A Project Report on Integrated E-Waste

Recycling Facility, West Bengal

Group No- 11(i) Puneet Yadav, A-40

(ii) R. Selvam, A-24(iii) Arup Kumar Saha, B-31(iv) Abhe Singh Yadav, A-17

(v) Ashok Kumar Sharma, B-44(vi) Anis M Mankad, A-10

Phase III- Mid Career Training Programme

Project Report

ContentsProject at a glance.......................................................................................................................................3

Financial Calculations from Owner’s Perspective................................................................................6

NPV & IRR in Banker’s Perspective....................................................................................................10

The Government’s Perspective Cash Flow.........................................................................................11

Economic Return in Country or Economic Point of View...................................................................13

Other Details- Project Justification............................................................................................................14

Building of E-Waste Inventory in West Bengal......................................................................................14

Objectives of the Project.......................................................................................................................14

Role of Operator/ Implementer.............................................................................................................14

Land Availability for the E-Waste Recycling Facility...............................................................................15

The Project Conception.............................................................................................................................16

Selection of land....................................................................................................................................16

Integration of unorganized sector.........................................................................................................16

List of E–waste items to be handled......................................................................................................16

Sources/ Origin of E-Waste Collection...................................................................................................17

Building awareness................................................................................................................................19

Manpower –Employment opportunities...............................................................................................20

Annexure 1................................................................................................................................................21

Project Planning :.......................................................................................................................................21

Compliance Management.....................................................................................................................23

Annexure 2................................................................................................................................................24

The Technology.........................................................................................................................................24

Flow Chart.............................................................................................................................................24

Collection & Transportation:.................................................................................................................24

Storage of E-waste:................................................................................................................................25

Manual Dismantling Section:.................................................................................................................27

Pre-Breaker Crusher:.............................................................................................................................28

Hammer Mill:.........................................................................................................................................28

Pulverizer:..............................................................................................................................................28

Vibro Separators:...................................................................................................................................29

Conveyor Belts:......................................................................................................................................30

Magnetic Separator Conveyor Belts:.....................................................................................................30

Vibrating Screens...................................................................................................................................30

Precious Metal Recovery:......................................................................................................................30

Cable Recycling:.....................................................................................................................................31

CRT Cutting Machine :...........................................................................................................................31

CFL/Tube Lights Recycling/Disposal :.....................................................................................................32

Utilities :................................................................................................................................................32

Common Facilities :...............................................................................................................................32

Advantages with Technology:................................................................................................................35

Annexure 3................................................................................................................................................36

Environment management plan................................................................................................................36

Air pollution...........................................................................................................................................36

Water pollution.....................................................................................................................................36

Noise Pollution......................................................................................................................................36

Hazardous waste disposal.....................................................................................................................36

Disposal of Metals & Non-metals:.........................................................................................................37

Environmental matrix:...........................................................................................................................37

Emergency preparedness & Safety Measurements:..............................................................................37

Quality Health & Safety Measurements;...............................................................................................38

Annexure 4................................................................................................................................................39

Detailed Calculations.................................................................................................................................39

Table of Pre-Operation Expenses and other calculations in Owner’s view........................................39

Banker’s View Financials....................................................................................................................47

Project at a glanceAs the usage of the ICT has increased over the last two decades in the everyday life, the amount of Electronic Waste created has also increased substantially. Along with the increased user base, the rapidly changing technology is also responsible for the generation of large amount of E-Waste; for example, the newer versions of storage devices (Large floppies, Small Floppies, Compact Discs (CDs), VCDs, DVDs, and pen drives etc.) create fast obsolescence and large waste. Similarly various types of changes in Processors, Servers and monitors also result in fast replacement of these items.

There are two important issues about the E-Waste- firstly, quite a few of the components are non bio-degradable and will continue to pollute the environment for a long time; secondly, there are quite a few expensive, reusable and upgradable items in the E-Waste which could be recollected and recycled.

Globally, Electronic Waste is being handled effectively in the developed countries. Even in India, the provisions for the handling of E-Waste are being created under the Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008 and E-Waste (Management and Handling) Rules, 2011. Currently various states are under different stages of implementation of the appropriate rules and handling of the E-Waste.

