Detailed Project Report on e-waste recycling unit

E-WASTE RECYCLING UNIT

[CODE NO.4310]  

Electronic waste or e-waste describes discarded electrical or electronic devices. Used electronics which are destined for refurbishment, reuse, resale, salvage recycling through material recovery, or disposal are also considered e-waste. Informal processing of e-waste in developing countries can lead to adverse human health effects and environmental pollution.

Electronic scrap components, such as CPUs, contain potentially harmful materials such as lead, cadmium, beryllium, or brominated flame retardants. Recycling and disposal of e-waste may involve significant risk to health of workers and their communities.

There cannot be a material in god’s creation which can be called ‘waste’. Every material / object has certain use in appropriate place. Therefore, placing it in the right place solves the problem.

This is the technology that we adopt. We see to that there is minimal processing in waste management so that there is no environmental pollution. Our strength lies in identifying who needs the components most and what best is the use for various parts of e-waste.

For example, a cooler fan in CPU may be used as such by the computer service centre. If the same fan is broken it sells for a lesser value as metal and plastic.

Every screw or bolt if segregated properly can be reused at appropriate place.

Following are the steps involved in e-waste handling 

1. Sorting 

2. Identify Usefulness 

3. Identify hazardousness 

4. Dismantling 

5. Segregation 

6. Treatment / Disposal

For treatment we follow national guidelines and best international practices. 

Process description is given in the following flow charts.

ELECTRONIC WASTE WORLD WIDE

E-waste is considered the "fastest-growing waste stream in the world" with 44.7 million tonnes generated in 2016- equivalent to 4500 Eiffel towers. In 2018, an estimated 50 million tonnes of e-waste was reported, thus the name ‘tsunami of e-waste’ given by the UN. Its value is at least $62.5 billion annually.

Rapid changes in technology, changes in media (tapes, software, MP3), falling prices, and planned obsolescence have resulted in a fast-growing surplus of electronic waste around the globe. Technical solutions are available, but in most cases, a legal framework, a collection, logistics, and other services need to be implemented before a technical solution can be applied.

Display units (CRT, LCD, LED monitors), processors (CPU, GPU, or APU chips), memory (DRAM or SRAM), and audio components have different useful lives. Processors are most frequently out-dated (by software no longer being optimized) and are more likely to become "e-waste" while display units are most often replaced while working without repair attempts, due to changes in wealthy nation appetites for new display technology. This problem could potentially be solved with modular smartphones or Phonebloks. These types of phones are more durable and have the technology to change certain parts of the phone making them more environmentally friendly. Being able to simply replace the part of the phone that is broken will reduce e-waste. An estimated 50 million tons of E-waste are produced each year. The USA discards 30 million computers each year and 100 million phones are disposed of in Europe each year. The Environmental Protection Agency estimates that only 15–20% of e-waste is recycled, the rest of these electronics go directly into landfills and incinerators.

Society today revolves around technology and by the constant need for the newest and most high-tech products we are contributing to a mass amount of e-waste. Since the invention of the iPhone, cell phones have become the top source of e-waste products because they are not made to last more than two years. Electrical waste contains hazardous but also valuable and scarce materials. Up to 60 elements can be found in complex electronics. As of 2013, Apple has sold over 796 million iDevices (iPod, iPhone, iPad). Cell phone companies make cell phones that are not made to last so that the consumer will purchase new phones. Companies give these products such short lifespans because they know that the consumer will want a new product and will buy it if they make it. In the United States, an estimated 70% of heavy metals in landfills comes from discarded electronics.

While there is agreement that the number of discarded electronic devices is increasing, there is considerable disagreement about the relative risk (compared to automobile scrap, for example), and strong disagreement whether curtailing trade in used electronics will improve conditions, or make them worse. According to an article in Motherboard, attempts to restrict the trade have driven reputable companies out of the supply chain, with unintended consequences.

