also affected.

Currently the attribute of SHW management practice in Astana city is the lack of measures on formation of enterprises with required material and technical facilities for population services throughout the city and lack of measures on active involvement of small and medium business entities into waste management.

SHW disposal in not specially designated areas can’t be unpunished. During the execution of existing unauthorized dumps analysis it is necessary to offer population to inform about incidents of unauthorized SHW disposal, to inform about the environmental consequences of unauthorized SHW disposal. It is required to intensify the work of supervisory sanitary and environmental services and local administrations.

Creation of specialized units of nature protection bodies with authorization to bring people to administrative responsibility for unauthorized disposal of waste may have positive effect.

It is required to increase penalty amount for unauthorized SHW disposal.It is required to allocate funds, equipment and man power for elimination of

unauthorized spontaneous dumps.Installation of containers on the areas with constantly generating

spontaneous dumps in the city will also contribute to organized SHW storage.Lack of facilities for waste recycling, accumulation of large volume of waste

in dumps and landfills, a significant number of spontaneous dumps requires the creation of the necessary infrastructure, the review of economic rates of public

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utilities activity, private capital involvement into the industry, the introduction of known technological lines for industrial waste recycling.

Organization and development of methods for SHW processing, neutralization and disposal.

In terms of SHW quantitative growth in Astana city the creation and expansion of capacity for waste processing, neutralization and disposal on the basis of advanced technologies with a maximum mechanization of all production processes becomes one of the main tasks.

The lack of proper SHW recycling, neutralization and utilization system in Astana city that meets environmental and sanitary standards became especially pressing issue at current stage. Therefore the creation of SHW treatment system at all stages of waste life cycle from the collection up to utilization and dumping requires solutions in coming years (Annex # 6,7,8).

At the same time the formation of optimal system for SHW treatment in Astana city is directly related to technological, environmental and economic indexes of SHW collection, recycling and neutralization and landfills type and capacity. However it is necessary to consider the role of public and private sectors, organizational and administration base for services provision and accounting of the location of sources and types of SHW generators.

For organization of SHW recycling, neutralization and utilization system it is very important not deteriorate the environmental security by selected technologies using but meet the requirements and conditions of public sanitation and hygiene, financial capacity for construction in the city.

The single method to avoid SHW negative impact in Astana city as of 2006 year is waste storage in landfills and authorized dumps with simple neutralization methods application.

Selection of method and recycling methods justification, SHW neutralization and utilization depend on the chemical composition, humidity content, caloric power, solubility of waste components in water, density and other characteristics. It requires relevant research works to obtain the necessary initial data on the morphology and elemental composition, properties of SHW that is generated in the city.

Research directions and criteria selection of the method for SHW neutralization and recycling are determined by necessity of problems solving on the environmental protection, public health and economic efficiency of recycling technology.

SHW neutralization and recycling methods up to final stages are divided into the following:

disposal (mainly solves sanitary-hygienic tasks); utilization (besides that solves economic – secondary resource usage tasks).

Currently there are more than 20 methods of SHW neutralization and utilization and the most widespread are the following:

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1. Storage and (dumping) in landfills is now the main method of SHW neutralization in many countries (the most simple and cheap engineering facility) including all Kazakhstan cities. This method results to the loss of valuable components while SHW dumping.

2. Incineration at waste incineration plants (WIP). The method requires preliminary sorting, requires a multi-step purification systems for hazardous gas emissions, substantial investment.

3. Aerobic bio-thermal composting. Composting products are not suitable for using in agriculture because of heavy metals content (in west countries such kind of "compost" is used only for landfills covering).

Considered methods - storage in landfills, incineration, composting and mechanized sorting allows SHW complete neutralization and utilization. However none of indicated methods is the unique recipe for problems solving on complete utilization of waste.

Technology for waste recycling in the cities must meet two important requirements: ensuring minimum emissions of pollutants into the environment and maximum recovery of valuable components from the waste. On the basis of this we can consider technologies offered by one of St. Petersburg companies. It is possible to choose one of three options to provide more or less global approach for waste problem solving:

Option 1.Total waste collection – transporting to an incineration facility for

combustible waste, dumping of non-combustible waste, slag, ash.Option 2.Total waste collection - transportation - mechanized and manual waste

sorting - recycling (recyclable material) – incineration facility for fuel not recyclable waste - composting of bio-organic and food waste - dumping of non-combustible waste and slags at landfill.

Option 3.Total waste collection - transportation of "SHLWU" plant allows you to

refuse from dumping landfills and waste sorting plants.Option 3 is the most appropriate for Astana city.It is required to provide establishment of chemical neutralization complex at

SHLWU plant for medical waste and non-radioactive hazardous combustible wastes that are subjected to special recycling and destruction.

Establishment and reinforcement of SHLWU material and technical base.Performed analysis allows us to suggest a continuous increase of SHW

generation volume per capita in proportion to growth of population welfare and scientific-technological progress: increasing complication of SHW morphological composition based on inclusion of large number of dangerous sanitary and toxicological components.

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Understated rates of SHW generation leads to low tariffs on SHW disposal and impossibility of urban municipal services to work without budget subsidies accordingly.

The only way of solid industrial and household waste neutralization in Astana city is its disposal in landfills and authorized dumps. At the time when the existing landfills and most part of authorized dumps in Kazakhstan cities do not meet sanitary and environmental requirements.

Lack of technology for waste sorting and recycling in the city leads to the widening of areas occupied for landfills and SHW dumps, increasing of the number of spontaneous dumps in the city and adjacent settlements.

Due to this the city is in critically need of modern engineering facilities and developed infrastructure for waste recycling, neutralization and utilization. The necessity of providing with technology and sanitary regulations for SHW collecting, processing and utilization requires a transition to modern technology and industrial methods of collection, neutralization and utilization of waste through SHLWM.

On this basis of abovementioned SHLWM foresees works execution on arrangement of compliance with rules of SHW existing landfill establishment and maintenance, sanitary-hygiene and environmental requirements, the acquisition of sufficient number of containers for waste collection, development of container platforms, the acquisition of special machinery for SHW disposal.

The increasing of waste recycling, neutralization and utilization degree up to required level suggests the commissioning of a new landfill that is built according to Spanish technology and the construction of SHLWU new-generation plant as a number of priority objects.

Prompt organization of works on SHW collection with ensuring the sufficient quantity of containers, special equipment, strict control of route schedule, the introduction of waste automated control system and the importance of creation of infrastructure for SHW recycling and utilization in Astana city becomes more urgent especially from the position of environmental safety providing, reduction and elimination of negative impact on the environment and inhabitants health.

At the same time the expansion rates of city economic on the basis of the “Development strategy of Kazakhstan up to 2030” also dictate the necessity of infrastructure development on waste recycling considering the concepts of sustainable development of MEP of the RoK for 2007-2024 years in Astana city.

SHLWM implementation mechanism.SHLWM implementation mechanism is based on the implementation of

technical, technological, environmental, social, economic, organizational and other measures complex focused on the following: development of solid household waste management system in Astana city for

the purpose of the environmental and health sanitary-epidemiological stability; providing of systematic solving of existing problems with SHW treatment on a

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scheduled basis through inclusion of social and economic development of the city in the medium and long term plans;

creation of waste collection, recycling, neutralization and utilization system with covering of adjacent settlements in Astana city;

reinforcement of material-technical base of municipal enterprises and the development of waste treatment infrastructure;

construction of SHLWU new generation plant; to involve the means and entities of small and medium-sized business into

SHLWM industry in order to build infrastructure of industrial waste utilization spontaneous dumps elimination, prevention of dumps generation and

reclamation of areas previously occupied with waste dumps.The main documents for ensuring of SHLWM implementation are Plans of

environmental protection measures in Astana city for 2009-2012 years. The mechanism of SHLWM implementation primarily foresees usage of the

instruments of economic, financial and budget policies of the Republic of Kazakhstan.

At the same time it is expected the involvement of bank credits, private investments and funds of small and medium-sized businesses entities. On the basis of state intention to carry out a gradual reduction of VAT amount and tax burden for local producers in order to support their competitive abilities after Kazakhstan accession to WTO.

Akimat of Astana city is the administrator of SHLWM and environmental protection activities that are funded by municipal and republican budget.

Construction of SHLWU new generation plant will contribute to spontaneous dumps elimination, refusal from dumping and waste sorting plants and reclamation of their areas.

One of the possible approaches for formation of SHW utilization infrastructure may be the development of funding strategy of SHLWM activities by foreign investors with involvement of funds of small and medium business entities in order to solve this problem.

Providing of the required funds and optimal distribution of investments in SHLWM priority directions is the most difficult stage in strategy preparation.

Considering the above mentioned it is necessary to use various forms of governmental support for SHLWM implementation: direct financing of activities (projects) from the republican budget (capital

investment and other expenses); granting of subsidies and grants to enterprises engaged in waste treatment field; encouragement of leasing activity for business entities focused on the

acquisition, modernization and upgrading of production equipment for waste neutralization, utilization and recycling;

provision of state guarantees on borrowed capital for financing of investment projects within the city budget;

assistance in organization of consortiums and other associations for financing of

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major projects in utility sector including foreign investors involvement; providing of tax and other benefits at the introduction of best technologies for

SHLWM treatment and secondary resources usage in accordance with the legislation of the Republic of Kazakhstan;

supporting of entrepreneurship, innovative and other activity (including environmental insurance) focused on the environmental protection and sanitary-hygiene welfare.

2.6 Market outlet for SHLWU plant products with industry waste

It is possible to get railway products and snow retaining fence and shield structures according to the railways snow fighting instruction of the RoK # CP-751/1 dated 2001 year through the extruding of various waste components (pulp that is received during solid household and liquid industrial waste utilization, construction waste, asphalt waste, metal waste).

There were carried out theoretical and experimental researches of technological processes of waste utilization, cleaning, recycling in electric field and also the researches of magnetic-hydrostatic separation in bio-neutralizing paramagnetic liquid that is subjected to magnetic field effect controlled by the voltage that results to deactivation of selected components. The following products and materials can be produced through SHLW and other industrial waste utilization: Railway products and signs; External and internal covering of worn out pipeline; Motor road products and signs; Window and door blocks; Soles for man, woman and children shoes; Agricultural products and construction materials; Furniture materials (slabs, decks, accessories)Мебельные материалы

(плиты, панели, фурнитура); Engineering materials and products.

Automobile, construction, woodworking, textile plants, municipal utilities and JSC “NC Kazakhstan temir zholy”, JSC “Kazakhmys” and JSC “Arcelor Mittal Temirtau” and others may be the main consumers of above mentioned products. The main objective of this project is the organization of non-waste, environmentally sound technology of household municipal waste recycling. Ferrous and non-ferrous metals can be supplied by metallurgical complex.

Since 2006 CJSC “Trunk railroad” is the consumer - the client for the production and implementation of snow retaining fences, shields, fences, road signs and rail pads for railway of polymer waste.

Polymer waste is subjected to recycling, paper, rubber and textile waste can be used as the raw material for manufacturing of cardboard or components of products for railways and polymer-sand construction structure (roof tiles, paving

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tiles and decorative tiles).SHLWU plant foresees the organization of plant production process for

SHLW utilization and other industrial wastes in order to produce on request products with sands and dyes usage: “Karaganda Zhylu” LLP, JSC “Water canal”, JSC “Arcelor Mittal Temirtau” JSC “NC “Kazakhstan temir zholy” and etc. Dasic dimensions of fence elements are shown in tables 2.10 and 2.11.

Table 2.10 –The main dimensions of lightweight fence elements of waste

Fence height,m

Poles size,sm

Baulk size,sm

Grillage size,sm

3,0 300x24x18 6х10х325 1,5x10x1004,0 400x24x18 6х10х325 1,5х10х1405,0 500х24х18 6х10х325 1,5x10x180

Table 2.11 – The main dimensions of snow overblowing fence of waste

Fence height, m Panel height, m Blown embrasure

height, m Poles size, sm Baulks size, sm

5 3 2 500х24х 18 60х 130х3301,5x10x330

Besides the above mentioned products for railways through extrusion of waste we can get the following: portable pan shields; identification signs for railway crossing and motor roads.

Raw material for products manufacturing will be waste components such as SHLW pulp, construction, road, steel, sand and dye.

The main components for used metal pipes coating are secondary granules at SHLWU utilization that are received from industrial and household waste mass.

Production method depends on the type of the surface insulation of pipes, their diameter and length.

Devices that allow simultaneously applying a coat of material on pipe inside and outside surfaces are used for pipes with cladding on inside surface or external inside surface.

Used metal pipes that are required for covering of impact-resistant thermoplastic will be supplied by dump and from interested parties - potential customers. Delivered pipes will be rolled if required. The residual part will be prepared to covering process through edge processing.

Production cycle of tube product with thermoplastic surface coating includes the following:

1. Mechanical treatment from tramp materials (dirt, a thick layer of rust) with subsequent lathe turning;

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2. Surface treatment for giving high adhesive properties to applied material through using a special machine with rolling devices with the application of polymeric tapes;

3. Metal pipe inputting in coverage area for electrical tape application;4. Final product removal from coverage area;5. Final products preparation for sending to consumers or delivering to final

products warehouse.The main raw material for the production of snow retaining fences and

bumpers, air stripper for vehicles, window frames and door units is a secondary polyethylene of industrial household waste. After receiving the liquid mass from recycled polyethylene there will be mass pouring into the special units - press mold. After cooling the product will be delivered to warehouse.

Used metal pipes with some surface damages and thermoplastic coating according to specified requirements that can be secondary used under the same operating conditions (except high heating). Since the modified surface is more resistant to aggressive properties during maintenance due to increased non-reactivity of coating thermoplastic (polyethylene) to acid, alkali, solvent and humid atmosphere air. The inside metal frame increases thin plastic layer stability to mechanical loads. A layer of thermoplastic material on the surface of used metal pipe increases maintenance-free service life in ten times. It will reduce the number of accidents due to corrosion of pipes.

The cost of worn out pipes that is determined mainly by expenses for surface thermoplastic coating that don’t have any value as raw material will be in seven - ten times lower than the cost of new pipes that means minimal cost. Transition of production to design capacity will allow us to reduce the production cost that will lead to marketing development.

Collection of industrial household waste will be carried out by special services with transport and specially equipped different colors sacks. After training of population on waste collection procedure in different cities as in the developed countries of the world it will allow us to improve the sanitary condition of the city and region and consequently have positive influence on the environmental situation on the areas and streets of the city.

In case of successful implementation of this project the experience of production organization may be applied in other regional centers of Kazakhstan cities and it is possible to establish mass production in the regions. Snow retaining fences and other polymer waste products are two times cheaper than wood and concrete fences and their service life is over than 50 years.

Selection of process diagram for industrial waste recycling for the connection with SHLW pulp composition.

It is required to use industrial waste as a raw material in order to reduce the cost of SHLWU plant products and goods. The most appropriate SHLW for pulp properties are construction, metallurgical plant, road-asphalt pavement wastes that

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allow us to increase quality parameters of products and to decrease the cost of following products: Railways and motor roads; Agricultural products and construction materials; Engineering products; Window and door frames; Architectural products and materials; Special fencing for buildings, organizations, local farms and etc.

Scheme of circuit management is shown in tables 2.7 - 2.10.