Government of West Bengal has planned to handle the problem of E-Waste in a timely manner and has invited proposals from various firms and institutions- national and international- to bring out their technical proposals towards the resolution of the problem of E-Waste.

The Government, however, has given a few clear indications about the project proposal to be submitted:

(i) Government agrees to spare 3-4 acres of land for the E-Waste Recycling Project from Calcutta Leather Complex Tanners Association (CLCTA), who has already been allotted with 50 acres of government land for a period of 10 years, extendible to another 10 years for collection and transportation of hazardous waste landfill facility. The market value of the government land may cost around Rs.2 crores/3 acres.

(ii) There will be no additional benefits made available to the implementer in form of subsidies. The Tax benefits will be available in the form of Minimum Alternative Tax and no further period of Tax rebate will be available.

(iii) The Project financial viability should be ensured by the implementer and it will be running on BOO model and given the lack of resources and technology to handle such a project, there is no plan for Transfer of the project to the Government at a later stage.

(iv) All risks associated with the Project are to be borne by the implementer. All the financial profits arising from the project will also accrue to the implementer.

A brief profile of the project is given herewith:

Sl.no Name of the Project Integrated E –Waste Recycling Facility1 Proposed location West Bengal Waste Management Ltd – West Bengal

2 Business Handling of electronic waste as per SPCB/ CPCB guidelines3 Service offered Collection ,storage ,recycling ,recovery and disposal of

Electronic waste as per CPCB guideline.4 Proposed capacity 6000MTPA (Phase-I)5 Technology Both in house & imported6 Principal of operation Pay/Charge for the E waste

(Depending on type of Material)7 Project cost Rs.26.55 crores8 Means of Finance

Description Amount in Rs LakhsEquity /OwnersContribution Term loans From financial Inst /bankMarket Value of Government Land Grant

795.49 1856

200

Total 2851.499 Schedule of Commissioning Scheduled to be commissioned within 15 month10 Strength of the Operator for the

proposed E-Waste recyclingThis is first of its kind facility being proposed in the state of West Bengal /Eastern India.Also the project operator will suggest

Land availability- with options Opting for best available technology The facility will be proposed within KMDA limits

located strategically, such that the location is the hub for present and future growth of industries in Kolkata

Strong financial resources of the operator Vast experience in Construction Projects Large experienced domain experts available with

the Operator11 Uniqueness of the project The proposed project is unique in itself. The facility shall be

the first of its kind in West Bengal and will bridge the yawning gap in the demand and availability of E- waste recycling facilities with complete end to solution in the country. In fact it will be a giant step in the drive toward environment protection

(Tables are in Chronological Order in the corresponding Excel Sheet)

Table-2 Cost of the projectSl no. Description Amount in lakhsA Land development and buildings 971.33

B Lab equipments 4C Plant and machinery 1425.27D Vehicles 10E Office equipments 5F Pre operative expenses 333.44G Contingencies 10.39H Margin money for working capital 92.06

Total 2851.49

The Sources for Financing of the Project have been estimated by the investor as follows:

Table-3 Means of financeSl no Description Amt (lakhs)A Equity/owners contribution 795.49B Term loans from financial institutions/banks 1856C Government Land Grant 200

Total 2851.49

(*) The financial statement has been developed for a period of ten years. The details of the financials are attached in the Annexure 4.

Table-8Calculation of EarningsSl. No. Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10

Earning Before Interest, Tax and Depreciation 139.46 346.21 573.20 604.28 636.94 671.28 738.86 778.36 819.88 863.50EBITDA (%) 16.39 25.83 30.54 30.67 30.78 30.90 31.41 31.51 31.61 31.71

Depreciation 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84Note: Cost escalation is taken 5%

Earning before Interest and Tax -40.39 166.36 393.35 424.43 457.09 454.44 522.02 561.52 603.03 646.66

