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For a Zero Waste Future
© 2014 Holcim Technology Ltd
Geocycle Pre-processing facility – Wadi Cement Works
2016-07-20
Geocycle Pre-processing layout
Operation & control Building
Detarping & sampling station
Geocycle Laboratory
Elaborate Fire-fighting System
Mobile ATEX Equipment
Fire water retention basin & Leachate collection system
Odour control system
Dedicated Weigh-bridge & drivers rest room facilities
Best and safe practices
Geocycle facility- An Overview
Pre-processing layout
Preprocessing Shed
Fire water Tank Pump House
MCC Room
Security Office
Pre-processing Shed
Storage & Processing Shed – Built with high concrete walls & the entire floor has been embedded with geo-membrane sheets to prevent percolation of pollutants.
Separated into Inbound and Outbound area for incoming waste & pre-processed waste respectively.
Quarantine area earmarked for Non-conforming waste.
Pre-processing System - Geocycle
Star Screen
M&J
▪ Consists of Metso M&J 4000 S hook shredder,
REMA belt conveyors, Steinert Magnetic Separator & Eco-star screen.
▪ Capacity = 200 m3/hour
▪ Safety features provided : Emergency stops, Pull cords limit switches for screen cover & hopper access. Instant tripping of the entire system from IR
detector. MVWS system for BC-1, BC-2 & reject bins. Foam suppression for shredder hopper & pits.
▪ 1000 m3 water tank with level indicators.
▪ 1 Main Electric pump, 2 diesel pump of
capacity 410 m3/ hr each & 1 jockey pump
of capacity 25 m3/ hr.
▪ 14 hydrant points in pre-processing area.
▪ 5 hose reels inside the shed.
▪ 13 UV/IR detectors provided inside the shed
for fire detection.
▪ 560 sprinklers (ESFR type) provided at roof
inside shed.
▪ MVWS system, activation through LHS
cable provided at BC-1, BC-2 & reject bins.
▪ Low expansion foam system provided for
both the pits and for shredder hopper.
▪ IR detectors for BC-1 & BC-2 for instant
stopping of shredding line.
▪ Portable fire extinguishers provided inside
shed, MCC, Metso containers, Weigh-
bridge Porta cabin, pump house, security
room etc.
▪ Smoke sensors provided at MCC room.
▪ LHS cable provided at Electrical cables in
MCC room.
Fire fighting System at Pre-processing
Co-processing System – Wadi Cement Works
Police Screen &
Wind Shifter
Chain Belt Conveyor
BC-1BC-2
BC-3
Walking Floor
Multiflex Bin &
Screw
RAL
Shut Off gate
ILC
▪ Dosing, transportation and feeding system for accurate
feeding of pre-processed waste.
▪ Consists of Walking floor -150m3/hr, Multi-flex -200m3/hr,
Rotary airlock - 300m3/hr.
▪ Safety features provided : Emergency stops, Pull cords ,
MVWS system for Multi-flex & CBC, Sprinklers for Walking
Floor, Interlocks provided for safety shut-off gate.
▪ LHS cable provided for Multi-flex, CBC, BC-1, BC-2
& BCD
▪ UV/IR detectors provided in walking floor, BC-1, 2, 3
& BCD
▪ 8 Manual call points provided covering all locations.
▪ Booster pump of 273 m3/hr capacity provided to
cover BCD & Zone 2 of BC3
▪ 6 Deluge valve provided for MVWS system covering
Multi-flex, CBC, Police screen, BC-1, 3 & BCD
▪ 40 sprinklers (ESFR type) provided at roof of WF
▪ Fire alarm interlock taken for tripping of Co-
processing circuit.
▪ Hydrant posts provided at WF & Multi-flex
▪ Temperature scanner with display provided for Multi-
flex
▪ Chute level sensor for BC-1 and BC-3 discharge
▪ Interlocks for shut-off gate provided with tank water
level, temperature & pressure apart from general
interlocks.
Fire fighting System at Co-processing
Operation & Control Building
Operation & Control Building is meant for administrative work
Houses Laboratory , Sample preparation & sample storage room
Conference room for daily production meetings & conferences
Drivers rest room
Washrooms & changing rooms with lockers for shop floor personnel
Detarping & sampling station
Horizontal Anchorage Line system equipped with shock absorbers.
Safety belt provided for safe anchorage.
Provided with fall arrest system.
For safe detarping of vehicle.
For safe sample collection from incoming waste trucks.
Mobile Equipment
▪ Liebherr Hydraulic arm Handler
▪ Atex 22 compliant
▪ Rear view camera
▪ Liebherr Wheel Loader
▪ Atex 22 compliant
▪ Rear view camera
▪ Terex Skid steer Loader
▪ Sound proof ROPS/FOPS cabin.
▪ Rear Egress for an Emergency exit.
▪ Jungheinrich Fork-lift
▪ Drum handling & tilting attachment
▪ Engine Spark Arrester, Diesel Particulate Filter
▪ Anti Spark & Anti Static Forks
▪ Genie Scissor lift
▪ Maximum workable height = 12.2 meters
▪ Maximum load carrying capacity = 349 Kg
▪ TPS Road sweeping machine
▪ Fitted with spark arrestor
▪ Workplace monitoring
▪ Stockpile temperature▪ Illumination level▪ Noise level
▪ Radiation levels▪ VOCs
▪ Checklists for periodic monitoring
▪ Incoming Vehicle inspection at main gate▪ Pre-start checklist for arm-handler, loader etc.