Figure 2.7 –General scheme of waste management

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Figure 2.8 – Municipal waste management scheme

Figure 2.9 –Scheme of construction waste management

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Figure 2.10 – Scheme of industrial waste management

General scheme of waste circuit management at the cities on the figure 2.7 shows that the lack of technology for waste sorting, recycling and utilization in the cities with over 500,000 residents leads to the increasing of areas occupied for landfills and SHW dumps, increasing of spontaneous dumps in the city and adjacent settlements.

Scheme of municipal waste circuit on figures 2.8, 2.9, 2.10 indicates on necessity of dumping landfills for SHW and construction waste.

Installation process diagram for construction and road-asphalt waste recycling is shown on the figure 2.11.

A process diagram for recycling of metallurgical and heating stations slag into crushed stone with metal separation is shown on figure 2.12. Present schemes on figure 2.11, 2.12 are operated in Russia and developed with a set of equipment that should be operated together with the construction in a complex of “SHLWU” new generation plant.

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Figure 2.11 – Installation process diagram for construction and road-asphalt waste recycling

Table 2.12 –Technical characteristics of installation

Size of feed material, max., mm 600Production capacity, t/h 128Installed capacity, kW 310Equipment mass, t 93Area size for installation, m 40х50

TCSI EQUIPMENT:1. Vibration feeder DRO-708-10 on bed frame;2. Coarse crushing unit DRO-646;3. Iron separator;4. Separation yard SBR-1;5. Sorting unit DRO-602M;6. Intermediate crushing unit DRO-667;

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7. Transporter DRO-913;8. Transporter DRO-923;9. Transporter DRO -912 (4 units.);10. Transporter DRO-922;11. Transporter DRO-902;12. Control unit DRO.4A.

Figure 2.12 – Process diagram for processing of smelter slag into crushed stone with metal separation

TCSI EQUIPMENT:1. Vibration feeder DRO-708-10 on bed frame;2. Sorting unit DRO-654;3. Tumbling drum DRO-655;4. Coarse crushing unit DRO-510-30;5. Intermediate crushing unit SMD-511;6. Sorting unit DRO-669;7. Transporter on the basis of DRO-904 (2 units);8. Transporter DRO-924;9. Transporters: DRO-923;

on the basis of DRO-923;10. Transporter on the basis of DRO-914;11. Transporter DRO-914;12. Transporter DRO-912 (3 units);13. Fixed iron separator (4 units);14. Control unit U7810.4A.

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Table 2.13 –Technical characteristics of TCSI

Size of feed material, max., mm 50-100Production capacity, t/h 700Installed capacity, kW 300Equipment mass, t 140Area size for installation, m 40х55

Final products are new construction materials: facing tile and paving slab, tile, paving curb, gutters and decorative fountains.

The received products and materials are differ from the common binding materials (sand, gravel, cement, crushed stone and etc.) in comparison with waste from SHLW pulp according to scheme on fig. 2.11, 2.12 and have higher quality of stability, environmental compatibility, durability and aesthetic properties.

New well-known in Russia technologies are suggested in order to use milled waste (construction, road-asphalt, metallurgical wastes, slags of heat power plants and etc.) as a secondary raw material for production of valuable construction materials (tiles, floor and wall tiles, borders, architectural structures and etc.).

According to technologies on figures 2.11, 2.12 milled industrial waste is used as a binder wherein the natural materials (sand) or production waste (crushed stone, gravel and etc.) can be a filler.

The suggested production line includes 12-14 units of major equipment for waste recycling that provides a sharp cost reduction of SHLWU plant products.

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3 PROCESS DIAGRAM DEVELOPMENT OF NEW GENERATION PLANT FOR SHW AND LIQUID INDUSTRIAL WASTE WITHOUT SORTING AND DUMPING

3.1 Development of innovative technology for solid household and liquid industrial waste utilization

The main advantage of the technological processes of solid household and liquid industrial waste utilization (SHLWU) is excluding of SHW sorting operations and refusal from municipal dumping landfill.

The matter of SHLWU process is accuracy providing for technological processes of SHW utilization of all morphological compositions through washing and drying then crushing and milling with a minimum of technical operations, increasing of productivity and efficiency of crushing processes of all SHW components through solid and liquid waste chemicalization.

SHLWU result is mixing the different combinations of chemicals waste: plastic, asbestos, batteries, garden waste, used oil, tires, electronic devices, acids, alkalis, information technology waste, chemicals. Besides that coloring matters, varnishes, dyes, adhesives, organic solvents, petroleum products, hydrocarbons, emulsions, decomposing organic waste, organic chemicals and other with crushed and milled to 10 mm SHW components that deliver to common mixer. Further there will be chemical reactions of polymers, organic compounds with subsequent molecular reactions of polymerization in a mixer.

A chemical reaction in mixer arises with high temperature and pressure with gases release (methane, propane, nitrogen and etc.) through the adjustment of gases release. In electric and heat furnaces it is possible to adjust the pressure in (mixer) blender. The temperature is regulated by cold water supply into the external case of mixer.

Chemical mixture of crushed solid household and liquid chemical waste that requires special connecting elements in the form of chemical additives such as: potash chloride, sodium, iron oxide, ferric chloride, chromium oxide, polymers and etc. is prepared in the chemical mixer.

After mixing of solid household and liquid waste chemical compounds with chemical additives they are ready to the next stage of extrusion, pressing and shaping in the form of pulp. For that stages it is necessary to determine the composition of binding elements for example sand, sludge, ash, crushed construction waste and other with dyes. For safety processes of waste utilization it is not allowed to use special hazardous, radioactive, medical, explosives substances, flammable liquids and soils, pyrophoric substances, flammable gases, spoils, industrial effluent, flashing water and etc.

Extrusion, molding and forming processes are conducted on the basis of the existing technological equipment required to determination of chemical additives and binding elements proportion depending on the type of products, goods and

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materials. For example for boards and poles of railway snow retaining fence production through extrusion it is required the following: chemical additives - 10% sand - 30%, ash 8%, slurry - 5%, colorants - 5% and the remaining 42% is a chemical pulp from the mixer-blender.

SHLWU technical task is solved first through selection of large-scale ferriferous construction waste with dimension of (length 500 mm, width 300 mm, height 200 mm) or more then through all waste (garbage) components washing and drying till unsticking condition of its components. This process is executed under its permanent transferring and subsequent cutting of large cardboard, wood, polymer and other boxes, containers by shear machines. Then the operation for all SHW morphological compositions crushing to the size of 80mm is started. After that there is the extraction of iron waste through the magnetic flux and then primary crushing to the size of 40mm, the secondary crushing and milling to the size of 10mm.Then everything goes into the mixer where it is mixing with liquid chemical waste (electroplating sludge, acid pitch, coke chemistry fust, mercury sludge, petroleum waste, varnish, paints, enamels, organic chemicals, waste oils, tires, acids, bases, resin, compound of zinc, chromium, lead, hydrocarbon, emulsions). Through the rotating diamond-shaped reversible screws that accelerate chemical compounds inside the mixture in various ratios and provide polymerization of waste components that are neutralized and subjected to detoxification as various phosphoric, nitrogen and other fatty acids are added. These acids in their turn are mixed with solid waste and form thick pulp and gases for further purification and using for extruding and forming.

As a result of chemical reactions at high temperatures up to 200 Celsius degrees and increased pressure to 40 atmospheres a full range of molecular processes is executed. During this process polymers, textile, rubber, organic and other materials are expanded and all living microorganisms in waste such as bacteria and fungi die, all the gases and vapors as a result of chemical process are recycled in gas treatment system and then they are using for heat power producing..

Almost no hazardous substances come into the environment and chemical process does not produce any by-products. It means the improvement of productivity and efficiency of milling of all morphological structures (components) of solid waste for the chemical mixture with liquid industrial waste. Acceleration of detoxification and polymerization of SHW morphological components through increasing of temperature and pressure in mixer-blender is provided at the expense of advanced utilization of solid household waste (garbage) by using the drive with diamond-shaped rotating and reversible screws in the mixer.

SHLWU technical result is steam-lining of technological processes of all SHW components crushing and milling to the size of 10mm and chemicalization of solid and liquid waste without manpower involvement at all operation stages. Serial technical facilities including measuring device at the final result of milling of all morphological components of economic solid waste are used as

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technological equipment.Scheme of solid household waste (SHW) (garbage) and liquid industrial

waste utilization method is shown on figure 3.1. Technological processes of solid household and liquid industrial waste utilization are shown on figures 3.2 and 3.3

SHW with all morphological compositions that incomes to garbage truck 1 for recycling is preliminary separated from large scale and ferriferous products of following dimensions: length-500 mm, width-300 mm, height-200 mm, from construction reinforced concrete waste that is not subjected to plastic deformation by grapple 3 at the unloading platform 2. SHW separated from large scale components is cut by shear machine 4 on scraper conveyor 5 where it is dried and desiccated from excess water. Evaporating water that is saturated with smells and gases is removed through smoke exhauster with neutralization.

Dried SHW is transferred into the storage tank 6 that adjusts the cyclical of SHW incoming. Then SHW portions are sequentially transferred to belt conveyor 7, then to preliminary crusher 8. After that it is executed the extraction of ferriferous materials from SHW through lifting electromagnet 9 on transported conveyor 10. Then SHW components with the size up to 80 mm are transferred to primary crushing 11 where they are crushed up to 40 mm, than through the conveyor 12 they come to secondary crusher 13 for milling up to 1-10 mm. This is the end of SHW crushing process that is carried out by toothed, roll and hammer crushing units and milling machine 14.

Later SHW chemical recycling method is started. Liquid waste transfers from special trucks with liquid chemical waste such as galvanic sludge, acid pitch, coke chemistry fust, mercury sludge, petroleum waste, varnishes, enamels, resins, compounds of zinc, chromium, lead, acid and other liquid industrial waste 15 into mixer 16.

Chemical processes of mixing solid and liquid wastes are carried out by following operations: crushed SHW up to 1-10 mm and liquid mixed chemical waste, polymer components, different acids that allow us to get chemical compounds for all components of solid and liquid waste transfer to general mixer-blender 16 from special tanks 15. It is foreseen a special structure of rotating diamond-shaped screws that are adjusted and reversed depending on SHW compound and chemical compound components in order to speed up chemical reactions in mixer 16 by mixer drive 17. Special modern devices for monitoring and controlling of chemical processes in mixer will be installed if required. Selection and preparation of method and installation for obtaining of chemical compounds in the form of pulp 18 during the processes of extrusion, compaction and forming 19 for producing of different goods, products for national economy 20 is executed after neutralization and detoxification of chemical processes through chemical reactions in the mixer. The choice of additional chemicals and ratios depends on the selected products and structures, such as the number of binding elements and dyes. The widespread introduction of the proposed method of disposal of solid waste and liquid industrial waste will give the option to exclude

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labor-intensive sorting and disposal of solid waste in urban landfills (Figures 3.1-3.4). Selection of compound and ratio of additional chemicals depends on produced goods and selected structures for example the amount of binding elements and dyes. Widespread introduction of solid household and liquid industrial waste utilization method gives an opportunity to exclude SHW labor intensive sorting and waste dumping on municipal landfills (Figures 3.1-3.4).

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Figure 3.1 – Utilization method of solid household waste

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Figure 3.2 – Process diagram of solid household and liquid industrial waste utilization.

Equipment of SHLWU JSC “Drobmash” Russia.1. Garbage track; 2. Magnetic grab; 3. SHW receiving site; 4. Scraper conveyor; 5. Liquid line after washing process; 6. Vibration feeder; 7. Iron separator; 8. Metal detector; 9. Belt conveyors; 10. Crasher (40-80 mm); 11. Crusher (20-40); 12. Crusher (10-20); 13. Milling machine (3-10 mm); 14. Mixing machine (mixer) of solid and liquid waste; 15. Drive with mixer screws; 16. Shape generators; 17. Extruders; 18. Control unit system (CUS).

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Delivery of SHW from garbage truck

Choosing of ferroconcrete waste

fragmentation of large pieces of solid waste and drying pre-cut solid waste up to 40-60 mm Choosing of ferroconcrete

waste crushing to 20-40 mm crushing and grinding to 1-10 mm flow

liquid waste into the

mixer

neutralization, mixing and

detoxification using screws

delivery of pulp from

mixer

compound of pulp w

ith other w

aste production output

Figure 3.3 – Technological processes of solid and liquid industrial waste utilization1 – garbage truck; 2 – SHW cleaning; 3 – magnet grapple; 4 – SHW cutting; 5 – scraper conveyor with drying unit; 6 – crushing bunker; 7 – belt conveyer; 8 – SHW cutting up to 40-60 mm size; 9 - magnet for metallic waste selecting; 10 – belt conveyer; 11 - SHW cutting up to 20-40 mm size; 12 – belt conveyer;

13 - SHW cutting up to 10-20 mm size; 14 – crushing up to 1-3 mm; 15 –liquid waste delivery; 16 – mixer; 17 – driver with screw mixer; 18 – thick pulp from mixer; 19 – extrusion, forming, compaction and other; 20 – new materials and products getting; 21 – pipeline.

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Figure 3.4 – Equipment layout of one production line of SHLWU plant of 200 tons/shift capacity.

Conventional symbols:1 – primary crusher;1' – mixed liquid waste for neutralization and detoxification;2 – secondary crusher;3 – milling;4 – mixed SHW;5 – solid and liquid waste mixing (SLQ in mixer);CPC – chemical polymeric components;LW – volume capacity of liquid waste;РХ – storage tank for mixed SHW.

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3.2 Technical design of the plant on solid household and liquid waste utilization (SHLWU)

It is required to build a plant for solid household and liquid industrial waste utilization SHLWU with production capacity of 200 t/shift for establishment of joint venture in order to attract investors.

3.2.1 SHLWU project description

Issues concerning outside coating of pipes and obtaining of construction and furniture materials on the basis of primary polymer materials are discussed in CIS countries and abroad (in USA, Japan, Italy, Germany and other countries).

Producing of goods of primary polyethylene sacks, bags and containers for liquor plants, fruit drinks and various liquid is increased last five years. 12 000 tons of polymer, plastic, industrial-household waste that pollute the environment incomes to municipal dumps every month in accordance with Karaganda municipal-transport authority.

Consequently the injury to population health and national economy of the Republic of Kazakhstan is calculated in billions of tenge per year. Breakage of municipal pipeline due to pipes corrosion also inflicts heavy damages to national economy. It leads to excess consumption of water, industrial and household waste discharge into drainage water. As a result soil structure is broken. All these factors effect on the environmental situation of the district and region.

The implementation of the present project will allow us to create environmentally sound production based on solid and liquid wastes recycling.

The results of carried out researches show that after primary treatment of polymer-plastic products their physic-chemical and mechanical properties are changed on 17-21% to the downside but the pressure and temperature are constant. After secondary temperature recycling of waste products the recycled product can be used in construction and automobile industries for production of window and door frames, plates, bumpers, protection grids of headlamps as well as for outside and inside coating of metal pipes in order to destroy the corrosive effect.

Workshop that is proposed to construction for solid household and liquid industrial waste utilization is developed on the basis of “NSL-HYDROMEX” waste recycling plant by NSL International, Trading, Inc, corporation registered in the Los Angeles, California, USA with application of Kazakhstan inventions indicated in Annex 1.

Suggested technology recycles liquid and solid wastes and produce environmentally sound products for domestic and production usage. The great advantage of this technology is the extraction of heavy metals from liquid medium such as strontium, mercury and many others.