Financial Expenses (Interest) 243.24 209.81177.4

5 135.08 92.83 50.69 54.82 57.55 60.41 63.42Interest on Working Capital 20.52 31.64 43.82 46.00 48.28 50.69 54.82 57.55 60.41 63.42Interest on Term Loan 222.72 178.18 133.63 89.09 44.54 0.00

Earning before Taxation -283.63 -43.45 215.90 289.34 364.26 403.75 467.20 503.97 542.62 583.24Income Tax (MAT) 0.00 0.00 29.38 50.01 70.07 83.85 101.19 112.64 123.88 135.01Earning After Tax -283.63 -43.45 186.51 239.33 294.19 319.90 366.01 391.32 418.73 448.23

-33.32% -3.24% 9.94% 12.15% 14.22% 14.72% 15.56% 15.84% 16.15% 16.46%

Financial Calculations from Owner’s Perspective As can be seen above, EBITDA, EBIT, EBT and Earning after Tax- all suggest that the requirement of fund is required in large amount initially to start the project and fill gap funding is required in the form of Short term liabilities. The Working Capital has been maintained at a bare minimum of 1 to 2 months stock. All this ensures that the Project is run on tight financials. High loan liability could be crippling, most frequently, for new projects. Wherever some investment is required (twice in the detailed report) for meeting hike in requirements, the firm goes into inter firm short term transfers to avoid high interests.

The loan schedule for the loaned amount is given below:

LOAN SCHEDULENominal Interest Rate 12%Year yr-1 yr-2 yr-3 yr-4 yr-5

Beginning Debt 1856.001484.8

0 1113.60 742.40 371.20Interest Accrued 222.72 178.18 133.63 89.09 44.54Loan Repayment Interest Paid 222.72 178.18 133.63 89.09 44.54 Principal Paid 371.20 371.20 371.20 371.20 371.20

Ending Debt 1484.801113.6

0 742.40 371.20 0.00

This along with the calculated Tax liability is used for the Final Net Cash Flow calculations as shown below; however, it may be noted in the detailed calculations in the Excel Sheet that given the nature of the business and Government Tax policies, a Minimum alternative Tax of 19.54 % per annum is applicable as against the usual tax of (30% plus 10% surcharge plus 3% education cess) :

Table-9CASH FLOW STATEMENT- OWNER (DEVELOPER) PERSPECTIVESl. No. Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10A Sources of Funds

Profit After Tax -283.63 -43.45 186.51 239.33 294.19 319.90 366.01 391.32 418.73 448.23Depreciation 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84Land Grant 200.00Equity 795.49 0 0 0 0 0 0 0 0 0Secured Loans 1856 0 0 0 0 0 0 0 0 0Increase in Bank Borrowings 170.97 92.67 101.51 18.16 19.07 20.02 34.45 22.74 23.87 25.06Increase in Current Liabilities 34 19.55 21.42 3.75 3.94 4.13 7.19 4.70 4.93 5.18Un secured loans from Group Companies 115 190 0 0 0 0 0 0 0 0Sub Total 3067.68 438.61 489.30 441.09 497.05 560.89 624.49 635.60 664.38 695.32

B Application of Funds Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10Capital Expenditure 2557.03 0 0 0 0 0 0 0 0 0Land Grant Utilization 200Increase in Current Assets 280.78 161.45 176.89 30.96 32.50 34.13 59.35 38.80 40.74 42.78Repayment of Term Loans 371.20 371.20 371.20 371.20 371.20 0 0 0 0Unsecured Loans Repayment 0 0 0 140 165 0 0 0 0 0Sub Total 3409.01 532.65 548.09 542.16 568.70 34.13 59.35 38.80 40.74 42.78

CCASH FLOWS- Surplus/ (Deficit) -341.33 -94.03 -58.79 -101.06 -71.66 526.76 565.14 596.80 623.64 652.54

The above Cash flows give the NPV and IRR as given below. Clearly the Project is attractive financially

Table-10NPV & IRR Surplus/ (Deficit)

NPV @ 12% 12% 672.09IRR 28.80%

Even the Debt Service Coverage ratio is attractive as shown below:

Table-11DSCR

Sl. No. Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6A Profit after Tax & Depreciation -283.63 -43.45 186.51 239.33 294.19 319.90B Depreciation 179.85 179.85 179.85 179.85 179.85 216.84C Interest on Working Capital 20.52 31.64 43.82 46.00 48.28 50.69D Interest on Term Loan 222.72 178.18 133.63 89.09 44.54 0.00

Sub Total 139.46 346.21 543.82 554.27 566.87 587.43

A Interest on Working Capital 20.52 31.64 43.82 46.00 48.28 50.69B Interest on Term Loan 222.72 178.18 133.63 89.09 44.54 0.00C Repayment of Term Loan 371.20 371.20 371.20 371.20 371.20 0.00

Sub Total 614.44 581.01 548.65 506.28 464.03 50.69DSCR 0.23 0.60 0.99 1.09 1.22 11.59

Average DSCR 2.62

It is felt that the critical factors for the success of this project will be the steady supply of the raw material and excellent processing quality which makes the processed output demandable in the market.

Thus the availability of Raw Material has been assumed, against the total installed capacity, to be 40% in Y-1, 60% in Y-2, 80% from Y3 to Y6 and 82.5% from Y7 to Y10. This keeps the scope of increased production available, within the installed capacity.

The other critical factor is the efficiency of the refining process and the plant which has been kept at 93% to keep the business competitive.

The Sensitivity Analysis Table given below shows the impact of varying these two factors over a wide range, to keep a broader planning in perspective.

Table-12SENSITIVITY ANALYSIS

NPV NPV672 672

Efficiency % 80% -494 Utilization % 40% -696.15

82% -314Collection % at T=3 45% -525.12

84% -135 50% -354.0986% 44 55% -183.0688% 224 60% -12.03

90% 403 65% 159.0092% 582 70% 330.0393% 672 75% 501.0694% 762 80% 672.0996% 941 85% 843.12

NPV & IRR in Banker’s PerspectiveAs per the calculations for Cash Flow from Banker’s Perspective given in the Annexure 4, the following are the NPV and IRR. While the IRR is less as the funding may be needed at a higher rate, the NPR improves as the initial liability of 1856 lakhs is not built up. Sensitivity Analysis is also done herewith:

Table-10NPV & IRR Surplus/ (Deficit)

NPV @ 12% 12% 836.36IRR 24.61%

Table-12SENSITIVITY ANALYSIS

NPV NPV836 836

Efficiency % 80% -330 Utilization % 40% -531.88

82% -150Collection % at T=3 45% -360.85

84% 29 50% -189.8286% 209 55% -18.7988% 388 60% 152.2490% 567 65% 323.2792% 747 70% 494.30

93% 836 75% 665.3394% 926 80% 836.3696% 1,105 85% 1007.39

90% 1178.4295% 1349.45

The Government’s Perspective Cash FlowGovernment is only offering the initial benefit in the form of 3 Acres of land valued at Rs 2 crores and the Tax relief through MAT. The financial cost to the Government of the two is calculated herewith, it may be noticed further that Government actually does not take any cash outflows from the operations and the benefit is only to the society in the form of control of hazardous waste.

(i) The Tax benefit given to the Owner

Sr. No Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10

A Normal Rate of Tax 33.99% 33.99% 33.99%33.99

%33.99

% 33.99% 33.99% 33.99%33.99

%33.99

%

B MAT 19.54% 19.54%19.54

%19.54

%19.54

% 19.54% 19.54% 19.54%19.54

%19.54

%C PBT -60.91 134.72 349.53 378.43 408.81 403.75 497.08 535.35 575.57 617.83D Add: Depr under Companies Act 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84E Sub Total 118.94 314.57 529.38 558.28 588.66 620.59 713.92 752.19 792.41 834.68F Less: Depr under IT Act 325.57 282.53 245.37 213.26 185.51 191.47 166.18 144.33 125.46 109.14G Sub Total -206.63 32.04 284.01 345.02 403.15 429.12 547.74 607.86 666.95 725.54H Exemption u/s 80 IA -206.63 32.04 284.01 345.02 403.15 429.12 547.74 607.86 666.95 725.54I Income chargeable to Tax 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00J Regular IT 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00K MAT -40.37 6.26 55.50 67.42 78.78 83.85 107.03 118.78 130.32 141.77