▪ Shredding line walk-by inspection▪ Fire-fighting inspection▪ Waste Profile forms
▪ OH&S compliance▪ Daily tool box talk▪ Alert sharing & implementation of learning
▪ Work permit system▪ Fire-fighting drills
▪ Incident reporting▪ Safety Observation tour (SOT)
Systems in place for safe operation
Practices in place
Daily safety talk & alert sharing sessions
Best practices implementation
Monthly tool box talks
Use of dedicated uniforms for operators & workers
Mandatory use of half face canister masks
All Mandatory PPEs to be adhered to at the workplace
Adequately trained on fire-fighting & safe handling methods
Best and safe practices- Geocycle
Safety signage display at all identified locations
Emergency contact numbers
Mandatory PPEs adherence
H&S policy of the group company
Provision of Emergency Eye Wash
Safety shower provided for accidental spills over body
Spill kits for arresting accidental spills on the floor
Best and safe practices- Geocycle
Fire Water Retention & Leachate Collection
1200 m3 fire water retention basin for capturing residual fire-fighting water.
Provided with a layer of Geo-membrane sheet to prevent percolation of water.
50 m3 Leachate collection sump provided at 2 locations.
Drains separating storm water with potentially contaminated water.
Drains are epoxy coated for prevention of percolates.
Submersible pumps provided for reuse of contaminated water through co-processing.
2015 2016 2017 YTD Sep 2018
Achieved TSR% 4.16 6.23 9.65 10.92
4.16
6.23
9.65
10.92
0
2
4
6
8
10
12
Thermal substitution rate
%T
SR
Thermal Substitution rates are on an increasing trend YOY basis
In 2019 post expansion of its Pre & Co-processing facilities, Wadi aspires to achieve 20% TSR
2015 2016 2017 YTD Sep 2018
Achieved 31720 45678 67197 58167
31720
45678
67197
58167
0
10000
20000
30000
40000
50000
60000
70000
80000
AF V
olu
me
s -
MT
AF & AR Volumes for Wadi
AF includes Haz & Non- Haz Industrial wastes, Biomass, Sorted Municipal Waste etc..
AR includes Red Mud, Fly-ash, Iron slag etc..
2015 2016 2017 YTD Sep 2018
Achieved 66343 97448 87732 66026
66343
97448
87732
66026
0
20000
40000
60000
80000
100000
120000
AR
Vo
lum
es
-M
T
Safety Promotional Activities - Training and assessment
Fire fighting training to Geocycle team
Training
Assessment
Class room Training for drivers
On Roa
Class room Training on Fire fighting
Certification training for drivers Rewarding Safety man for the month
Safety Promotional Activities
Laboratory & quality assurance at Wadi facility
Only pre-analyzed and approved waste materials are allowed to be received at our pre-processing facility
The materials received in closed trucks are tested for properties in line with WAC before pre-processing – Waste Characteristics Evaluation.
The samples of pre processed material ready for dispatch are tested for requirements for co-processing at our cement plant.
Any non-conforming material will be rejected and send back to respective waste generator
Geocycle Laboratory
• ICP : Used for spectroscopic analysis of elemental
composition of waste.
• GC : Used for the determination of PCB
(Poly Chlorinate Biphenyl) in the sample.
Lab is equipped with14 ultra modern instruments which are used for analysis of waste samples for finger Print & Comprehensive analysis.
• CHN&S ANALYZER : Determination of Carbon, Hydrogen,
Nitrogen & Sulphur content in the waste.
• BOMB CALORIMETER : Used for measuring the Calorific
value of the sample .
• PROXIMATE ANALYZER : Used for determination of
moisture, volatile matter, ash and fixed carbon in the sample.
Geocycle Laboratory
• AUTO-TITRATER: Used for titration of colored solution whose
end point cannot be detected properly by visual observation.
• KARL FISHER ANALYZER: Used to determine moisture
content in the organic samples.
• SUPRA PURE WATER SYSTEM: Ultra pure water is used in
sample preparation elemental analysis on ICP spectrometer
and Chloride analysis in Autotitrator.
Geocycle Laboratory
• MICROWAVE DIGESTER: Used for sample preparation for
analyzing them on ICP spectrometer.
• PH METER & ISE: Quick simple and accurate measurement
of pH of the solution & to determine the Fluoride content.
• RADIATION SURVEY METER: Used to detect the presence of
radioactive material in the sample.
Geocycle Laboratory
• MOISTURE ANALYZER: Used to determine the moisture
content by weight loss method.
• VISCOMETER: Used to determine the viscosity of the liquid
samples.
• FLASH POINT ANALYZER: Used to determine the flash
point of the liquid samples.
Geocycle Laboratory
Geocycle Awareness cum Personality Development: April 2018
Program organised at Disha Wadi Center Wadi
Geocycle Awareness:
Video presentation on Clean and Green Wadi
Corporate Video Presentation of Geocycle India
Basic Introduction presentation on Geocycle India
Personality Development:
Factor enhancing Personality
Improve communication Skills
Leadership Quality
Group presentation on Beat Plastic Pollution: DAV School
The Group Competition was organised at DAV
Public School Wadi
● Four different group of student were presented
the studies of four different designated area of
India.
● The Problem of plastics pollution were identified
by the Groups.
● All Groups were presented the solution of
plastics pollution in there respective presented
area.
● The presentation were evaluated by the faculty
and Geocycle employee
● The winner group was recognised with a gift
Geocycle Awareness cum Road Safety Training: July 2018
Road Safety Training for two wheeler rider was
organised at Government High School Wadi
● Equipments and controls of motor bike
● Personal Protective Gear
● Language of Road sign
● Braking to stop distance
● Brainstorming session on Road safety violation
through Videos