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The present technology is improved for recycling of solid and liquid waste, chemicals, toxic waste, packaging materials of polymer products (various containers, bags of food and alcoholic products and etc.), contaminated soils, municipal waste, hospital waste, textile materials, plastics, tires, paints, solvents, waste oils and many other waste that are mixed in different ratio (besides iron and reinforced concrete waste).

There were carried out theoretical and experimental researches of technological processes of waste sorting, cleaning, recycling in electric field and researches of magnetic-hydrostatical separation in bio-neutralization paramagnetic fluid that is subjected to adjustable voltage magnetic field impact with deactivation of the separated components. The following products may be produced through solid and liquid waste recycling: Railway products and signs; Motor road products and signs; Heat and electric insulation materials; Furniture materials (slabs, boards, accessories); Construction materials (tile, paving slabs and other).

Automobile, engineering, construction, woodworking, textile factories and utility companies may be the main consumers of such products. Basic objective of this project is organization of non-waste technology for municipal waste recycling. Ferrous and non-ferrous metals may be supplied by metallurgical companies.

Since 2002 CJSC main railway line "Kazakhstan temir zholy" is a consumer and client of production and implementation of snow retaining and snow blowing fences and shields, guards, road signs and rail pads for railway of polymer waste. Polymer wastes are subjected to recycling, paper and cloth may be used as raw material for production of cardboard or component of products for railways and motor roads.

The present project foresees the organization of workshop production process on solid household and liquid industrial waste recycling in order to get products on the orders of the following companies: JSC “Karaganda-Pauer”, JSC “Karaganda-water channel”, JSC “Arselor Mittal Temirtau”, JSC “NC “Kazakstan temir zholy”, JSC Corporation “Kazakhmys” and others.

Production buildings necessary for production process will be constructed or assembled on the basis of two-story buildings with underground utilities.

Since the workshops are assembled the installation and construction works will require less than six months. Purchase and manufacturing of equipment through Porhomenko plant will be conducted along with workshops installation.

It is planned to establish a joint venture company based on shares for organization of production. Since “Enbekshi” company does not have property capital but has copyright certificates and patents for the establishment of environmentally sound production of construction and other materials on the basis of solid and liquid waste recycling (annex 3) then some part of patents and copyright certificates in the amount of $ 1,200,000 are suggested as a contribution

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into the joint venture. In this case the capital in the amount of 88 million tenge should be a contribution from another other party.

3.2.2 Products and goods manufacturing trough SHLWU

The following materials can be produced through the extrusion of different waste components (plastics, cardboard, paper, textile, rubber, glass and others): railway products, permanent snow retaining fence structures according to the instructions for snow control on railways of the RoK # -751/1, 2001 year .

Table 3.1 – Basic dimensions of lightweight fence elements of waste

Fence height, m

Pole diameter,sm

Pole length, sm

Bracket diameter, sm

Baulk size, sm

Grillage size, sm

3,0 25 460 20 6х10х325 1,5х10х100

4,0 25 56 20 6х10х325 1,5х10х1405,0 25 660 20 6х10х325 1,5х10х180

Table 3.2 – Basic dimensions of snow blowing fences of wasteFence

height, mPanel

height, mBlown

embrasure height, m

Pole diameter, см

Bracket diameter, sm

Baulk size, sm

5 3 2 25 20 60х130х330, 1,5х10х300

Besides the abovementioned products for railways we can get the following

products through the extrusion of waste: – portable pan shields;– identification signs for railway and motor way crossings.

The following waste components will be used as raw material for goods production: plastic products, paper, old clothes and plastic waste with sand and dye additives.

Waste will be delivered to SHLWU workshop that will be located in JSC “Astana Gorkommunkhoz” landfill in accordance with the permission of Astana city Akimat.

The main raw material for the production of bumpers, air strippers for vehicles, window frames and door units is recycled polyethylene. Mass pouring into special press molds will be executed after obtaining of liquid mass from recycled polyethylene. After cooling the product will be delivered to warehouse. More detailed description of production cycles will be given in negotiations process.

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The main production will be the obtaining of insulation materials, electrical insulation tapes, snow retaining fence elements, shield and etc.

The following products will be produced within the year:1. Outer cladding of pipeline coating - 8 mln. tenge; 2. Thermal insulation material - 2 mln. tenge;3. Electric insulation tapes – 6 mln. tenge;4. Snow retaining fences, pan shields for railways and etc.;5. Construction materials (tile, paving slab and other).

3.2.3 SHLWU plant advantages

Low production cost; Lack of transportation expenses for raw materials production; Lack of transportation expenses for import of equipment from other countries; There are no hazardous emission into atmosphere and water sources as all types of waste are neutralized; There are no harmful residual products that require further destruction or dumping;

Collection of industrial and household waste will be carried out by special machinery into specially equipped containers following the example of developed countries like USA, UK, Japan and etc. It will allow improving the sanitary condition of the city and the region and thereby positive impact on the environment in the area. To achieve this requires training and organizational activities with the public. It will allow us to improve sanitary condition of the city and exert positive impact on the environmental situation in the region. It is required to arrange training organizational activity with inhabitants.

In case of successful implementation of present project the experience in production organization can be used in other Kazakhstan regions and mass production in the regions can be established.

Snow retaining fences and other products of plastics waste are two times cheaper than wood and concrete fences and their service life is 50 years.

3.2.4 Distribution area"Enbekshi" company is planning to supply its products to the following

companies:– CJSC mainline railway network “Kazakhstan temir zholy”;– “Karaganda-Power“, “Karagandy zhylu”;– JSC “Water canal-Karanda”;– JSC “Arselor Mittal Temirtau”, ADJSC “ Arselor Mittal Temirtau”,– “Kazahmys” corportion;– municipal CAO and other.

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Table 3.3 – Technical characteristic of workshop equipment (extruder)

Product name

Production indexes

External cover consumption of heat pipeline

Heat insulation materials

Electric insulation tape

External inside coating of metal pipe

Product elements for railway

Technical 30m/hour 40m/hour 25 m/hour 10m/hour 36m/hourMaintenance 240m/shift 320m/shift 200m/shift 80m/shift 350m/shiftDaily 480m/day 640m/day 400m/day 160m/day 700m/dayСуммарная мощностьТЭН

26kW.h 37kW.h 22kW.h 28kW.h 60kW.h

Table 3.4 – SHW morphological composition in 2006 year

SHW classification % from total SHW amountEurope CIS USA Astana city RoK Karaganda city

Paper 24,7 20-36 38,0 25,85 36,0 36,0Food waste 37,8 20-38 25,0 24,60 13,0 14,0Wood - 1-4 - 4,35 4,0 3,0Textile 7,8 3-6 - 3,85 6,0 6,0Bones - 2,5 - 4,0 4,0 4,0Scrap-metal 2,8 2-4 8,0 4,35 4,0 4,0Glass 2,8 5-7 7,0 3,30 4,0 4,0Plastic 8,0 8,9 8,0 14,75 9,0 9,0Other (oversized items, chemical and construction waste, rubber, tires and etc.)

16,1 10-35,5 15,0 16,35– 24,0 20,0

Total 100 100 100 100 100 100

As of 01.01.2006 year total amount of SHW in Karaganda city landfill is 4495 thousand tons. Amount of generating SHW per day is over 500 tons.

Table 3.5 – SHLWU plant technical and economic indexes per year

п/п

Indexes name Meas. un.

Quantity Price (tenge)

Annual output (thous.

tg)

Guaranteed consumer

(customers)

1 2 3 4 5 6 71 Design capacity ton 72000 146000

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A In natural units waste per year

B External cover consumption of heat pipeline coating

m² 50000/240т. 70 8000 “Karaganda Zhylu” LLP

C Heat insulation materials m³ 3000/230т. 1150 2000

“Karaganda Zhylu” LLP

D Electric insulation tapeM 80000/340т. 50 6000

JSC “Karenergo”, JSC “Ispat-Karmet”

E Construction materials (tiles, paving slab)

m² 20000 240 84000

Construction companies of the Republic of Kazakhstan cities

F Snow protection fence elements and other products for railways and motor roads

M 80000/640 400 46000 IRS, CC, NC «Kazakhstan temir »zholy

Total 3460 146000 Including VAT 146300000 tg.VAT 7726666 tg.

2 Estimated cost A Construction works thous. tg 6000B Equipment

(purch.) 31000C монтажные работы 10000D Other expenses (DCE,

lease, el. power, utilities, salary and other)

6000

E Equipment production 25000F Taxes 10000

Total 880003 Workers on payroll per. 16A Worker per. 9B Driver per. 1C ETS, employees per. 64 Operation hoursA Working days in the

yearday 260

B Shift per day shift 2C Shift duration hour 85 Installed capacity of

power collector kW/hour 180

A Heat kcal 98-120B Water m³/ hour 0,84

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Table 3.6 – Explanation of financial expenses for one “SHLWU" process line equipment of 200 tons/shift capacity at the cost of 88 million tenge (eighty eight million tenge)

п/п Name Type, model

Position on SHLWR

plan

Quantity Measur. unit

Price, thous. teng

1 2 3 4 5 6 71. Tank (bunker) SHW Welded

structure with 20 m³ volume

SHW

1 un. 1800

2. Iron separator EPR-120 1 1 un. 8503. Crusher DDZ-6 2 1 un. 11004. Miller M8-6Б 3 1 un. 14005. Spectrometer tank Fuel tank-3 4 2 un. 14006. Mixer tank SHW (B-3) 5 1 un. 7007. Chemicals tank CPC (B-3) 5' 1 un. 8008. Mixer tank B-3 1' 1 un. 7009. Tank (bunker) ZhO (Б-3) LW 1 un. 70010. Reserve tank B-3 RT 3 un. 110011. Air compressor TV175-1,6 1 un. 150012. Conveyor СК-600 2 70013. Pumps GP-120 2 un. 80014. Electric equipment - 3 un. 75015. PC, programming

ACS of tech. process IBM-PRO System command

- 1 - 1800

16. Pressure regulator valve

RD-0-14 4 un. 120

17. Shutters activator SF-38-172 5 un. 9018. РН controllers РН-12 5 un. 20019. Pipes and fittings D.45-80 - - - 270020. Tools ET-45 - - - 8021. Safety equipment as required - - - 89022. Rent equipment Fork. Lifts - - - 3023. Steel and construction

design 5440

24. Facility Nuts.bolts 200025. Manual tools Snap On 85026. Chemicals Annex # 2 28027. Design and survey

work7800

28. Transportation and insurance

860

29. Construction works 600030. Special assembly 1000

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works 31. Arrangement of

workshop and work process

2000

32. Commissioning works 200033. Staff training and

work 3500

34. Profit of SHLWU workshop constructor 500

35. Equipment manufacturing

17000

36. Other expenses: utility services, maintenance

396037. Business expenses,

taxes, salary and other

TOTAL: 88000

Table 3.7 – The list of chemicals that are used in “SHLWU” workshop, total cost is 280 000 tenge.

It.#

Chemical additives name It. #

Chemical additives name

1 2 3 41. Potash chloride 9. Ferric chloride2. Solvents 10. Chromic oxide3. Hydrogen nitrate 11. Polymers4. Phosphoric acid 12. Fatty acid5. Hidrogen peroxide 13. Lactic acid waste6. Sulphate 14. Glue7. Sodium chloride 15. Processed oil products 8. Iron oxide 16. Sugar production waste

Figure 3.5 – Polymer crusher

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Figure 3.5 – Dry mixer

Figure 3.6 – Kneading machine and control cabinet

Figure 3.7 – Screw mixer

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Figure 3.8 – Process line of the plant

SHLWU Plant equipment

3.3 Products of SHKWU plant

Heat insulation materials, insulating tapes, snow retaining shields elements and etc. will be the main production. (fig.3.10.);2. External cover consumption for heat pipeline coating (fig.3.11);3. Heat insulation materials (fig. 3.12);4. Agro-industrial products (fig.3.13);5. Snow retaining fences, guard cards for railways (fig.3.14) and motor ways (рис.3.15);6. Engineering products (fig. 3.16);7. Construction materials (tiles, paving slabs and others) (fig.3.17);8. Sole for men and women shoes and other.

Figure 3.8 – Structure of price formation and variable expenses per one product in Russia and Kazakhstan countries

The list of produced goods and products Cost indicators, tg

Figure 3.9 – Crusher mill 2812A is intended for bone cuts, grains, plastic, circuit boards crushing and others.

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In Russia SHLWUplant

In Kazakhstan

1 2 3 41. External cover consumption for heat pipeline coatingExpenses for 1 s.m.Price for 1 s.m.

4590

3070

4085

2. Thermal insulation materialsExpenses for 1 s.m.Price for 1 s.m.

7201450

6501150

7051350

3. Electric insulation tapesExpenses for 1 м.Price for 1 m.

128450

120380

125395

4. Construction materials (tile, paving slab)Expenses for 1 s.m.Price for 1 s.m. 8,8

8607,5640

8,2680

5. Electrical powerExpenses for 1 s.m.Price for 1 s.m.

124

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6. Snow protective fence elements and other products for railways and motor roads. Expenses for 1m/price

80/600 60/400 70/5807. Waste compound for products output (for railways and motor roads) Waste pulp – 35%Sand and dye - 30%Cement – 10%Construction waste – 25%Price for 1 mᵌ 1800 800 12008. Power generation, kW/shiftPrice for 1 kW/hour 4,0

100003,0 4,5

It is required to execute certification of offered product categories at all manufactured products and goods considering their components as they are made from different waste after its chemical treatment.

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Compound: SHLW pulps– 40%; Construction waste – 20%; Asphalt waste – 15%; Metallurgical waste – 20%; Dye – 5%.

Figure 3.10 – Snow retaining fence of solid household and liquid waste pulp and other compounds

(black, blue, red and green colors)

Conventional symbols:1-covering pipe; 2- cooler; 3-bunker; 4,5-shuter of bunker port;

6-heater; 7-rolling device; 8-rollers.Figure 3.11 – Implementation of method for external covering of pipes through HF

current and HF softening of thermoplastic layer before layer leveling

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Table 3.9 – Technical characteristic

Product name

Production indexes

External and internal coating of metal pipes

Technical 10 m/hOperating 80 m/shiftDaily 160 m/dayTotal power of TEH 28 kW/hour

Figure 3.12 – Covers for heat pipeline external consumptions

Covers for outdoor dimensional costs for heating pipelines

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Figure 3.13 – Products of chemical compounds of household and liquid waste (pulp) and other components (sand, cement, dye, construction waste, bricks, slag blocks, road-construction waste, asphalt coating, metallurgical slags)

Plastic waste with sand and dye

Состав теплоизоляционных лент:Пульпы ТБЖО – 60%Асфальтовые отходы – 20%Строительно-отделочные отходы – 15%Красители – 5%

Состав электроизоляционных лент:Пульпы ТБЖО – 60%Строительно-отделочные отходы – 25%Асфальтовые отходы – 10%Красители – 5%

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For forming tips connection Conventional symbols:

1- channel for thermoplastic heating; 2-heat distribution substance; 3-exterior heat insulation; 4,12-electric heaters; 5-pushing device;

6- driving spring; 7-rotating rollers; 8- round cam gear;9-reduction gear; 10-electric motor; 11- bunker-heater.