LIT Payable (Maximum of regular IT & MAT) 0.00 0.00 55.50 67.42 78.78 83.85 107.03 118.78 130.32 141.77

(ii) The Land Value- 200 Lakh

Cash Flow Analysis

Sr. No Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10

Inflow 0 0 0 0 0 0 0 0 0 0

Outflow 200.00 4.63 41.04 49.86 58.26 62.01 79.15 87.84 96.37 104.84

NCF -200.00 -4.63 -41.04 -49.86 -58.26 -62.01 -79.15 -87.84 -96.37 -104.84

12.00%NPV ($447.42)

Economic Return in Country or Economic Point of ViewEconomic Return = Total Benefits- Costs (Investing and Operating) valued at Economic Prices

Consider the Hazards associated with E-Waste like:

(i) Source of Lead Poisoning(ii) Sensory impairment, dermatitis, memory loss and muscle weakness, reduced fertility, liver

damage, kidney and heart diseases, eye and throat irritation are also some of the common associated ailments.

Hence the Governments are under moral obligation to control the damages cost to the public by the E-Waste. However, given the hugely large number of beneficiaries over a long period, it is difficult to quantify this information

On its part, the Government is contribution land amounting to Rs 2 crores. However, this land is underdeveloped and adjoining a large dumping ground. Its future value is also not quantifiable given its poor location close to tanneries large development costs associated.

Other Details- Project Justification

Building of E-Waste Inventory in West Bengal “The e waste inventory is expected to exceed 800,000 tones/ Annum in India by 2012” as per

CPCB. As per the E-waste inventorisation report given by Dr Juergen Bischoff Director of GTZ-ASEM

“the Kolkata Metropolitan Area (KMA) generates 26000 tones of protection E-waste annually out of which only 2,000 tons is being recycled. The report also projected that E-waste generation is likely to likely to increase to 1,44,823 tones by the year 2020

Kolkata is among the top 5 cities generating the major quantity of e–waste and West Bengal is amount top 10 states that contribute at least 70% of the total e–waste being generated in the country.

Kolkata is the hub of commercial activities in the eastern part of the country and hence almost all major companies: & banks have their presence in the city. This is one of the main reasons for the substantial e –waste generation

There is no mush awareness among the consumers in the city regarding the hazards of improper disposal of EEE (Electronics and Electrical Engineering Waste)

The methods used for dismantling and recycling E-waste are very crude and have no norms for occupational or environment safety, for example open burning of wires.

Objectives of the Project To setup a complete integrated E –Waste Recycling facility at KMDA Kolkata with complete end

to end solution for E –waste. To setup the facility with such a capacity to address the E-waste problem at least for the next

25-30 year and make it further expandable To provide safe and secured E-waste destruction services on notified site To provide innovative and pollution free technology for recycling To recycle & extract base metals To provide best environment management system and solutions To ensure customer satisfaction

Role of Operator/ ImplementerThe Project is proposed to be developed on Design, Built, Finance, Operate and Own basis. The role of the Operator would mainly include the following:

To increase the e-waste recovery rate through propagation, collection mechanisms

Setting up an integrated E-waste processing facility in line with SPCB/MoEF /CPCB rules. Planning, designing, financing, developing, operating and maintaining the project. Operator to complete all the civil mechanical electrical & infrastructure work of the facility

including plant & machinery To Provide all the pollution control & safety measures at the site To apply & obtain all the compliances required like SPCB & CPCB registration and other licenses

required for an E-waste recycling facility as per E-waste (Management & Handling Rules, 2010) To arrange a complete set up for collection & transportation with sufficient capacity of E-Waste

complying SPCB/ CPCB & guidelines & E – Waste Rules, 2011 Regular submission of form & necessary information to WBPCB and CPCB

Land Availability for the E-Waste Recycling FacilityThe following three sites have primarily been identified for the purpose of this facility,

1. The existing TSDF land at is the first available option for establishment of the E-Waste Recycling facility. The total area needed for the facility will be 3-4 acres.

