Responsibilities of Collection and Dismantling centre · ENGINEER,GARC 20th July 2012 . Today's discussion topics Scenario of dismantling in unorganized sectors Recycling demo unit

Responsibilities of Collection and Dismantling centre

Presented by

M.PRAVEEN KUMAR,ENGINEER,GARC

20th July 2012

Today's discussion topics

Scenario of dismantling in unorganized sectors

Recycling demo unit at GARC

Our facility-overview

Highlights of Recycling Demo Unit

Details of vehicles provided for dismantling

Process flow of an ELV

Certificate of Destruction

Dismantling report

Current achievements

Code of practice for two wheelers(TVS Apache)

Cost details on dismantling a two wheeler

Code of practice for four wheelers(VW CAR)

Future activities at GARC

SCENARIO OF VEHICLES DISMANTLING IN UNORGANIZED SECTOR OF INDIA

• There are many vehicle dismantling centres in unorganized sector in India.

• Some of the places are Pudupet in Chennai, Mayapuri in Delhi,Lohar

Chawl and Chor Bazaar in Mumbai, Ukkadam in Coimbatore etc. • Dismantling of cars and bikes in these unorganised sector takes place in

a haphazard and unscientific manner.

• These were small units in the early days, when the cities weren't crowded, but their operations currently present significant health hazards to the citizens.

• In all, it is estimated that more than 100,000 people are employed in the unorganised sector, dismantling vehicles of various types and recovering parts and materials for sale/reuse/recycling.

DISMANTLING OF VEHICLES IN UNORGANIZED SECTOR IN INDIA

PUDUPET,CHENNAI

MAYAPURI,DELHI

The main ill-effects of these places of recycling are:

1.Air Pollution. 2.Contamination of ground water and land. 3.Highly unhygienic process posing threat to the workers handling it.

Recycling Demo Unit at GARC

The Recycling Demo Unit was setup by SIAM and NATRIP at GARC, Oragadam on 2th August 2011. A budget of 1.41 crores was allotted from the Auto R & D cess fund to establish this facility. The objective of this project is to study the process and establish the Code of Practice of dismantling and scrappage of selected automobile vehicles offered by OEM’S for the specific purpose, under Indian conditions without environmental degradation.

1.Arrangement of vehicles 2.Monitoring status of report 3.Technical support 4.Airbag neutralizing kit 5.Special tools

1.Dismantling facilities. 2. Cost estimation of scrap and labour. 3.Method of dismantling and disposing scrap 4.Cert of Destruction 5.Training/ Awareness programmes 6.Final project report

CLASS ROOM

BALING PRESS

PARTS STORAGE

DISMANTLING AREA

TIRE

STORAGE

ELECTRICAL PANEL

COMPRESSOR

OFFICE

RECEPTION

2/3 WHEELER DISMANTLING

AREA

Engine storage area

Gla

ss s

tora

ge

area

Fabric storage

PU storage

Details of Demo Unit Building Size 35mX25m Dismantling Area 16mX7m Parts Storage Area 16mX7m Total building area -510 sq m Vehicle body storage area-600 sq m

Our facility at GARC

Cost Break-up for Establishing RDU

S.No item Cost (Rs)

1. Bailing press 1677850

2. Air compressor 99800

3. Four wheeler scissor lift

215949

4. Two wheeler lift 65472

5. Fork lift 740940

6 Gantry crane 304594

S.No Item Cost(Rs)

7. Plastic crates for storage

119118

8. Material storage racks 134703

9. Dismantling tools 120060

10. Trolleys and jacks 44765

11. Oil collector 39236

12 Weighing machines 31700

Infrastructure cost :84 lakhs

Equipments and tools cost(only major items are displayed ):

The budget allotted for this project is 1.41 crores. The amount spent on various heads are displayed below.

Few equipments are now identified as stage two items which shall be procured from the remaining fund amount.

Highlights of our facility

Impermeable surface for appropriate areas with spillage collection crates to avoid land pollution.