Figure 3.14 – Facility for single block products producing

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Technical characteristics of extruder:

For producing of boards for snow retaining fence of polymer waste along railways1. Extruder type ESZZPO;2. Working capacity at boards output of 3100x160x40 mm size;3. Total design capacity, kW/hour – 60;4. Electrical network voltage, volt – 220; 5. Adjustable temperature regime, degree – 480-1200;6. Operation temperature, degree:– LDPE = +500, +700;– LDPE = +600, +1000;7. ESZZPO mass, ton – 9,5;8. Basic dimension, mm:length – 6400;height – 21000;width – 600.

Table 3.10 – Plant indexes

Products name

Production indexes

Outer cover ofheat pipeline

flow

Thermal insulation materials

Electric insulation tapes

Elements of products for

railways

Technical 30m/hour 40m/hour 25m/hour 36m/hourOperating 240m/shift 320m/shift 200m/shift 350m/shiftDaily 480m/day 640м/day 400м/day 700m/dayTotal power of TEH

26kW.h 37kW.h 22kW.h 60kW.h

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а – liner (with resistant steel element)Extruder production at boards output 3100х160х40Per hour = 10-12 un. Per month = 2640 boardsPer 1 shift = 60-65 un. Weight of 1 board = 19,2 kgPer day = 120 un. During two shifts Per 1 km of fence = 19,2 kgCost of 1 board = 400-450 tenge Cost of 1 kg of waste = 8:12 tengeFor 1 km of fence it is required 3340 un. bordsMonthly amount of polymer waste in Karaganda = 128000 ton.

Figure 3.15 – Forming head for boards of snow-retaining fence

Figure 3.16– Plastic coating method

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Figure 3.17 – Complete cycle for production of high-quality polymer-sand construction materials (tiles, paving tiles, wall tiles, decorative accessories,

building blocks, window sills, table boards and etc.).

3.4 Advantages over well-known technologies in CIS countries and abroad

The main advantages of SHLWU plant are the following:There is no need for waste dumping since chemicalization recycles all type

of solid household and liquid wastes;There is no need for sorting, preliminary selection and separation of waste;Recycling process is very fast;Resulting gas is used for heating and electric power generation;There are no hazardous residual products that require further destruction;Catalysts required for “SLW Hydromix” process are in the garbage and

industrial liquid waste;

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There are no residuals and hazardous emissions into the atmosphere and ground surface;

All types of garbage and liquid waste (except metal and reinforced concrete) are recycled into useful import-substituting products and products for industrial, construction, railways and motor roads, power supply, as well as for the production of men, women and children shoe soles.

Expected results.Production of heat-power supply through waste chemicalization;All types of waste are utilized into useful import-substituting products and

products for different industries that have over 40 items;There is no need for SHW sorting and dumping;Processes are not accompanied with hazardous emissions into the

atmosphere, water resources and the ground surface;Complete labor safety is provided by al production processes automation; All manufacturing products are environmentally sound; There is no need for preliminary sorting and separation;Economic and technical requirements.

The cost of one production line under 200 tons of waste recycling per shift is 188 million tenge excluding building and communications; Annual output of one production line is 186 million tenge; Payback period of solid household and liquid waste utilization plant

SHLWU is 9 months; All technical equipment is provided within the Republic of Kazakhstan and

Russia; Processes for products production are absolutely automated; Complete labor and safety is provided; The design capacity of one production line is 720,000 tons per year; Planning annual production volume of one production line is 146 mln tenge; The requested amount for project implementation is 160 million tenge. It includes the cost of “SHLWU” plant construction and assembly works. The type of business proposal is the establishment of JV

3.5 Development of utilization technology improvement considering new innovative methods for all morphological compositions of solid waste cutting

A new design of solid household waste cutting to 0.5 mm size due to special shears with torques.

There are the following facilities: screening, waste unloading and recycling stations for waste sorting, crushing and packaging with subsequent recycling of food and plastic waste by press shaping. USSR # 1727914. Cl. V03 V9/06, B65 G7/00, 1992 year.

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Sorting station disadvantage is that it does not provide a deep separation of components suitable for secondary use of all morphological compositions of solid household waste and the multistage: sorting, crushing, re-sorting and packaging as well as waste separation on components by analyzing extracting device.

It is known the level of technology on machine flow sheet of equipment for sorting and separation of variable compositions dry mixtures which the morphological composition of solid household waste (garbage) and recovery of other components suitable for secondary use and depth recycling of solid household waste (SHW) residues after extracting of recyclable materials is referred. [22, 23]. A disadvantage of the abovementioned device is usage of different equipment for sorting of SHW that is separated into several streams with given SHW size fractions. Also it is multistage through sorting works with multistep separation and inefficiency of footwear, textile, and tire cutting.

There is a method for solid household waste utilization. The invention to provisional patent # 18444. The invention is related to a method of solid household waste (SHW) and liquid industrial waste utilization and can be applied in public service.

The disadvantage of the abovementioned technology is usage of different equipment for transportation, crushing and milling that separates waste on several streams with given SHW size fraction, multistage through crushing mechanisms of enrichment (cloth, etc.) plants with complicated structures and complicated cutting of men, women and children shoes.

Invention objective is the elimination of crushing mechanisms and SHW milling as well as the reduction of transport devices at chemical utilization of solid household and liquid industrial waste [66].

The matter of invention is structure simplification and reduction of milling processes power consumption especially of complex waste such as footwear and textile products and others by shears cutting as well as morphological compositions (of SHW) through cleaning and drying at first and then direct milling by cutting all SHW components under solid and liquid waste chemicalization.

The result of the invention is the mixing of different chemicals waste combinations. For example, plastic, asbestos, batteries, garden waste, waste oil, tires, electronic devices, acids, alkalis, information technology waste, chemicals, paints, lacquers, dyes, adhesives, organic solvents, pesticides, petroleum products, hydrocarbons, emulsions, degrading organic waste, organic chemicals and others with crushed and milled to 10 mm SHW components that income to common mixer. Further there will be chemical reactions of polymers, organic compounds with subsequent intermolecular reaction of polymerization in mixer.

Chemical reaction in a mixer is occurred with high temperature and pressure with gas release (methane, propane, nitrogen and others) by controlling of gases release. It is possible to regulate the pressure of mixer in electric and heat furnaces. Temperature regulated supply of cold water into the outer casing mixer.

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Chemical mixture of milled solid household and liquid industrial waste that requires special connective elements in the form of chemical additives such as potassium chloride, sodium oxide, iron oxide, ferric chloride, chromium oxide, polymers and others is prepared in the mixer.

After mixing of solid household and liquid industrial waste chemical compounds with chemical additives they are ready in the form of pulp to next step of extrusion, pressing and forming. For execution of these steps it is required to determine the composition of binding elements such as sand, sludge, ash, crushed construction waste and others with dyes. It is not allowed using of special hazardous, radioactive, medical, explosives, flammable substances and soils, flammable substances, spoils, industrial waste water, wash water and others in order to provide safety of waste utilization processes.

The processes of extrusion, molding and forming are conducted on the basis of the existing production equipment that is required to determine the correlation of chemical additives and binding elements depending on the products, goods and materials. For example for production of boards and poles for railway snow retaining fence materials through the extrusion it is required the following: chemical additives - 10%, sand - 30%, ash 8%, slurry - 5%, dye - 5% and the remaining 42% is the chemical pulp from the mixer .

The technical task of the invention is solved by the following: selection of large size, iron-containing construction waste (length is 500 mm, width is 300 mm, height is 200 mm); through all waste components (garbage) drying up to non-sticking condition of its components under its constant moving and subsequent cutting of large cardboard, wood, polymer and other boxes, containers by shears; primary crushing (vehicle tires, men, women and children footwear, textile products for men, women and children clothing and other waste) of all morphological compositions of SHW to the size of 80 mm; separation of iron waste through the magnetic flux; secondary crushing to the size of 40 mm, 20 mm, 10 mm up to the size of 0.5 mm with subsequent transferring into the mixer where it is mixed with liquid chemical wastes (galvanic sludge, acid pitch, coke chemistry fust, mercury sludge, petroleum waste, varnish, paints, enamels, organic chemicals, waste oil, tires, acids, pesticides, alkali, resin, compounds of zinc, chromium, lead, hydrocarbons, emulsion). Through the crushing by rotating diamond-shaped reversible screws that accelerate chemical combinations of different ratios components inside the mixture and ensure polymerization of the waste components that are neutralized and subjected to detoxification as various phosphorus, nitrogen and other fatty acids that are mixed with solid waste are added The result is a thick pulp and gases for extruding and forming, as well as heating and electricity.

As a result of chemical reactions at high temperatures up to 200 Celsius degrees and pressure up to 40 atmospheres a full range of molecular processes is performed. During these processes polymers, textile, rubbers and other organic

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materials are expanded, all living microorganisms in waste such as bacteria and fungi are died, all generating gases and vapors during the chemical process are recycled in gas treatment system and then it is used for heat and power generation.

Almost no hazardous substances are entered into the environment, chemical process gives no byproducts, all liquid after SHW washing comes into the mixer. Increasing of productivity and efficiency of all morphological compositions (components) of solid waste crushing for chemical combination with liquid industrial waste through deep solid household waste (garbage) utilization under using the drive with diamond-shaped rotating and reversible screws that provides rapid mixing and chemical reactions of solid and liquid waste with neutralization and detoxification and polymerization of SHW morphological compositions by increasing the temperature and pressure in the mixer.

Technical result of the invention is stream-lining of production processes of all SHW components crushing up to the size of 0.5 and chemicalization of solid and liquid waste without manpower involvement at all operation stages. The serial technical facilities considering measuring device at the final result of all morphological structures of SHW crushing are used as technological equipment.

Device for municipal household waste crushing through SHW cutting is shown on figure 3.18.

The result of device invention is the special structure for municipal household waste crushing through all morphological structures of SHW cutting that is a composite element of production process of waste utilization.

The matter of device is that on practice toothed-roll, cylinder and hammer crushers are mainly based on hammer firing mechanism for hard rocks.

It is not effective to use such kind of mechanisms for SHW crushing since physical and chemical compositions do not allow crushing by impact loads that does not provide SHW crushing that’s why it is required to use cutting method with sharp knives.

The invention objective is the development of device that will include production processes of SHW utilization that is achieved by the usage of structures that provide various waste components cutting through numerous rotating double-sided blades of knives that are interacted with different soft properties of waste.

A general design of the device with special structure of cylinder and rotating drive is shown on figure 3.18. The device consists of electric or hydraulic motor 1 with a reducer 2 that is fixed to the cylinder 6 through the channel beam 7 with rotating and reversible shaft 3, rigidly fixed crisscross double-sided blades 4, rigidly fixed shaft 3 and the cylinder 6 with fixed crisscross double-sided blades 5 that are contacted with rotating shaft (axis) 3 in the form of knifes through interacting with two blades 4 and 5 that provides SHW cutting operation.

Increasing of blades amount that are interacted with the rotating shaft 3 at different distances provides more efficient SHW crushing from 80 mm to 0.5 mm.

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In order to compact crushed cut waste there are screws 7 that are rigidly fixed at different distances on the shaft 3 with interacting knives 4 and 5. For example in order to get SHW pieces of size up to 0.5 mm with 12 knifes at the outlet

Рmin = 15 kW, до Рmax = 30 kW

Figure 3.18 – Device for municipal household waste crushing by cutting

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3.6 Innovative technology for obtained materials application in various sectors through the implementation of anti-crisis program

Innovative technology is related to plastics processing such as plastics combination, thermoplastics particularly. A method of production manufacture of thermoplastic resins products (see Japan, request # 52-32656: B29S11/00; B29G 3/00. Sumimoto K.K.). A mixture of a thermoplastic resin and fine-grain polymer is subjected to softening by its fluidity temperature.

The disadvantage is the limitation of composition application for example “Thermoplastic resin - polymer granules” because of their large differences in physical and chemical composition and possible concentration of mechanical stress on contact surface of thermoplastic resin and granule.

There is a method for thermoplastic products manufacturing for example polyethylene (see Germany (DE) request # OS 3,713,951, B29 C49/01). Thermoplastic is processed or saturated with agglutinant in press mold prior to extrusion.

The disadvantage is that agglutinant should proportionally spread branched surface of thermoplastic that is enclosed in press mold.

The purpose of the invention is to produce polyethylene products through extrusion method. The product is made of composition of high pressure polyethylene as agglutinant and low pressure polyethylene as thermal accumulating substance.

The objective is achieved through the usage of high pressure polyethylene (HPPE) and low pressure polyethylene (LPPE) that is taken in the form of small granules - chips or filings. These two types of polyethylene have different melting temperatures are high at near density. If low pressure polyethylene volume exceeds high pressure polyethylene volume in 1,5-2 times it allows LPPE to save heat without increasing of melting temperature in amount enough for melting of one volume of high pressure polyethylene (HPPE) under its heating above melting point (figure 3.19, 3.20)..

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Figure 3.19 – Thermal pressing method of polyethylene and polyethylene regenerate products

Figure 3.20 –Thermal pressing method of polyethylene and polyethylene regenerate products

The novelty of proposed method is in application of high pressure polyethylene (HPPE) as an adhesive component under using of excess amount of

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heat that low pressure polyethylene (LPPE) stored under its heating up to the temperature that is not exceed its melting temperature [71].

Block-diagram of the device for getting the products through agglutinating during the pressing process upon availability of excess amount of heat that is sealed in one of the components is shown on figure 3.19.

Block diagram of the device for getting the products by the same way but upon availability of filler in high temperature component that has temperature characteristics not less than temperature characteristics of the component is shown on figure 3.20.

The device on Figure 3.19 has bunker 1 with small chippings or filings of low pressure polyethylene (LPPE) with high melting temperature and bunker 2 with high pressure polyethylene (HPPE). It also has a synchronous dosing unit with two tanks 3 that allows keeping of ratio for products quantity and for the implementation of the process. It has heaters 4 and 5 that heat portion of polyethylene up to the temperature close to the temperature of melting. After heating the plastic components are poured into heated press-mold 6. The temperature of inner surface does not exceed melting temperature of high pressure polyethylene (HPPE). Upon the pouring into press-mold the polyethylene is uniformly mixed in free stream.

The device on figure 3.20 has the bunker 7 with filler. Besides that the device has dosing unit 8 wherein the required portion of low-melting component is measured.

Production process is the following: the components are transferred from the bunkers 1 and 2 (figure 3.20) into dosing unit 3 with two tanks wherein the portions in amount required for product getting are measured. The same is with high and low pressure polyethylene volume ratios necessary for melting of high pressure polyethylene through thermal accumulating properties of low pressure polyethylene. Each component transfers from the dosing unit 3 into its heater 4 and 5 where it is heated up to the temperature that not exceeds its melting temperature. From heater 4 and 5 the components are poured into the heated press-mold 6. After that the press-mold 6 is cooled and the final product is removed.

The cycle of operations is carried upon availability of filler. After measuring of appropriate volume in dosing unit 3 the high melting polyethylene and filler are mixed and heated together.

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Laboratory researches results show that recoverable polyethylene (product wastes of polyethylene on municipal dump) can be used for manufacturing of secondary products that are not subject to high mechanical loads (temperature regime, pressure efforts and etc.). Widespread implementation of this method is provided at sorting and recycling of municipal household waste (garbage) due to self-production of secondary raw materials. It provides huge technical and economic effect.

New materials usage during the coating of worn metal pipes through the implementation of materials with I, E, K, V, M brand.

There is method of polymer coating applying by plastic polymers coating through extrusion method. Screw extruder is the device for such coating applying with complete central passage inside the screw (see Fisher E. “Extrusion of plastic mixture” M, “Chemistry”, 1970, pp. 201 - 208).