2. Site at Calcutta Leather Complex Tanners Association (CLCTA) is being developed for collection and transportation of hazardous waste landfill facility for a period of 10 years, extendible to another 10 years. The site is over 50 Acres and a small portion of 4-5 Acres could be used for the E-Waste Recycling Facility.

3. WB Electronics Development Corporation Ltd. (WEBEL) Electronics Park Sonarpur, could also be considered as a suitable site.

The Project Conception

Selection of landSuitable pieces of land (approx 4-5 acres) have been identified within the limits of KMDA & which are also convenient in all the aspects and which will be developed in future as per further requirements under the guidance of WBPCB. Another piece of land has been identified in Haldia

For the identified land, the Operator will undertake the investment of the project and will develop it as per the CPCB guidelines.

Integration of unorganized sector Currently, a small sector of industry is using, dismantling, disposing or reselling the components of this E-Waste; this is a completely unorganized sector. In order to protect the existing livelihood of this informal sector, the Operator will undertake the following

Converting the existing locations of dismantling E-Waste into E-waste collection centers with all the compliances as per E-waste Rules, 2011

Supporting them in obtaining necessary authorization as approved E-Waste collection centers Providing them necessary training & education Utilizing the experience of informal sector by providing them employment opportunities in

dismantling division of E-Waste Recycling facility

List of E–waste items to be handled List of E–waste Products to be handled in the facility

S No Category s of E-waste

1 IT and telecommunication equipment centralized data processing Mainframes Minicomputers Personal computers Personal computers (CPU with input and output devices ) Laptop (CPU and CPU with input and output devices ) Notebook, Notepad etc Printing including cartridge Copying equipment Electrical and electronic typewriters Pocket and desk calculators

And other products and equipment for the collection, storage, processing, presentation or communication of information by electronic means

Used terminals and systems Facsimile Telex /telephones Pay telephones Cordless telephones Cellular telephones Answering systems

And other products and equipment of transmitting sound images or other information by telecommunications

2 Consumer electrical and electronics: Television sets (including LCD & LED ) Refrigerator Washing Machine Air –conditioners Fans Tubes lights /CFL lights Radios Mobile Phones And any other electric item that are used for house hold Purposes and any

other items as per E-Waste Management & Handling Rules 2010

Sources/ Origin of E-Waste CollectionAs per the experience gained in the field of E-Waste, the following segments will be focused to collect the E-Waste within the state of West Bengal

IT/ Software Companies 25%Electronic Good Manufacturers (Process Waste) 15%TSDF Customers & Other Industries 20%E-Waste Tenders (Online & General) 15%House Holds 5%MOU with Government Organizations 10%Schools/ Colleges/ Hospitals/ Commercial Complexes 10%

TOTAL 100%

IT/ Software Com-panies25%

Electronic Good Manufactureres (Process Waste)

15%TSDF Customers & Other Indus-tries20%

E-Waste Tenders (On-line & General)

15%

House Holds 5%

MOU with Gov-ernment Organiza-

tions10%

Schools/ Colleges/ Hospitals/ Commercial Complexes

10%

E Waste Collection Scenario

IT software companies:

Kolkata being among the leading IT hubs have number of software companies which contributes the major portion of electronic waste. They generate computer laptop printer & other official waste along with the regular E-waste like bulbs cables &wires.

Electronic Equipment manufacturers

The process waste generated from the electronic manufacturing companies will fall under the category of E-waste. Since it will be produced daily regularly tie ups with such units will be concentrated

Industries & TSDF customers:

The pharma automobile steel etc also generate huge quantities of e-waste. The operator in the state will reach to the TSDF customers.