COST ESTIMATION

Plant Capacity                                   5000 Kg/Day

Land & Building (6000 sq.mt.)  Rs. 3.19 Cr

Plant & Machinery                              Rs. 48 Lac

Working Capital for 3 Months    Rs. 3.91 Cr

Total Capital Investment                   Rs. 7.67 Cr

Rate of Return                                      44%

Break Even Point                                 42%

• INTRODUCTION
  
• FOLLOWING ARE THE STEPS INVOLVED IN E-WASTE HANDLING
• ELECTRONIC WASTE WORLD WIDE
• THE ENVIRONMENTAL IMPACT OF THE PROCESSING OF DIFFERENT ELECTRONIC WASTE COMPONENTS
• TYPES OF E-WASTE
• THE MOST COMMON TYPES OF E-WASTE
• SMALL EQUIPMENT
• LARGE EQUIPMENT
• TEMPERATURE EXCHANGE EQUIPMENT
• BENEFITS AND IMPORTANCE OF E-WASTE RECYCLING
• THE PROBLEMS WITH NOT RECYCLING E-WASTE
• THE BENEFITS OF RECYCLING E-WASTE
• CHALLENGES AND OPPORTUNITIES IN E-WASTE MANAGEMENT IN INDIA
• GLOBAL CHALLENGES OF RECYCLING E-WASTE
• E-WASTE MANAGEMENT
• MARKET OVERVIEW OF E-WASTE RECYCLING
• E-WASTE RECYCLING
• SCENARIO OF E WASTE IN UTTAR PRADESH
• DETAILS OF E-WASTE RECYCLING PROCESS
• STEP ONE — COLLECTION
• STEP TWO — STORAGE
• STEP THREE — MANUAL SORTING, DISMANTLING, SHREDDING
• STEP FOUR — MECHANICAL SEPARATION
• MAGNETIC SEPARATION
• WATER SEPARATION
• STEP FIVE: RECOVERY
• HOW THE UNIVERSAL RECYCLING PROCESS DIFFERS ACROSS  COMMON ITEMS
• THE RECYCLING PROCESS FOR BATTERIES
• THE RECYCLING PROCESS FOR CATHODE RAY TUBES
• THE E-WASTE RECYCLING PROCESS FOR COMPUTERS AND LAPTOPS
• PCB CIRCUIT BOARD RECYCLING MACHINE
• PRODUCTS STRUCURE
• PROCESS DESCRIPTION
• PRODUCT FEATURES
• TECHNICAL PARAMETERS
• WORKING PROCESS OF PCB RECYCLING MACHINE
• CLASSIFICATION OF E-WASTE
• COMPOSITION OF E-WASTE
• COMPONENTS OF E-WASTE
• TABLE 1: RECOVERED MATERIAL 1000 KG. OF PC
• TABLE: 2 SALEABLE MATERIALS RECOVERED FROM 1000 KG. 
• ASSORTED E-WASTE (CONTAINING PC. TV, MOBILE PHONE ETV.
• TABLE 3: MARKET VALUE OF THE METAL RECOVERED FROM 1000 KG. OF PCBS
• TABLE 4: RECOVERABLE QUANTITY OF ELEMENTS IN A PC (TYPICAL)
• TABLE 5: RECOVERABLE QUANTITY OF ELEMENTS IN A TV (TYPICAL)
• (1) PLASTICS CONTAINING BROMINATED FLAME RETARDANTS (BFRS)
• (2) INSULATION
• (3) ASBESTOS
• (4) REFRACTORY CERAMIC FIBERS (RCFS)
• (5) LIQUID CRYSTAL DISPLAY (LCDS)
• (6) COMPONENTS CONTAINING PLASTICISERS/STABILISERS
• (7) CIRCUIT BOARDS
• (8) FLAME RETARDANTS
• (9) LEAD
• (10) MERCURY
• (11) BERYLLIUM
• (12) CAPACITORS
• (13) ELECTROLYTE CAPACITORS
• (14) CAPACITORS CONTAINING POLY CHLORINATED BIPHENYLS (PCBS)
• E-WASTE SCENARIO
• RECYCLING, REUSE AND RECOVERY OPTIONS
• (I) DISMANTLING:
• (II) SEGREGATION OF FERROUS METAL, NON-FERROUS METAL AND PLASTIC
• (III) REFURBISHMENT AND REUSE:
• (IV) RECYCLING/RECOVERY OF VALUABLE MATERIALS
• (V) TREATMENT/DISPOSAL OF DANGEROUS MATERIALS AND WASTE
• TREATMENT & DISPOSAL OPTIONS
• LANDFILLING - INCINERATION
• LANDFILLING
• INCINERATION
• E-WASTE RECYCLING/TREATMENT TECHNOLOGIES IN INDIA
• ENVIRONMENTALLY SOUND TREATMENT TECHNOLOGY FOR E-WASTE