The disadvantages of this method are the increased consumption of material, the necessity of screw extruder with complete central passage inside the screw.

There is method of polymer coating applying on the pipe or wire by 5-50% solution of high molecular weight olefin (polyethylene or polypropylene) that is extruded through annular mouthpiece. Pipe or wire is passed through the central hole of annular mouthpiece (see EPV (ER) B29S47/02, request # 281209, 1988). The residual solvent is removed from the extruder after extrusion. The disadvantage of this method is the necessity of solvent availability that dissolves by olefin and the necessity of its removal after coating.

There is a device for plastic coating of steel pipes (see Japan (JP) B29 C63/18.47/02). The device has a cylindrical extruding head. The pipe is pulled through the central hole of extruding head and flexible roller crimps foot of weld bead at the extruding head outlet, plastic surface is cooled.

A disadvantage of the device is in availability of weld bead in the upper part of the pipe on extruding head outlet.

The invention objective is a method of thermoplastic coating of metal pipes and the device for its arrangement.

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This objective is achieved through the following way: at first external surface layer of metal pipe is heated by high frequency currents up to the temperature above the melting point of used thermoplastic, then the pipe is transported through the layer of powdered thermoplastic wherein thermoplastic particles adhere on heated surface. When the pipe is take out from powder layer the adhesive particles are subjected to melting from external side or by infrared radiation or by high frequency electric field. When the pipe goes out from the heater its surface with melted thermoplastic is processed by rollers with anti-adhesive surface. Rollers are located on rotating cylindrical head that covers transported pipe [70].

Figure 3.21 – Method of external thermoplastic covering of metal pipes and its arrangement

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Figure 3.22 –Method of external thermoplastic covering of metal pipes and its arrangement

Figure 3.21 shows the sequence of the method and device elements position for its implementation wherein the infrared source is dissolving element. Figure 3.22 shows the same sequence of the method and device elements position but upon the availability of dissolving element-condenser of high electric field.

Device for external coating of metal pipe 1 by thermoplastic material film has inlet conveying and centering rollers (not shown), cooled inductor 2 powered by high-frequency vibration generator (not shown), the bunker 3 with thermoplastic powder (floating of fluidized), adjustable shield 4,5 that blocks conveying holes of the bunker, heater 6 and rolling device 7 consists of free rotating on resilient mounts (not shown) rollers 8 (straight cylindrical or cone type or curved that forms side surface) of anti-adhesive coating or the similar coating for used thermoplastic. Plasticized surface (coated by thermoplastic film) is cooled in a cooler (not shown) and outlet conveying rollers (not shown) removes final product and vacate workspace for the next pipe.

The device operates as follows: Pipes 1 with preliminary cleaned surface from oxides and dirt are delivered by conveying and central rollers (not shown) through inductor hole 2 that heats external surface of the pipe up to the temperature sufficient to partially presence and agglutination of powder particles of used thermoplastic.

After that the heated pipe passes through the hole of bunker wall 3 that contains powdered thermoplastic and goes out through the hole of bunker opposite wall. Bunker inlets and outlets are blocked with opening shields 4, 5 that are adjusted for given diameter of pipe. Under melting condition the powdered thermoplastic in bunker 3 adheres to pipe surface that carries out some part of the powder that is not adhered but still is in interlayer through bunker outlet 3. This part of powder drops down into collecting container or transport tray (not shown) and returns back to the bunker for subsequent usage.

The pipe with adherent thermoplastic particles is moving through the heater with reflector or cylindrical high-frequency capacitor 6 wherein the infrared radiation or high-frequency electric field heats adherent thermoplastic particles up to plastic condition with a partial meltdown. Heated and partial meltdown thermoplastic is rolled on pipe surface by free rotating rollers 8 that are elastically mounted on cylindrical rolling device 7.

An integral plastic film is generated on pipe surface as a result of rolling.There may be two rolling devices that are located one behind another and

rolled pipe surface mutually antithetical in order to eliminate torque effect on the pipe.

Plasticized pipe is cooled by cooler (not shown) and outlet conveying rollers (not shown) remove final product and vacate workplace for next pipe.

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Preliminary analysis shows that the annual volume of plastic waste only in Karaganda city is over than 1.5 million tons.

New materials application for internal coating of worn metal pipes. Material brand - (D1, V, V1, I1).

Innovative technology is related to the methods for plastic coating applying on the inner surface of specified length metal pipe.

There is a method for products manufacturing of thermoplastic resin mixture with fine-grain polymer (see Japan (JP), request # 52-32656, B29 C11/00, B29 F3/00, Sumimoto K.K.). The product that is made of this mixture is subjected to temperature processing between the temperature of thermoplastic resin softening and its effusiveness temperature.

The disadvantage is availability of binding component such as thermoplastic resin that does not generate homogeneous substance with used granulated material within the product manufacturing process (3.23, 3.24).

There is a method for pipeline products manufacturing (see German (DE) request # 3326387, B29 C65/64, 47/20) wherein a strand that is received through powder or granule extruder and then is formed with residual voltage. The received product is inserted into the metal pipe then it is heated and inflated. Plastic pipe is pressed into the metal pipe through residual voltage removing under heating condition.

The disadvantage is in preliminary manufacturing of plastic material intermediates and two-stage process wherein the plastic material is heated two times.

The invention objective is the increasing of corrosion resistance for metal pipe due to isolation of pipe surface from the contact with the substance that is transported through the pipe by plastic coating layer.

Figure 3.23 – Method of plastic coating on internal surface of metal pipe

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Figure 3.24 – Method of plastic coating on internal surface of metal pipe

The objective is achieved as follows: tube or bar with minor diameter than inner diameter of coverable metal pipe is inserted into the coverable pipe. The inserted tube or bar has anti-adhesive surface for applicable plastic substance. [70].

Powder or granules of applied plastics is compactly poured into cylindrical annular gap of the system. Then both metal clads are heated to a temperature of "softening" or "sintering" of applicable plastic and simultaneously with crosscutting the additional amount of material is inserted under the pressure in order to eliminate voids and cavities. After completion of the formation of a uniform layer of plastic whole system is cooled to a temperature curing plastics and entered a pipe or rod is removed.

The annular perforated detents that are prefabricated of applicable plastic material but with higher temperature resistant that becomes it integral part during the insulation layer formation are inserted with the interval between the layers of plastic half-finished product into annular space for elimination of displacement and drifting of pipe or bar inside the coverable pipe.

A method of plastic facing layer coating on the inner surface of the metallic volumetric pipe is shown on figure 3.23. The scheme of plastics material application is shown on figure 3.24.

A tube or metal bar 2 with anti-adhesive outer surface is inserted inside the metal pipe 1. A powder or plastic granules 3 is compactly poured into annular cylindrical space. Annular perforated detents 4 of the material closely related to the material that is used for facing layer may be inserted into annular cylindrical space for elimination of curvature. At the end of encased pipe there are removable pressing devices 5, 6 with dielectric tubular pistons 7, 8. These devices are used for injection of plastic half-finished portions that eliminate voids and cavities and execute plastic layer crimping. They are keeping on the pipe until plastic solidification.

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. In the annular gap with the seal poured powder or granules of plastics 3. To eliminate the annular affectation cylindrical gap may be administered annular perforated tabs position 4 of related material used to create the top layer. At the ends of the pipe has a removable lined, pressing devices with 5.6 dielectric tubular piston 7.8, which is administered by a portion of a plastic semi eliminate voids and cavities, and perform and keep the pipe before hardening plastic.

New materials application at waste recycling process in order to produce different goods and product through extruding of materials (I1, M1, K1, D1, V1, etc.).

There is an extruder for processing of high molecular weight polyethylene (see USA B29D23/04 patent # 3954372, 1976). The extruder is configured as elongated body with two pairs of flat plates with a channel between them for extruding of original granulated material by the piston through reciprocating motion. The heaters that generate three heating zones: compression, intermediate, cooling are mounted along the length of the frame.

Along the length of the frame mounted form three heating zones:. The material extruded through the extruder outlet slot. On the site of compression body is provided with stiffening ribs.

The disadvantage of long device is in its intention only for recycling of polyethylene with a high molecular weight that has a high coefficient of volume expansion when heated.

There is a device for continuous production of thermoplastic single block products (see USSR B29 C47/14 as # 4526961, 1989). It is a screw extruder. Its pipe with heater is allotted from heating part in order to melt the extrusionable material with subsequent cooling of the melt in cooling jacket.

The disadvantage of proposed device is the requirement for complete melting of thermoplastic and a delivery pipe with the heater.

Invention objective is a device for producing of thermoplastic singe block products. It can be achieved through primary heating of processed material in heater bunker, structure of transport channel and transporting mechanism. the material in the hopper, the preheater structure of the transport channel and the. General design of the device with inner section of the channel and bunker structure is shown on figure 3.25

The device consists of channel 1 that is transported heated thermoplastic, heat-distributing material 2 enclosed in case with external thermal insulation 3. Electric heaters 4 are located in heat-distribution agent.

The device has a piston pusher 5, return springs 6 and free rotating roller 7 at the end of piston pusher, round eccentric that runs the roller 8 fixed to the shaft of the reduction gear 9 that is driven by rotating control electric motor -10. Heater bunker 11 consists of heaters 12 is integrally linked with channel 1.

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Figure 3.25 – Installation for producing of single block products of thermoplastic plastic

The installation operates as follows. Heat distribution material 2 and original raw material bring to operating level by turning on the electric heaters 4 and 2. Original raw material transfers from heater bunker through piston pusher 5 into the transport channel 1 that is done in the form of mutually perpendicular plane-bevel foots of rectangular shape.

Thermoplastic raw material is heated and compacted in transport channel.Piston pusher 5 makes reciprocating motions due running of free rotating

roller 7 fixed on piston pusher that is run in by round eccentric 8. Such kind of device acts as a vibrator compacts and transfers thermoplastic

material in transport channel but without vibrator noise and strong mechanical vibrations.

According to thermoplastic material heating and compacting in contractor section of the channel the non-linearity of its transferring is adjusted and becomes close to uniform.

When the heated thermoplastic material goes out from the transport channel it is passed through cooling device and cut into pieces of required length.

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4 GENERAL LAYOUT. “SHLWU” PLANT LOCATION

4.1 Construction site characteristic

“SHLWU” plant is located nearby dumping landfill for solid household waste (SHW), (dump) that is operating since 1990. The construction site has rectangular shape and it is limited to:from the north-east with a waste incineration plant;from the south with SHW dumping landfill.

The construction site is located within SHW landfill (dump) border. The site is free of buildings and covered with 3-8 m fill ground that is subject to removal. Hydrological conditions of the site are favorable for construction.

Construction area is 4,17 hectaresBy pass road from the north-west of the company is an entry on the territory

of the company. Site for SHWSR plant construction is horizontally profiled on the natural ground.

4.2 Architectural and planning concepts

The general layout of “SHLWU” plant is developed in accordance with the scheme solution of plant location nearby SHW dumping landfill considering process diagram - interrelation of company process flows and external transport links with interplant transport highways.

It is foreseen a clear zoning of “SHLWU” plant territory together with architectural and planning concept

There are the following facilities in the center of the site: industrial complex of SHW sorting line and SHW recovered materials recycling with workshop for receiving of SHW that is delivered by trucks and storage tanks, installation for SHW rough sorting from the items that can be not sorted at the process line of the plant, site for SHW preliminary drying consists of plant workshop # 1 for SHW main drying process and separation of materials with common physical-chemical and physical-mechanical properties. Workshop # 1 includes the following:

A) administration part;B) workshop;C) sites for SHW recovered materials recycling; D) transforming station.Workshop # 2, workshop for SHW recovered materials recycling are

situated in production building. Short end walls of the workshop # 1 and # 2 are conjugated through covered pass-through. The second short end wall of workshop # 2 adjoins to materials warehouse of production.

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Building for compost sorting from the organic part of SHW, production sludge and residuals, sludge and treatment facilities filtrate, trapped and precipitated dust of the site is located in parallel with workshop # 1 through interplant road.

Belt conveyor and heat supply pipes for compost building heating are located in workshop #1 that is intended for compost production.

4.3 Engineering networks Engineering networks are designed along the main road inside the site

considering construction on the shortest distance. They are located in trenches, underground tunnels, in transport gallery for pipelines (heat), sewage, drainage and on bearings - for power supply networks.

Creation of sanitary-hygienic conditions and safety regulations compliance for employees on the factory and on the site of future “SHWSR” plant. It is foreseen the arrangement of sidewalks, short break places (benches, bins for summer time) on the offsite area and along plant road

Basic indexes: 1. area size - 4,17 ha;2. construction site – 1,263 ha;3. platform and road area – 0,75 ha;4. road length - 0,768 km;5. ratio of built up area – 31%;6. plot ratio - 46%;7. planting.

All the indexes are determined by internal economic possibility of "SHLWU" plant on the payment and delivery of irrigation water for planting.

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5 RAW MATERIALS, MATERIALS, ENERGY AND HUMAN RESOURCES PROVIDING

5.1 Providing with raw materials and materials

Availability of waste that is transported from the city to the SHW dumping landfills and delivered on the plant territory by special trucks and municipal services of the city provides SHWSR plant with raw materials in the form of solid household waste [22, 23].

Providing with materials and spare parts, product components, purchase, manufacturing on the machine park of production workshop.

5.2 Power supply

Power supply of SHW sorting and recycling plant (SHWSR) is executed through built-in transformers 10/0, 4 kv

The results of data for electrical loads calculation are shown in table 5.1.

Table 5.1 – Electric loads calculation

Item#

Consumer name Installed capacity, kW

Designed capacity, kW

Coefficient,Kс

Voltage,kw

Note

1 2 3 4 5 6 71 Site for raw materials

preparation – power load is lightening

34025

20425

0,61

0,40,23

2 Production building: workshop # 1, power load is lightening.Workshop # 2, power load is lightening.

32425

22525

19425

13525

0,61

0,61

0,40,23

0,40,23

3 Main production workshop 150

45 0,3

4 Materials warehouse 18 11,7 0,65 0,45 Compost preparation

site26 15,3 0,6 0,4

6 Administration building

20 12 0,6 0,4

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7 Treatment facilities 100 65 0,65 0,48 Territory lighting 20 20 1 0,4

(0,23)TOTAL 1318 797,3 677,7

considering combustion rate in max.

Ci=0,8Calc= 677,71

kW

According to the data the total installed capacity of current collectors is Ру=1318 кВт, the calculated is Рр =797,3 кВт. Annual consumption of electric power by the company is 2,829.0 thous. kW / hour.

The company belongs to the third category of reliability level of current collector power supply. Integrated distribution systems. SSA-366 is located in a separate room next to the transformers room.

The shield is situated in a separate room and it is equipped with EP-70 with the installation of meters of active and reactive power. Condenser units of UK-0, 38-150 KUZ type are foreseen to improve the power factor up to 0.98.

10 kW power line is made of AASHVU brand cable that is laid in the ground (the trench). 0,4 kW supply mains are made of AVVG cable that laid inside the room. Electric lighting of all buildings and structures are performed under individual and standard projects in accordance with acting standards and traditional solutions.

The following energy-efficiency measures are applied 1. power factor increasing;2. disconnection of power transformers during off time;3. application of economic light sources and their optimal location.