Appropriate storage for dismantled spare parts, including impermeable storage for oil contaminated spare parts

Appropriate containers for storage of batteries. Appropriate storage tanks for the segregated storage of end-of-life vehicle

fluids like brake oil, power steering oil, engine oil, transmission oil, engine coolant, wiper washer fluid, left-out fuel, etc

Appropriate storage for used tyres, including the prevention of fire hazards. SEDA Airbag neutralizing kit with universal adapter for bursting of airbags

and seat belt pretensioners. Exposure and hands-on experience on dismantling of 60 two wheelers and

15 four wheelers. Fork lift capable of handling breakdown vehicles and vehicle white bodies Bailing press with a capacity to handle bales of size 16”x16” weighing 60 to

100 kgs. Oxy-acetelene gas cutting for cutting the car white body. Weighing machines to handle various weights to a maximum of 500 kgs.

Vehicles were provided to RDU from OEM’s for dismantling

Sl.No OEM No of Vehicles Type

1 Tvs motors 15 Un registered

2 Bajaj 36 Un registered

3 Hero honda 5 registered

4 Yamaha 4 Un registered

Four wheelers

Sl.No OEM No of Vehicles Type

1 Maruti Suzuki 7 Registered

2 Volkswagen 7 Un registered

3 Toyota 1 registered

4 General motors 1 registered

5 Mahindra 2 Un registered

6. Renault Nissan 1 Un registered

7 Tata motors 2 Un registered

Vehicles provided for dismantling to RDU

End of life vehicle

• Willful donation

• Vehicle details

Documentation

• Acknowledgement

• Undertaking

• Photos

• Registration details

Process flow for an ELV

Dismantling

• Pretreatment

• Operation

Planning

• Tentative date of dismantling

• Vehicle parked in safe location

Process flow for an ELV cont..

Segregation

•Ferrous, non- ferrous, plastics, rubber

•Weighment

•Storage at marked location

Process flow for an ELV cont..

COD

•Preparation of certificate of destruction

•Report on parts recovered.

Certificate of Destruction- specimen copy

The Certificate of Destruction are issued to vehicles which are dismantled a our facility.

For

un

-reg

iste

red

veh

icle

s

For

regi

ster

ed v

ehic

les

Dismantling Report - Contents

The dismantling report will be made for vehicles which were dismantled in recycling demo unit.

S.No Item Data

1 Registration No.

2 Model

3 Manufacturer

Name

4 Year of Make

5 Last owner's

name

6 Odometer

reading

7 No. of reusable

parts taken out

For studying

the trend of

reusable parts

8 List of reusable

parts (with

quantity)

9 Weight of

metals

10 Weight of

plastics

S.No Item Data

11 Weight of glass

12 Photos of Chassis no.

13 Photos of white body for rusting

pattern

14 Photos of

suspension/steering

parts

for rusting

pattern & weld

condition

15 Photos of PP/PU

interior parts - I/P,

steering wheel, steering

column, gear knob etc.

for color fading

pattern

16 Photos of rubber parts for cracking

pattern

17 Oil fluid drained

18 Battery removed

19 Tyre removed

The recycling demo unit has dismantled 60 two wheelers which were provided by OEM’s.The following results were obtained.

Type of vehicle

Ferrous scrap(Kg)

Non ferrous scrap(Kg)

Plastics(Kg)

Rubber(Kg) Time taken for dismantling (man-hours)

Moped 32.09 1.65 14.84 8 2

Bike 68.26 2.8 7 10 4

scooter 84.84 1.56 6.72 8.2 3

Current achievements

Code of Practice for Two Wheelers

OIL 2. OIL DRAININGDRAINING 3. BATTERY REMOVAL

4. SEAT REMOVALDRAINING 5. FUEL DRAINING/TANK

REMOVAL 6. FUEL DRAINING/TANK

REMOVAL

OIL 1. MOUNTINGDRAINING

11. AIR FILTER

8. ELECTRICAL REMOVAL 7. HEADLAMP REMOVALRAINING OIL 9. MUD GUARDDRAINING

OIL 10. CLUSTER REMOVALDRAINING OI 12. SHOCK ABSORBERDRAINING

Code of Practice for Two Wheelers contd..

