30 September 2019
Bhubaneswar: Lot of non-ferrous scrap is generated in workshop for which there is no efficient method of disposal. As a result, they find their way to landfills, which is environmentally hazardous. Carriage Repair Workshop, Mancheswar has found a way for tackling this problem in a patented technology called POLYCRACK.
It is world’s first patented heterogenous catalytic process which converts multiple feed stocks into hydrocarbon liquid fuels, gas, carbon and water. This is the 1st-of-its-kind in Indian Railways.
Polycrack can be fed with the following:
All types of Plastic; Petroleum sludge; Un-segregated MSW with moisture up to 50%; E – Waste; Automobile fluff; Organic waste including bamboo’s garden waste; and Jathropa fruit and palm bunch
Polycrack has the following advantages over the conventional approach of treating solid Waste:
Pre-segregation of waste is not required to reform the waste. Waste as collected can be directly fed into Polycrack;
It has high tolerance to moisture hence drying of waste is not required;
Waste is processed and reformed within 24 hours;
It is an enclosed unit hence the working environment is dust free;
Excellent air quality surrounding the plant;
Biological decomposition is not allowed as the Waste is treated as it is received;
The foot print of the plant is small hence the area required for installing the plant is less when compared with conventional method of processing. All constituents are converted in to valuable energy thereby making it zero Discharge Process.
Gas generated in the process is re-used to provide energy to the system thereby making it self-reliant of its energy requirement and also bring down the operating cost.
There is no atmospheric emission during the process unlike other conventional methods except for combustion gases which have pollutants less than the prescribed norms the world over.
Operates around 450 degrees, making it a low temperature process when compared with other options.
Safe and efficient system with built-in safety features enables an unskilled user to operate the machine with ease.
Low capital cost and low operating cost; Fully automated system requires minimum man power.
Its process is a closed loop system and does not emit any hazardous pollutants into the atmosphere. The combustible, non-condensed gases are re-used for providing energy to the entire system and thus, the only emission come from the combustion of gaseous fuels. The emissions from the combustion are found to be much less than prescribed environmental norms.
This process was awarded:
The Best innovation Gold Medal in 2007 by Lockheed Martin, Dept of Science & Technology, Govt. of India, FICCI,
Best Innovation Gold Medal 2007,
Best Innovation Gold Medal 2008,
Best Innovation Gold Medal 2009,
Nominated for Tech-Museum Awards 2008,
Frost & Sullivan – Global Innovation and Leadership Award -2011,
IGCW-2011 – Best Green Chemistry Innovation Award.
“Energy to be produced here will be in the form of Light Diesel Oil. This oil is used to light furnaces. Target date of commissioning is January 2020 within four months and the cost will be around Rs 2 crore,” said Manas Poddar, Chief Workshop Manager, Mancheswar Workshop.
Waste generated from carriage workshop, coaching depot at Bhubaneswar and railway station will be feeder material for this plant, Poddar added.