5.3 Heat supply

The source of heat supply is SHW incineration complex that is located nearby “SHWSR” plant. Water with Т1-Т2 (180-70)0 С parameters is heat transfer medium for technology, heating, ventilation and hot water supply requirements.

Hot water supply system is connected to heating network in a closed circuit with two pipelines lines – dead-end two-funnelled.

It is provided the heating unit with the installation of isolation valves and instruments.

Under the terms of general layout the heat networks are accepted in the impenetrable reinforced concrete channels and aboveground installation on the poles.

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Compensation of thermal expansion - due to the heat line turning and U-shaped expansion joints.

Pipelines and facilities as well as equipment are heat insulated in order to decrease heat loss.

5.4 Power supply

There is no water supply in existing water supply network and drainage at the site of projected “SHWSR” plant.

Water for drinking and domestic requirements is taken from the city network.

Water consumption rates for drinking and domestic requirements are taken in accordance with SNiP 2.04.01 - 85 “Internal water pipeline and sewerage of buildings”.

Industrial water consumption rates are taken according to technological requirements of “SHWSR” plant that has treatment facilities and closed system of water purification and tank for storage and refilling of industrial water.

Availability of water for firefighting is in accordance with SNIP 2.04.02 -84, P.2.22 and P.2.24 with the number of simultaneous fires on 150 hectares. Firefighting duration is 3:00 hours.

The main building for determination of water consumption for external firefighting is: production building of 51530 m3 volume, production category of fire danger "D", the degree of fire resistance is PP. According to SNIP 2.04.02 - 84, P 2.14, and P 2.16, tab. # 7 - water consumption for external firefighting is 10 l/s.

Firefighting tank with 4 reinforced concrete tanks of 50mᵌ with total volume of 200 mᵌ is foreseen on the territory of the plant (building catalogue, part 2, standard project of enterprises, buildings and facilities, standard project TP.901-4-57.83.)

Water supply decision is selected on the basis of drinking water consumption (for economic - drinking purposes) considering its delivery and the number of employees involved on polluting production areas except management staff.

For domestic requirements: 1. working shift – 2;2. number of employees involved on the sites associated with pollution - 48

persons;3. shower heads amount - 6 units

1) Q day = 25х48=1,2 (m3/day); б) Q day /hot w = 11х48=0,528 (m3/hour); в) Qhour=0,4х48=0,4512 (m3/hour); г) Qhour.h.w. =4,4х48=0,2112 (m3/hour);

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2) Q day.show = 0,375х5х2=3,75 (m3/day); б) Q day.show.hot w.=0,2х5х2=2,0 (m3/day); в) Q hour.show. =0,5х5=2,5 (m3/hour); г) Q hour.show.hot w. = 0,2х5=1 (m3/hour).

The amount of water for process requirements is up to 2-3 m3 per hour:а) for cleaning of SHW heavy fraction;б) for waste paper unreeling;в) for washing of pipes treated form mud and rust;Press mold cooling.

The required amount of circulated (that is cleaning in treatment facilities) water is 50mᵌ per month. The required delivery for technological losses recovery is 15mᵌ.

There is a reserve tank of 50mᵌ at the treatment facilities of industrial waterSorted water by precipitated pollutants is used for compost preparation.а) Qhour =1,2+ 2,5 = 0,075+2,5+2,55 (м3/час); 16б) Q hour.hot w = 0,528 +1=0,033+1=1,033 (m3/hour); 16в) Q day.hot w = 9,528+2,0=2,528 (m3/hour);г) Q day =1,2+3,75=4,95 (m3/hour).Floor washing: 2,804 (м3/day).

5.5 Sewage

The following sewage systems are foreseen on “SHWSR” plant in accordance with the terms of production and environment protection:

1. Domestic - for discharged of domestic waste water 5,53 m3. Domestic waste water is discharged into municipal sewage system.

2. Closed network of storm drains with storm-water inlets on the roads, grounds, driveways and lowlands and from the roof of buildings with organized and non-organized drainage is arranged for rainwater and melt water. Rainwater and melt water is partially directed to the treatment plant for industrial water where it is purified in one of the treatment plant sections with drain into the tank that is not used for recharging of industrial water loss of 50mᵌ volume (TP.901-4-57.83.)

5.6 Heating and ventilation

Heating and ventilation are carried out in accordance with acting standards and regulations:

– SNiP 2.04.08-86. “Heating, ventilation and air conditioning”.

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– SNiP 2.09.04-87 “Administration buildings”.– GOST 12.1.005-76 “Working area air. General sanitary requirements”.– СН–245.71 “Sanitary standards for industrial companies designing”. The design parameters for heating and ventilation calculation are the

following:– for the designing of heating and ventilation systems in buildings within the

period: -320C;– average temperature of heating period: -7.500 C;– for ventilation designing in summer: +250С;– the duration of heating period is 212 days.The design parameters for premises:– manufacturing facilities: +160С;– warehouses: +100С;– accommodation: +180С.Heating for objects is provided from external heat networks. Heat transfer

medium for heating and ventilation systems of industrial buildings is superheated water with 180-700С parameters; for administration building heating water temperature in heat distribution station drops to 105-700 С

Thermal energy accounting is executed in each consumer building. Heat consumption for the units are shown in tables 5.2 and 5.3.

Table 5.2 – Thermal energy accounting

Heat consumption per hourObjects name Heat consumption, kcal# For heating For ventilation Municipal water

supplyFor process requirements

1 2 3 4 51 Production building:

-workshop #1-workshop #2 363500

29968012837401460000

23300-

2 Workshop of the main production

37290 182700 -

3 Materials warehouse 54270 - -4 Compost preparation site 10740 52330 -5 Administration part 58464 87900 -6 Total: 723944 3066570 23300 Table 5.3 –Annual heat consumption, Mcal

№ For heating For ventilation

Municipal water supply

For process requirements

Annual consumption

1. Production building

workshop #1

121

workshop #2 655,8745,9

21312423,5

12,0-

2710054200

2 Workshop of the main production

92,81 303,3 - -

3 Materials warehouse 93,3 - - -4 Compost preparation

site26,73 86,9 - -

5 Administration part 157,3 157,5 - -Total 1771,83 5102,2 12,0 27100

54200

Production building.

Workshop # 1. Water heating by bare pipes register.Supply and exhaust ventilation with mechanical and natural activation.

Local exhausts are foreseen besides general ventilation. The main hazard is dust, heat. Air change rate for general ventilation is 1.

a) The main production workshop.The main hazard is carbon dioxide, heat. Local exhausts are foreseen. Air

change rate is according to SNiP 2709.04. b) Compost preparation siteWater heating - bare pipe line. Supply and exhaust ventilation (mechanical

and natural). Air exchange is 2. Local exhausts are foreseen.c) Materials warehouses.Water heating – bare pipes register. Supply and exhaust ventilation

(mechanical and natural).Air change rate for premises is in accordance to its purpose (SNiP 2.09.04-

87). Compressed air supply (centralized). 5.6.2. In case of lack of compressed air supply (centralized) the stationary

site compressor is provided.

Total compressed air requirement in the enterprise is 1,05+1m3/hour.

5.6.3. Electrical technology and automatic devices

In order to ensure management reliability of SHW sorting line and recycling lines of extracted materials from SHW the following types of control schemes are foreseen:

- local push-button and remote;- automatic control;-program control designed by KarSTU on the basis of PCMC (program

control of mechanisms and sets of machines) with adaptation from external sensors. It controls hydraulic and pneumatic devices and set of PC with internet program

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6 CONSTRUCTION DESIGN

6.1 Architectural and construction concepts

The site for SHWSR plant construction is located outside the city nearby the landfill for SHW duping. The complex of buildings and facilities is related to the II-nd class of responsibility. Workshops block for SHW receiving, drying, sorting and recycling of materials from SHW is combined in frame-panel building. The following principles are the basis of the space-planning and construction decisions:

- maximum planning of main and additional rooms;- application of unified large sized elements of complete factory-assemblage;- application of structural design to ensure the reduction of labor intensity and

construction period through the introduction of standard and mining r/c structures;

- structural design integration with construction industry enterprises of Karaganda city.

6.2 Space-planning and structural decisions

Production building is four wells building with the size of 184x18 m and the height of 5.90 m up to 10.70 m (4.20 -9.0 m) to the bottom. It is equipped with 2 crane-beams with 1-3 tons of carrying capacity. The building frame is constructed from standard precast reinforced concrete columns. Distance between columns is 6 m, aisle of precast reinforced concrete duo-pitch beams covers 12m. Typical cell is 12x6 m. Frame structure is provided at the end walls. The outer walls made of haydite concrete panels with textured front surface: sandwich, roll, heat insulated roof coating. The roof slabs are standard precast reinforced concrete, ribbed with the sizes of 6x3 m and 6x1,5 m.

Basement - support piles beyond reinforced concrete built-up framework columns. Basal blocks beyond external walls. Elevation marks from the column foot is 0.9-1.0 m. Interior walls around SHW milling site in axes 4-7 should be made from gas-concrete blocks for acoustic insulation.

Building frame for composting contains semi-detached warehouse of non-slaked lime; compost preparation site and warehouse of compost proportioning is a single story, single-aisle building, frame bay is 12 m, columns are 6m, the height to the floor beam bottom is 4.2 m. Building length is 114 m. Precast reinforced concrete structure is accepted as the production plant.

Household sewage tank is 18x6 m single story building, the height up to the roof slab is 3,6 m (5,5). Walls may be constructed with bricks.

Treatment facility for industrial water is a single aisle building made from precast r/c, the length is 42 m, the aisle is 12 m, the height to beam floor is 3.6 m

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(5.5). The tank for circulating water filling of 50 mᵌ volume (TP 901-4-53.83) is constructed from the back and exterior sides of the wall.

There are 4 standard firefighting tanks of 50 mᵌ volume (TP 901-4-53.83) from the side of service road.

7 ENVIRONMENTAL PROTECTION

7.1 General data

Atmosphere air protection from hazard substances pollution during SHW sorting and recycling is executed on the basis of accepted guidelines and reference documents:

– SNiP 1.02.01-85 “Instruction about the structure, order, development of approvals for construction of enterprises, buildings, facilities”;

– SNiP 245-71 “Sanitary standards of industrial enterprises designing”;– GOST 17.2.302-78 “Nature protection. Atmosphere. Rules for

establishment of maximum permitted emissions”;– SNiP 2,01,01-82 “Construction climatology and geophysics”;– SNiP 2.04.05.- 91 “Heating, ventilation, air-conditioning”;– GRD-1-86 "Procedure for calculating of hazardous substances

concentration in atmosphere air that contains in enterprises emissions".The list of hazardous substances MPC (maximum permitted concentration)

that are emitted in atmosphere air of settlements # 3086-84.

7.1.1 Physiographic and climate conditions of region and construction site

Construction site in dumping landfill area is characterized by the following climate data:

– calculated geographic latitude is 480S.N.L.;– calculated barometric pressure is 715 mm Hg;– estimated outside air temperature;– average temperature of the coldest five days is 12.90 ° C;– average maximum temperature of the hottest month is +25,10С;– duration of the heating season: 212 days.Wind parameters in cold and warm periods:Cold period is January: average wind speed is 5.6 m/s;Warm period is July: average wind speed is 4,5 m/s; Terrain relief is with gradients. The territory climate is strongly continental

with hot dry summer and cold winter. The nearest settlement is at a distance of 1000m.

7.1.2 Characteristics of pollutant emissions in atmosphere air

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Main emissions (without treatment): heat and dust particles (table7.1)

Table 7.1 – Main emissions (without treatment): heat and dust particles

Contaminants MPC,mg/m3 APH mg/m3

Dust 0,5 68Hydrogen sulfide 0,0078 0,03Calcium oxide 1,3 -

In case of dust emission it is foreseen the exhaust ventilation device with subsequent cleaning of polluted air in multicyclone collector and final cleaning in foam-liquid devices. Deposited dust in cyclones is used (preliminary watering) in compost production.

7.2 Air pollution estimation

Air cleaning estimations from pollution through local exhaust ventilation are carried out on GRD-86 method, calculation method of hazardous substance concentrations in the air from the plant emissions considering the transition of 1% of dried and sorted SHW into dust particles.

There are four sources of possible atmosphere pollution on SHWRS in case of lack of air cleaning devices.

Air cleaning measures through local and general exhaust ventilation that consists of sequential purification in dust-collecting battery cyclone with foam cleaning application are foreseen by the (SHW) project.

Source # 1 is the emission from drying room of “hot emission” category. Source is a disposal moisture in cylinder drier during the process of SHW drying where SHW is treated with dry hot air at с t0 = 1250-1200С that is received from heated water cooling in heat exchange unit. There is no polyethylene products in SHW at the temperature tn = 1250-1200С that should be extracted and used in products manufacturing (tnл, polyethylene =1150-1200С).

Paper presence in SHW also does not allow increasing the drying temperature. "Hot emission" in the shape of steam goes out with air that is used for drying at tв= 1150 C to ensure the drying time reduction of SHW parcel loaded in the cylinder drier. SHW delivered to SHLWU plant contains organic that is capable to dissolution with different odorous substances emission under certain conditions. Hydrogen sulfide (Н2S) is dominated. It is slightly soluble in water gas with strong odor that appears among the first.

Other sources of hazardous emissions:# 2 is the site of SHW mechanical separation;# 3 is the site of pipes thermoplastic covering (mechanical cleaning of pipes

surface from contamination);

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# 4 is the site of compost preparation (non-slaked lime milling and its mixing it with recyclable SHW residues).

On the sites # 2, # 3, # 4 there are dust collector units that suck air directly from the emission zone.

Facilities and installation that can be source of emissions and pollution in the form of suspended particles in atmosphere air and plant air are sealed hermetically. Exhaust fitting pipes of local treatment facilities in the form of fixed and exhaust fans combined with dust cleaning cyclones and foam-liquid devices for dust suppression are installed in facilities and installations operating area.

7.3 Treatment facility of household effluent

For household effluent discharged from “SHWSR” plant it is foreseen the cleaning from organics through its precipitation and filtration, water aeration by air, neutralizing of biological particles by ozone, water clearing, its carbonation with subsequent discharge into sewerage.

Treatment facility of household effluent is a covered heated building where two parallel rows of water treatment lines in the form of three subsequently based reinforced concrete tanks are allocated.

Double-row of treatment facility is foreseen for periodic cleaning of the tanks from precipitated particles in order to ensure continuity of treatment through periodical change of cleaning line. Cleaning lines are the same type. The first tank has a filter in the form of container that is filled with small porous inert material suitable for usage on a line of SHW composting.

The estimated capacity of the tanks is three days. The tanks are connected by pumps that transfer liquid from the tank into the tank. Household effluent is processed by lime milk that is produced in treatment facility building and transfers into the first tank. Lime milk promotes coagulation of suspended particles that are collected in the filter.

Water discharged from large particles is pumped into the second tank of cleaning line where it is aerated with air consists of ozone (0,001from the air volume). Ozone is prepared locally from existing ozone generators. Air with ozone after filtration oxidizes the organic agents including biological through their neutralization. Treated water is pumped into the third tank where it is subjected to carbonization (by chalk milk) in order to precipitate the suspended residues and to clear water.

Suspended residues may be also precipitated in the tank where water aeration through an electrostatic coagulation of particles is executed.

Carbonated water is settled and then discharged into the sewage. Sediments are removed by suction and clean layer and sent to SHW

composting site where SHW together with residues (tailings and sludge) is subjected to pasteurization at the mixing with non-slaked lime.