13. SWITCHES & CONTROLS

17. HANDLEBAR

15. CARBURETTOR

16. BRAKE FLUID DRAINING 18.EXHAUST SYSTEM REMOVAL

14. BRAKE REMOVAL

Code of Practice for Two Wheelers contd..

21. ENGINE REMOVAL 20. BRAKE SHOE

24. PARTS SEGREGATION&STORAGE 22. BRAKE DISC

OIL 19. HORNRAINING

23. FRAME REMOVAL

Code of Practice for Two Wheelers contd..

Cost details of dismantling a two wheeler

From earlier slides the amount of scrap generated from dismantling a two-wheeler is shown.

Market rate for two wheeler scrap

Ferrous Non ferrous Plastic Rubber

30 Rs/kg Al-100Rs/kg,Cu-300Rs/kg 10 Rs/kg 1 Rs/kg

Moped Bike Scooter

1650 Rs 3350 Rs 3800 Rs

Considering the above mentioned rates the cost which can be recovered from dismantling a two wheeler and selling the scrap

Cost incurred at GARC-Recycling demo unit for dismantling a two-wheeler

considering manpower ,infrastructure and other expenses is 450 Rs.

Note : The scrap rate said above are subject to vary on day-to-day basis.

1. AIRBAGS 2. BATTERY REMOVAL

3. AC GAS 4. FLUID DRAINING

Code of Practice for Four Wheelers

5. BONNET 6. HEAD LIGHT

7. DOORS 8. DOOR TRIMS

Code of Practice for Four Wheelers contd..

9. WIPERS 10. TYRES

11. BUMPER OIL 12. FENDERDRAINING

Code of Practice for Four Wheelers contd..

13. CRASH BAR 14. RADIATOR REMOVAL

OIL 16. ENGINE & DRIVESHAFTDRAINING

Code of Practice for Four Wheelers contd..

15. CAT-CON REMOVALRAINING

19. INSULATION MATS

17. BOOT DOOR 18. SEAT

20. ROOF COVER

Code of Practice for Four Wheelers contd..

24. REAR AXLE

O21. BRAKE CYLINDERDRAINING OIL 22. SUSPENSIONDRAINING

OIL 23. STEERING COLUMNDRAINING

Code of Practice for Four Wheelers contd..

25. DASH BOARD OIL 26. FUEL TANKDRAINING

OIL 27. WHITE BODY REMOVALRAINING

Code of Practice for Four Wheelers contd..

OIL 28. BAILING OF BODY AND DOOR PANELS

Code of Practice for segregation

1.Ferrous and non ferrous parts 2.Plastic,Fabric,wiring harness

3.Engine ,PU, Rubber, Pyro, Battery 4.Fluids in separate barrels

Future activities of RDU-GARC

• The cost estimation of four wheeler scrap is to be carried out.

• ELV take-back responsibility needs to be assigned.

• The license for authorization and operation of waste management generated at

dismantling facility need to processed.

• The disposal of four wheeler scrap has to be carried out.

• RDU shall be able to handle premature End-of-life vehicles.

• To make and fine tune a road map which can guide a dismantler to sell the scrap

and the same material shall be used by OEM’S in their newer models.

• To upgrade the existing facility by adding few items to the already available facility

1. Freon capturing kit (approx-75,000 Rs)

2. Auto glass removal kit (approx-75000 Rs)

3. Fluid extraction kit

• To analyse the market for dismantled parts taken from ELV’S and to effectively

conserve the energy which is utilised for making the same part.

• To suggest a business model which shall be inline with the ELV regulation to be made

effective in India.

Thank you

Visit our facility for more information

We are available at:

[email protected] [email protected]