• ENVIRONMENTALLY SOUND E-WASTE TREATMENT TECHNOLOGIES
• ANALYSIS
• FIGURE 1: SIMPLIFIED VERSION OF EST FOR E-WASTE
• EST FOR 1ST LEVEL TREATMENT
• 1. DECONTAMINATION
• 2. DISMANTLING
• 3. SEGREGATION
• OUTPUT:
• EST FOR 2ND LEVEL TREATMENT
• FIGURE 2: PROCESS FLOW OF NON CRT BASED E-WASTE TREATMENT
• THE SALIENT FEATURES OF THIS TREATMENT TECHNOLOGY AND PROCESS IS GIVEN BELOW.
• FIGURE .3: NON- FERROUS METAL DISTRIBUTION VS SIZE RANGE FOR PC SCRAP
• CRT TREATMENT TECHNOLOGY
• DIFFERENT TYPES OF SPLITTING TECHNOLOGY USED ARE GIVEN BELOW
• - NICHROME HOT WIRE CUTTING
• - THERMAL SHOCK
• - LASER CUTTING
• - DIAMOND WIRE METHOD
• - DIAMOND SAW SEPARATION
• - WATER-JET SEPARATION
• 3RD LEVEL E-WASTE TREATMENT
• INPUT/ OUTPUT AND UNIT OPERATIONS
• PLASTIC RECYCLING
• MECHANICAL RECYCLING PROCESS
• FIGURE 4: RECYCLING OPTIONS FOR MANAGING PLASTICS FROM END-OF-LIFE ELECTRONICS
• FIGURE 5: REPRESENTATIVE PROCESS FLOW DIAGRAM FOR THE MECHANICAL RECYCLING OF POST CONSUMER PLASTICS
• CHEMICAL RECYCLING PROCESS
• FIGURE 6: DE-POLYMERIZATION OF PLASTICS & CONVERSION PROCESSES
• GUIDELINES FOR ESTABLISHMENT OF INTEGRATED E-WASTE RECYCLING & TREATMENT FACILITY
• FACILITY OPERATION REQUIREMENTS
• COLLECTION SYSTEMS FOR E-WASTE
• STORAGE AREAS
• DISMANTLING & SEGREGATION OF DISMANTLED PARTS
• RECYCLING
• TREATMENT & DISPOSAL
• ANNEX IA
• ANNEX IB
• 1. LARGE HOUSEHOLD APPLIANCES
• 2. SMALL HOUSEHOLD APPLIANCES
• 3. IT AND TELECOMMUNICATIONS EQUIPMENT
• 4. CONSUMER EQUIPMENT
• 5. LIGHTING EQUIPMENT
• 6. ELECTRICAL AND ELECTRONIC TOOLS (WITH THE EXCEPTION 
•    LARGE-SCALE STATIONARY INDUSTRIAL TOOLS)
• 7. TOYS, LEISURE AND SPORTS EQUIPMENT
• 8. MEDICAL DEVICES (WITH THE EXCEPTION OF ALL IMPLANTED AND INFECTED PRODUCTS)
• 9. MONITORING AND CONTROL INSTRUMENTS
• 10. AUTOMATIC DISPENSERS
• PROCESS FLOW DIAGRAM OF AN INTEGRATED FACILITY
• PRINCIPLES OF PLANT LAYOUT
• MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
• PLANT LOCATION FACTORS
• PRIMARY FACTORS
• 1. RAW-MATERIAL SUPPLY:
• 2. MARKETS:
• 3. POWER AND FUEL SUPPLY:
• 4. WATER SUPPLY:
• 5. CLIMATE:
• SPECIFIC FACTORS
• 6. TRANSPORTATION:
• A. AVAILABILITY OF VARIOUS SERVICES AND PROJECTED RATES
• 7. WASTE DISPOSAL:
• 8. LABOR:
• 9. REGULATORY LAWS:
• 10. TAXES:
• 11. SITE CHARACTERISTICS:
• 12. COMMUNITY FACTORS:
• 13. VULNERABILITY TO WARTIME ATTACK:
• 14. FLOOD AND FIRE CONTROL:
• EXPLANATION OF TERMS USED IN THE PROJECT REPORT
• 1. DEPRECIATION:
• 2. FIXED ASSETS:
• 3. WORKING CAPITAL:
• 4. BREAK-EVEN POINT:
• 5. OTHER FIXED EXPENSES:
• 6. MARGIN MONEY:
• 7. TOTAL LOAD:
• 8. LAND AREA/MAN POWER RATIO:
• PROJECT IMPLEMENTATION SCHEDULES
• INTRODUCTION
• PROJECT HANDLING
• PROJECT SCHEDULING
• PROJECT CONSTRUCTION SCHEDULE
• TIME SCHEDULE
• FOR LICENCE AND CLEARANCES
• SUPPLIERS OF METAL TESTING LABORATORY
• SUPPLIERS OF PLANT AND MACHINERY
• SUPPLIERS OF E-WASTE RECYCLING MACHINE
• SUPPLIERS OF E-WASTES

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)