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Treatment lines are equipped with liquid transfer pumps, micro compressors, level gauges, water analyzers.

The treatment facility has extract and input ventilation with the chemical (lime milk) converters of exhaust air. Air change rate is in the capacity of treatment facility.

The treatment facility for industrial water that is used in manufacturing processes of enterprises is located in covered heated building.

Industrial water is treated in three connected treatment lines and after treatment it transfers into circulation on its technological area.

Treatment lines are constructed in the form of reinforced concrete tanks or metal containers located in areas where periodic shut down of line for sediments removal is required. At the end of the line there is a storage tank of treated from suspended solids industrial water. Water disinfection is carried out in cells of filters allocation.

Water is on each site of SHW washer: the site of thermoplastic products manufacturing, paper recycling site has different degree, type of pollution that is why the length of treatment lines are different.

Precipitated particles of water:a) natural precipitation;b) rough filtration;c) fine filtration, organics neutralization.Treatment lines have pumps for water pumping, level gauges, instruments of

chemical composition control, automatic devices for cleaning process.The main pollution agents of industrial water:A) mineral particles (soil particles, glass particles) SHW particles of

inorganic origin that fell into the washer as a result of SHW components adhesion on the surface;

B) small particles (extracted) of nonfood waste (vegetable and animal origin);

H) fat particles of organic and mineral oil;D) cellulose particles.The tank for water loss refilling as a result of manufacturing processes is

located close to the building. Precipitated pollution agents are periodically removed and sent to the compost manufacturing site.

7.4 Description of cleaning line

Industrial water inflows to the treatment facilities after heavy SHW washing prior to its separation on ferro-hydrostatical separator (highest pollution rate of used industrial water).

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Polluted water with its polluting substances (small floating, suspended and sedimentary particles) is removed from the bath by induced forced circulation of industrial water between washing area and cleaning lines of treatment facility.

Water is removed from the washer at three levels:A) gravity sedimentation;B) rough filtration through porous inert material;C) purification in ton settling blocks.Then the residue that was not precipitated by traditional method is subjected

to coagulation through dispersion of opposite electric charges particles suspended in water by feed water passing in two separate streams through two plastic pipes arrangement and each plastic pipe provides its electric charge to particles in water through surface friction

After that water flow with oppositely charged particles is discharged as a type of interstratified layers. Oppositely charged particles are attracted, agglomerated and form flakes that are held by filter while feed water passing through it. Purified water is treated with air consists of ozone once again, settled, treated with air consists of ozone, settled and returned back to the production line (washer). Structure of treatment facilities, other cleaning lines of treatment facility is determined by the type and degree of pollution (availability of biological agents, compounds of pollution agents).

Filtration from pollution agents, clearing and industrial water softening are executed on the production line without biological contamination

Conclusions and suggestions1. It is carried out the review and analysis of condition of solid household and

liquid industrial waste utilization and recycling in CIS countries and abroad.2. Operating parameters of polymer waste and physical-mechanical properties

prior and after extrusion were determined through laboratory researches.3. The main dimensions of fences and snow defence elements for railways and

roads, various industry branches and other materials and products of SHLWU plant were determined.

4. Consecutive reactions - chemical transformations of solid household and liquid waste with new physical-chemical properties as a pulp while SHLW utilization are justified.

5. Calculation of equipment parameters for SHW washing and drying, SHW crushing and various tanks and containers is performed.

6. Calculation of aerodynamic resistance of snow-protection fence for railways and roads of waste is executed.

7. The parameters of SHW and liquid waste chemicalization considering the environmental, industrial safety requirements and environmental safety of products are justified.

8. Process diagrams of industrial waste (construction, road asphalt pavement, metal plant, power plant and etc.) recycling for the connection to SHLWU pulp compounds are suggested.

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9. Business plan of SHLWU plant is developed. 10. It is developed the process diagram of SHLWU new generation Plant

instead of urban landfills, waste sorting plants and different ways of waste incineration.

11. As a result of laboratory research of physical-chemical properties of waste utilization by chemical method the following new materials were received: the secondary granules of boards (strips) of snow protection fence for railways and roads, structural tiles, roof tiles, road curbs, electrical insulating tape for underground high-voltage cables of 350 volts and above, heat insulating tape for heating, special materials for external and internal coating of worn metal pipes, various rail way and road signs and etc.

12. Laboratory researches show that it is possible to get up to 20mᵌ of methane, propane gas from one ton of SHW chemical compounds and liquid industrial waste that provides electric power up to 100 000 kilowatts per shift. It is required the full name of innovative materials for various industry branches that allow connecting pulp with other production waste.

13. As a result of laboratory research it is received an innovative pulp through solid household and liquid industrial waste chemicalization that makes possible to get new materials at the expense of other production and industry waste. A new experimental production line is used for producing of innovative materials and products for various industries. All development works are protected by copyright certificates on inventions on the basis of the patents of the RoK.

14. According to the results of laboratory research the positive decisions and responses of experts and organizations such as the first deputy akim of Astana city, FSUE “Institute “GINTSVETMET” of Moscow city and “Kazakh center of HUS modernization and development" LLP were received. They mentioned effectiveness, prospects and novelty of RD “Research and justification of recycling and utilization parameters of consumption, production and industry waste”. It was also mentioned that it is necessary to create a trial plant for research and justification of mechanical, physical, chemical and other properties of innovative materials and products for the development of L. N. Gumilyov ENU scientific activity. Abstracts from minutes of conferences and diplomas are shown in Annexes 1,2,3,4.

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THE LIST OF SOURCES

1. The Law of the RoK dated November 12, 2006 # 216 “On environmental protection”;

2. Sustainable development concept for 2007-2024 years. MEP of the RoK 14.11.2006;

3. The Law of the RoK dated December 4, 2002 year # 361 “On the sanitary-epidemiological welfare of population”;

4. The Law of the RoK dated January 23, 2001 year # 148 “On local state supervision in the Republic of Kazakhstan”;

5. The Law of the RoK dated March 24, 1998 year # 213 “On regulatory legal acts”;

6. Kazakhstan development strategy up to 2030 year;7. The concept of environmental security of the Republic of Kazakhstan for

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8. Rules of industry (sector) and regional programs development and implementation in the Republic of Kazakhstan approved by the Government regulation of the Republic of Kazakhstan dated February 26, 2004 # 231;

9. Sanitary regulations of SHW landfills arrangement and maintenance. The Ministry of Health of the RoK, 1997 year;

10. SNiP of the RoK # 3.01.016.97. Hygienic requirements to SHW landfill arrangement and maintenance;

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55. Yermekov T.Y., Sholanov K.S., Tazabekov I.I., Arpabekov M.I. Calculation method of performance parameters determination for the transportation unit of the robotic complex. Bulletin of the Kyrgyz agrarian university. Bishkek, 2009y. # 1 (12). Pp.98-103.

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81. The first international forum on Sustainable development issues that was coinciding with the celebration of the World environment day and the tenth anniversary of the capital in June 4-5, 2008 year in Astana city on the III

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International exhibition “Environmentally effective and resource-saving technologies 2008” and the III international scientific practical conference “Environmental safety of urban areas in sustainable development conditions”.

82. Yermekov A.T., Kaliyeva Zh.Zh. on booklet subject: "Development of technology for municipal and liquid waste utilization by chemical methods instead of urban landfills and waste treatment plants usage" was awarded a diploma MEP of the RoK.

83. Kaliyeva Zh.Zh., Yermekov A.T. Generation of heat electrical power and production of import-substituting products through utilization of household and liquid waste by chemical method. Proceedings of the international scientific conference of young scientists “Science and Education 2008” – Astana, L.N. Gumilyov ENU, 2008 y.: Part 1 - 421s. Pp. 177-180.

84. Participation in “CONGRESS HALL ASTANA” exhibition were executed under the supervision of DES Professor Yermekov T.Y. and Yermekov A.T. in the section of “WASTE” exhibition with “Solid household and liquid industrial waste recycling " project also there were reports on international scientific practical conference “Environmental security of urban areas in sustainable development conditions” within the frame of exhibition.

85. Participation in the manufactures exhibition of Kazakhstan and Russia adjacent areas dated September 21-22, 2008 in Aktobe city within “Solid household and liquid industrial waste recycling” project. Authors: Yermekov T. Y., Dolgov M.V., Yermekov A.T. and others were awarded a diploma in the name of ENU of L.N. Gumilyov from the Ministry of industry and trade of the Republic of Kazakhstan.

86. Research of electric power parameters at consumer waste utilization. Yermekov T.E., Yermekov A.T. Theses of the International scientific conference of students, postgraduates and young scientists “Lomonosov-2009”, part 2, dedicated to the 15-th anniversary of the President of Kazakhstan N. Nazarbayev initiative to create the European Union, Kazbranch of MSU of Lomonosov M.V., Astana, 2009 y. Pp. 232-233.

87. Methods to improve educational services quality at the request of «ISO-9001-2000" Idrisov B.R., teacher, Kaliyeva Zh. Zh. graduate student, Yermekov T.E. academic adviser. Proceedings of the VI International scientific conference of young scientists “Science and Education-2009”, part I, Astana, 2009 y. Pp. 328-331.

88. An innovative method of solid household and liquid waste utilization instead of municipal dumping landfills usage. A.T. Yermekov, academic adviser T.Y. Ermekov. Proceedings of the VI International scientific conference of young scientists “Science and Education-2009”, part I, Astana, 2009 y.

89. Yermekov T.Y., Gloson G., Bekenov T.N. Development of new technology for household waste utilization that meets international standards. International scientific practical conference proceedings, October 5-6, “Environmental security of urban areas in sustainable development conditions”. MEP of the RoK, Astana city Akimat, ENU of L.N. Gumilyov, Astana, 2006 y, 405s. Pp. 223-229.

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90. Yermekov T.Y., Tulegenov Sh. A., Muhatchina F.O., Oralbayeva M.R. Program development of solid household waste management in Astana city conditions. International scientific practical conference proceedings, October 5-6, "Environmental security of urban areas in sustainable development conditions", Astana, 2006 y. 405s. Pp. 225-233.

91. Yermekov T.Y., Tultabayev M.Ch., Shutenko L.N. Comparative analysis of international practice and alternative solutions selection of solid household and liquid wastes recycling. International scientific conference proceedings, October 5-6 "Environmental security of urban areas in sustainable development conditions", Astana, ENU publishing office, 2006 y. 405p. Pp. 233-237.

92. Yermekov T.Y. and others. Provisional patent # 18441 for the invention of “Solid household waste utilization method”. Published: 15.05.07. Bull. # 5, NIIP.

93. Yermekov T.Y., Daniyarov N.A., Nesipbayev Zh.S. Adaptive computer control of mining equipment diagnostic condition. Proceedings of International scientific conference "Science and education is the leading factor of “Kazakhstan-2030” strategy (June 27-28, 2006 y.) MES of the RoK, KarSTU, KFAEN of the RoK, KFIAN of the RoK, CCTMAR. Karaganda, KarSTU publishing office, 2006. Issue 2 - 482s. Pp. 21-24.

94. Yermekov T. Y., Bekenov T.N., Arpabekov M.I. Development of mining robotic technology systems for complicated and emergency mining situations. Proceedings of International scientific practical conference "Current problems of mining and metal industry complex of Kazakhstan" MES of the RoK, Karaganda STU, "Institute of comprehensive exploitation of natural resources" LLP. - Karaganda, KarSTU publishing office, 2005 y. -232p. Pp. 37-40.

95. Ismagambetov M.U., Bekenov T.N., Yermekov T.Y. Model of ATS quality upon the request of ISO 9000 series international standard. University education: quality, MES of the RoK, technology, elitism. The VI scientific methodological conference proceedings of L.N. Gumilyov ENU (March 1-2, 2005 y.) – Astana: ENU publishing office, 2005. -278p. Pp. 26-28.

96. Bekenov T.N., Yermekov T.Y., Temirbekov E.S. Scientific principles ox projection robototechnolodycol complexes or compound extreme minetechnicol situation «GEOTEXNICAL ASPECTS OF NATURE AND MAN – MADE DISASTERS» PROCEEDINGS OF ENTERNATINAL GEOTEXNICAL SIMPOSIUM 1-3 of June 2005. ASTANA. KAZAHSTAN. 307 P. p. 231-233.

97. Yermekov T.Y., Daniyarov N.A., Togyzbayeva B.B. Assessment of efficiency and adaptive computer control of mining equipment condition. Scientific journal of ENU of L.N. Gumilyov. Bulletin # 2 (48). 2006. 210s. Pp. 115-122.

98. Bekenov T.N., Yermekov Т.Y. Justification of assessment requirement and management of agricultural products quality in the RoK. The implementation of state programs should be the priority in the course of education development for the government. International collection of Baikonyrov books. Second volume. The Ministry of Education and Science of the Republic of Kazakhstan. Zhezkazgan. ZhU, 2005. 480 Pp.8-10.

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99. Yermekov T.Y., Bekenov T.N., Idrisov B.R. Assessment of functional diagrams quality of machineries, equipment and complexes control system. Scientific and technological progress in metal industry (scientific proceedings). - Almaty, DEC for educational and methodological literature 2005 y. – 530p. Pp. 24-27.

100. Yermekov T.Y., Bekenov T.N., Arpabekov M.I. Creation of a robotic technology complex of coal beds selective mining in complicated mining situations. Scientific and technical progress in metal industry (collection of scientific proceedings). Almaty, DEC for educational and methodological literature, 2005. -525p. Pp. 27-30.

101. Usembayeva Zh.K., Bekenov T.N., Yermekov T.Y. The model of ATS quality and specialist training at the request of the international standard ISO-9000. Proceedings of the International scientific-practical conference “Current problems of mining and metal industry complex of Kazakhstan”. MES of the RoK KarSTU, “Institute of Mineral Resources Exploitation” LLP - Karaganda, KarSTU publishing office

102. Bekniyazov B.K., Baytasov T.M, Tultabayev M.Ch., Yermakov T.Y. "Society – human being" is an interconnected and interdependent system for creation of consumer waste in unlimited amount and forever. “Current problems of environment and natural resources exploitation in Kazakhstan and adjacent areas”. International scientific and practical conference proceedings. MES of the RoK, MEP of the RoK, PSU of S.Toraigyrov. October 23-24, 2007 y. Part1. Pavlodar: PSU publishing office 2007 y. 437p. Pp. 34-36.

103. Yermekov T.Y., Innovative technology of liquid industrial and household waste utilization by chemical method. “Current problems of environment and natural resources exploitation in Kazakhstan and adjacent areas”. International scientific and practical conference proceedings. MES of the RoK, MEP of the RoK, PSU of S.Toraigyrov. October 23-24, 2007 y. Part 2. Pavlodar, PSU publishing office. 2007 y. -224p. Pp. 118-121.

104. Yermekov T.Y., Bekniyazov B.K., Tultabayev M.Sh. The economic problems of ecology and environmental security as interconnected system of "society – human being" environmental security. International scientific practical conference proceedings. Astana, 2008 y. Pp. 17-19.

105. Yermekov T.Y., Bekniyazov B.K., Tultabayev M.Sh. Innovative chemical method of solid household and liquid waste utilization instead of municipal dumping landfills usage. International scientific conference proceedings. Astana, 2008 y. Pp. 292-302.

106. Yermekov T.Y., Zhumataeva S.O., Kalieva Zh.Zh. The Production of thermal Energy and Import substitution wares buchemical utilization of the Domestic and biguid wastes. Ecological safety under urbanized territories conditions materials of the international scientific and practical conference – Astana. 2008. 311-316 pp.

107. Yermekov T.Y., Arpabekov M.I. Principle diagram selection of mining and construction machineries adaptive computer control at loads stabilization system. Proceedings of the 8-th international scientific and practical conference

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dedicated to the 45-th anniversary of ICIC "Modern architecture, construction and transport: development status and prospects”: May 12-13, 2009 y. ENU of L.N. Gumilyov, Astana. Pp. 375-378.

108. Zhylkybay Zh. Newspapers: “Yegemen Kazakhstan” - «Kazakh dalasy kyl-kokys” dated 14.10.2011, 9.11.2011y.

109. Yermekov T.Y. Nespaper «Kazakhstanskaya pravda» - “How to get… from the waste” dated 18.11.2011y.

110. Urazbayev Zh.Z., Yermekov T.Y., Dolgov M.V. "Comparative analysis and synthesis of new materials from waste." The 8-th international scientific and practical conference proceedings. Moscow. FSUE “GINCSVETMET” Institute”. 2012 year. 105 p.

111. Urazbayev Zh.Z., Yermekov T.Y., Dolgov M.V. “Research and development of the technology of consumption, production and industry waste recycling”. The 8-th international scientific and practical conference proceedings. Moscow. FSUE “GINCSVETMET” Institute”. 2012 year. 116 p.

112. Urazbayev Zh.Z., Yermekov T.Y., Dolgov M.V. "Innovative solutions of consumption, production and industry waste recycling." Proceedings of the 1-st international scientific and practical conference “Scientific support of housing and utility sector branches". Astana. “Kazakhstan scientific and technical center of housing and utility sector development" LLP. 2012 year. 86 p.

113. Urazbayev Zh.Z., Yermekov T.Y., Dolgov M.V. “The development of innovative production line of municipal household and liquid industrial waste utilization.” Proceedings of the 1-st international scientific and practical conference "Scientific support of housing and utility sector branches ". Astana. "Kazakhstan scientific and technical center of housing and utility sector development” LLP. 2012 year. 93 p.

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TERMS AND DEFINITIONS

1. Basic terms and definitions accepted in accordance with the Law of the Republic of Kazakhstan

Terms name DefinitionsMunicipal household waste

Waste generated as a result of human activity

Type of waste Complex of waste with common features

Class of waste hazard Indicator of waste hazard that is defined by the degree of possible hazard impact on human health and the environment

Limits on environmental pollution

The income limits of total volume of polluting substances, production and consumption waste as well as noise, vibration, magnetic fields and other physical hazard impact on the environment in the levels where favorable environment is preserved.

Waste treatment standard Quantitative and qualitative restrictions related to generation, collection, storage, usage, utilization, transportation and dumping of waste considering its impact on the environment

Waste treatment All types of activity related to generation, collection, storage, usage, utilization, transportation and disposal of waste

Waste disposal objects Landfills, slurry storages, rock dumps and other specially equipped places for waste disposal and dumping

Hazard waste Waste that contains hazardous substances and hazardous characteristics (toxic, explosive, inflammable and highly reactive) or that may be hazard to human health or the environment independently or in case of interaction with other substances.

Consumption waste Products, materials and substances that have completely or partially lost their consumer properties as a result of physical or mental depreciation

Production waste Residuals of raw materials, material, chemical compounds formed during the production, performance of other technological processes and that have completely or partially lost all original consumer characteristics necessary for application in relevant industry including man-made mineral formations, agricultural waste

Low waste technology Production process with less amount of waste generation while manufacturing of product unit in comparison with existing methods of the same product receiving

2. Terms and definitions accepted in accordance with SGNG interstate standard ratified by the RoK (interstate standard, resource-saving. Waste treatment.

GOST 30772-2001. Terms and definitions.)

Name of terms Definitions

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Non-hazardous wastes Wastes and/or waste treatment that define in certain conditions and certain time as non-hazardous for human life, health and environment

Explosive waste Wastes, waste mixtures that contain chemical agents capable to chemical reaction with emission of gases of such temperature, pressure and speed that it causes an explosion

Waste owner The legal body or the individual entrepreneur who executes waste preparation, utilization, transportation to the places of storage, dumping and/or destruction under the agreement with the owner of waste

Waste demercurization The neutralization of waste that consists in mercury and/or its compounds extraction from the waste.

Liquid flammable waste Wastes in liquid form, mixture of liquid and/or waste that consists of solids in solution or suspension that emit flammable vapors at the temperature above 60 deg. in a closed container or above 65 6 deg. in an open container

Dumping of waste Disposal of waste in a place designated for storage within the unlimited period that exclude hazardous impact of dumped waste on unprotected people and the environment

Identification of waste Activity related to determination of this object affiliation to the type of waste that is accompanied with data identification on its dangerous, resource, technological and other characteristics.

Classifier of waste An applied information reference paper where the data is distributed and coded in accordance with certain characteristics in the form of table, diagrams, description according to the results of waste classification for convenient perception and storage

Coding of waste The technique that allows completely, briefly and reliably present the classified waste in type of signs groups (letters, numbers and etc.) according to the rules established by the classification system

Waste disposal limit Limiting quantity of a specific type of waste permitted for disposal by a certain method in a certain place (territory, container and etc.) for established period to a private or legal person by the authorized bodies

Waste minimization Reduction or complete termination of waste generation at the source or technological process

Waste neutralization Physical, chemical or biological treatment of waste in order to reduce or completely eliminate its harmful impact on the environment

Waste detoxification Waste processing in order to exclude its hazard or to reduce it up to permitted value level

Waste treatment Activity related to the performance of any technological process that may lead to a change of physical, chemical or biological condition of waste for providing of subsequent work on waste treatment

Waste hazard Measured and recorded properties of waste that stipulate possibility that waste substances with one of hazard features under certain conditions can pose an immediate or potential danger for human health and the environment.

Wastes Residual products or additional products that are formed during the process or on completion of certain activity and that are not used in a direct connection to this activity.

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Waste certification Sequence of activities on identification including physical-chemical and technological description of waste properties on the stages of technological cycle of its treatment that is carried out on the basis of waste passport for the purpose of resource-saving and safe management of work in this area

Waste recycling Activity related to technological processes execution on waste treatment for secondary usage of received raw materials, energy, materials in the economy.

Waste landfill Specially equipped territory for waste dumping to exclude dumped waste impact on unprotected people and the environment

Waste producer Any legal body or an individual entrepreneur that produces waste or if these bodies are known it is the owner of the waste or the owner of the territory where the waste is located

Waste disposal Activity related to the completion of operations complex on execution of the waste disposal or dumping

Waste recovery Action that results to recovery of waste up to the level of secondary raw material or material for secondary usage on direct purpose or other purposes in accordance with the acting documentation and existing requirements

Waste collection Activity related to waste withdrawal during a certain period from the places of its generation with the purpose of subsequent operations on waste treatment

Waste incineration Thermal oxidation process with the purpose of waste amount reducing, extraction of valuable materials, ash or power production

Waste storage Activity related to waste disposal ordering in buildings, facilities on designated areas in order to keep them controlled within a certain time

Owner of waste Legal body or an individual entrepreneur who produces waste in his property, who intends to execute waste preparation, treatment and other works on waste treatment including its disposal

Solid flammable waste Solid waste except those classified as explosive and flammable while transportation or highly explosive or those that can intensify fire during extinguishing

Waste technological cycle

The sequence of technological processes of specific waste disposal

Toxic wastes Waste consists of substances that can be hazardous to human beings in case of entry into the environment as a result of bio concentration and (or) toxic effects on biological systems

Waste transportation Activity related to waste transferring between places or objects of its generation, accumulation, storage, utilization, dumping or destruction

Waste destruction Waste treatment for the purpose of its complete destruction

Waste utilization Activity related to waste usage at the stages of its technological cycle or provision of iterated (secondary) usage or processing of written off products

Waste storage Mode (type) of waste existence that consists in definite place location, in definite specified or known conditions for a certain period of time for subsequent processing, transportation, usage, destruction or dumping

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Stages of waste technological cycle

The sequence of treatment processes with specific waste during the period from its generation up to its destruction: on the stages of the life cycle of the product and further certification, collection, sorting, transportation, storage (warehousing) including utilization, dumping or destruction of waste

CONTENT

Introduction 31 Investigation of the parameters and technological equipment

selection for solid household waste crushing and milling processes of all morphological structures

10

1.1 Review and analysis of solid household and liquid industrial waste recycling and utilization in CIS countries and abroad

10

1.2 Economic problems of ecology during the transition period of the Republic of Kazakhstan

20

1.3 Selecting and calculating of equipment parameters of waste utilization technological line

24

2 Investigation of parameters of industrial waste chemicalization considering the requirements of environmental and industrial safety

36

2.1 Laboratory research of operational conditions and physical-mechanical properties of polymer waste

36

2.2 Design and operating principles of laboratory mixer 392.3 Laboratory researches results of chemical processes of solid and

liquid industrial waste46

2.4 Ensuring of environmental and industrial safety of waste utilization technology for chemical method

47

2.5 The main objectives and tasks of (solid household and liquid industrial waste utilization) SHLWU

49

2.6 Market channel for SHLWU plant products with industry waste 683 Process chart development of a new generation plant of SHW

and liquid industrial waste without sorting and dumping78

3.1 Developing of innovative technology for solid household and liquid industrial waste utilization

78

3.2 Detail design of the plant for sorting and recycling of solid household waste

85

3.3 Products of “SHLWU” plant 963.4 Advantages in front of well-known technologies in CIS

countries and abroad103

3.5 Development on utilization technology improvement 105

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considering new innovative methods of all morphological compositions of solid household waste cutting

3.6 Innovative technology for the usage of received materials in different fields through the implementation of anti-crisis program

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4 General layout. Allocation of “SHLWU” plant. 1214.1 Construction site characteristic 1214.2 Architectural and planning solutions 1214.3 Engineering network 1225 Providing with raw material, materials, energy and human

resources 123

5.1 Providing with raw material and materials 1235.2 Power supply 1235.3 Heating supply 1245.4 Water supply 1255.5 Sewage 1265.6 Heating and ventilation 1276 Construction solution 1306.1 Architectural and construction solutions 1306.2 Space planning and design concepts 1307 Environmental protection 1327.1 Common data 1327.2 Estimation of air pollution 1337.3 Waste treatment facility of household flow 1347.4 Description of cleaning line 136

Conclusions 137The list of used sources 139Terms and definitions 150Content 154Annex 156

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Annex 1

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Annex 2

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ABSTRACT FROM MINUTES

of the 8-th international scientific practical conference “Waste recycling, processing and clean technology” FSUE “GINCVETMET” Institute”

Moscow city October 23, 2012 y.

After listening and discussion the reports of L. N. Gumilyov ENU scientists about RD on

household and industrial waste recycling and utilization (П3) the Organizing Committee notes

relevancy and prospects of directions for executed RW. Further development and implementation

of this direction give possibility to refuse from urban landfills, dumping and waste sorting plants.

Organizing Committee chairman V.A. Potylicynof the 8-th international scientific practical conference “Waste recycling,processing and clean technology”

Secretary E.Y. Byhovskaya

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Annex 3The I International scientific and practical conference "Scientific support for housing and utilities service"October 26-27, 2012 year "Kazakhstan center of HUS

modernization and development" LLP

RESOLUTION

Participants of the I International scientific and practical conference “Scientific support for housing and utilities service” held on October 26-27, 2012 year organized by “Kazakhstan science and technical center of HUS development” LLP on the basis of their work have decided the following:.

1. It is required to expand the existing Program of applied scientific research in HUS field and Program of regulatory technical documentation development in HUS field financed from the Republican budget to improve the efficiency and systematization of work on scientific support of housing and utilities service. It is required to increase the amount of topics of applied scientific research, to expand the scope of work on applied research, to increase the amount of processing regulatory-technical documents in Programs. To use extensively the potential of existing local and foreign scientific institutions and universities, industrial enterprises, public associations and international organizations during the conducting of scientific research works.

1. It is required to enhance and expand current work on information courses execution for industry experts and all population to implement new technologies. It is necessary to create a Fund of new technologies implementation in HUS for the commercialization of scientific research results. It is impossible to implement such kind of activity without state support.

2. Currently the laboratory of “Kazakhstan science and technology center of HUS development” LLP has weak material and technical base. Therefore it is necessary to accelerate procedures of finance receiving for implementation of the project on material and technical equipping of “Kazakhstan science and technology center of HUS development” LLP laboratories. Equipping is planned on the basis of energy efficiency Center in HUS field that are under construction according to verbal instructions of the Head of State dated May 4, 2011 year and the instructions of Prime Minister Massimov K.K. dated May 11, 2011 year # 17-31/2569.

3. It is required to create a trial plant for research and justification of mechanical, physical, chemical and other properties of innovative materials and products for the development of scientific activity of L.N. Gumilyov ENU.

4. It is required to carry out detailed study of the selected technologies and technical solutions effectiveness with involvement of research and other specialized companies and associations during the investment projects preparation in housing and utilities service field with the budgetary funds involvement. At the same time it is necessary to pay attention on the effective and already implemented pilot projects in Kazakhstan and to replicate and spread the experience of such projects. A good example is the work of “Tabigat” the Environmental union of associations and enterprises of Kazakhstan for SHW sorting on the places of generation on a trial site in Almaty city within 8 years.

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5. To approve the creation initiative of “Kazakhstan Korkeytu” the Association of enterprises in solid household waste treatment field. To solve this issue with relative organizations additionally.

We consider that implementation of indicated measures will effectively assist in development of housing and utilities service resource saving and in improvement of Kazakhstan population life quality.

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General Director of “Kazakhstan center of HUS development modernization” LLP D. Yegizbayev Annex 4

ABSTRACT FROM MINUTES of the 1-st international scientific practical conference "Scientific support for housing and utilities

services"

149

Astana city

October 26, 2012 year

150

The report on "The development of innovative production line of municipal household and liquid industrial waste utilization” of Professor Yermekov T.Y was heard in October 26-27, 2012 year on section 4 “The improvement of municipal waste treatment system” of the 1-st international scientific practical conference.

Organizing committee of conference notes the relevance and prospects of the present subject.

General Director of «KazSTCHUS» LLP D. Yegizbayev

Secretary A. Zhusupova

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Orazbayev Zhumatay Zeynollayevich is a Doctor of Engineering, leading research scientist of Research works department of L. N. Gumilyov ENU

Toleuhan Yermekovich Yermekov is a Doctor of Engineering, USSR MHE laureate, chief of mechatronic and robotic technology systems laboratory of Institute of Artificial Intelligence of L. N. Gumilyov ENU

Maksim Victorovich Dolgov is a Master of Science, lecturer of “transportation management, transport traffic and operation” faculty of L. N. Gumilyov ENU

RESEARCH AND FEASIBILITY OF PARAMETERS OF CONSUMPTION AND PRODUCTION WASTES UTILIZATION

Passed for printing

Printed in printing office

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Zh.Z. Orazbayev, T.E. Yermekov, M.V. Dolgov

RESEARCH AND FEASIBILITY OF PARAMETERS OF CONSUMPTION AND PRODUCTION WASTES UTILIZATION

Format 60x84/1 on litho paperEdited in 150 exemplars

Order # 420

L.N.Gumilyov ENU Astana, Kazhymukan street, 13

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