Tenders /Auctions

Most of the public Ltd companies /central government organizations /ports ets are disposing their E –waste though tender / auctions. Tie Ups /Memberships and necessary procedure will be followed for getting E-waste through them

Schools / Colleges /Hospitals / commercial complexes

Schools, hospitals, collages, university etc will have huge quantities of obsolete good /E –waste. So awareness programmes will be designed for the collection and disposal of E-Waste from such organizations

Building awareness Conducting awareness programme’s on E-Waste through self and joint initiatives with WSPCB,

Cll and other organizations Utilization of NGO services Spreading awareness through roaming of specially designed vehicle at all the places of cities at

regular intervals Utilization of existing strong approach to the public through Hazardous Waste & MSW stake

holders Aggressive advertising through paper & electronic media

Organogram

ORGANOGRAM –INTEGTATED EWASTE RECYCLING FACILITY

Project head

HR Head MBD

DGM-Collection

GM/ AGM-Operations

Manager-EHS

Collection Team

Environmental Engineer

Incharge Store

Incharge Dismantling Section

Incharge Recycling line

Incharge –Precious Metal

Helpers TechniciansOperators & Helpers Technicians

Manpower –Employment opportunities The total manpower required for facility will be as follows

Qualified /Professional : 15

Skilled &Unskilled labour : 35

(At least 25 % of the required manpower will be taken present informal sector to give them employment opportunities)

Annexure 1

Project Planning :The Activities for the project implementation has been defined and recorded as given below:

Sr No Activities defined for Project CompletionA DPR-release enquiry & Freeze ConsultantB Receive review and approve DRPC Freeze consultant for detailed Engg.D Prepare / approve drawings for layoutE Prepare Detailed BOQ for each areaF Release enquiry for civil ContractorG Review, negotiate and finalize civil contractorH Release work order for civil and mobilizeI Enhance Recycling Team prepare documentsJ Prepare documents for equipment specificationK Release enquiry for equip / receive quotationsL Prepare techno commercial comparisons for equipM Review and negotiate for equip procurementN Finalize and Place OrdersO Release Enquiry for mechanical, Piping Contractor/ fabricatorP Review/negotiate / finalize contractorQ Mobilize and start fabricating of tanks/ pipingR Receive Equipments, start ErectionS Release enquiry for Electrical contractorT Review negotiate and finalize Electrical ContractorU Mobilize and start Electrical workV Negotiate and finalize sources for input waste material suppliesW Mobilize input waste material at siteX Complete Erection / piping /civil jobsY Trial run and commissioning

Project Duration Calculation

Expected time Te-is the duration of completion of an activity based on three time possibilities-

Pessimistic Time --- tp

Most likely Time --- tl

Optimistic Time --- to

Statistically, Te = (tp+4*tl+to)/6

Critical path network: The Expected time for each of the activities defined above are calculated after assigning the three possible times.

The Critical path Network has been developed based on above activities, their dependence, event start and finish dates and expected time for each. From the network attached the critical path activities which are identified have been tabulated below.

The Critical path has been identified to consist of the following activities:

A-B-C-D-E-F-G-H-I-R-X-Y

Total Duration in Weeks- 60

DPR and Land Acquisition-18 weeks

Implementation Duration- 42 weeks

Project duration: The sum of expected time (Te) of each of the Critical path activities.

Sr No Activities in the Critical Path Expected Time (Te)A. DPR-Release Enquiry and Freeze Consultant 2B. Receive, review and approve DPR 8C. Freeze Consultant for detailed Engineering 8D. Prepare layout and release drawings 2E. Prepare detailed BOQ for each area 4F. Release enquiry for Civil Contractor 1G. Review, negotiate and finalize Civil Contractor 2H. Release work Order for Civil and mobilize 2I. Strengthen Recycling team 2R. Receive Equipments, Start erection 11X. Complete erection piping and civil jobs 16Y. Trial run and commissioning 3

Total- 61 weeks

Summary :

DPR and Engineering Consultant 19 Weeks Total Implementation Phase 42 Weeks Total Project Duration 61 Weeks

Compliance Management The facility will be operated as per the E-waste (Management & Handling) Rules, 2010 and in

standards laid in accordance with the standards laid down in the guidelines published by the central pollution control board from time to time.

Consent for Establishment (CFE) consent for establishing the E-waste facility will be taken from the West Bengal State Pollution Control Board (WBSPCB) to commence the activities.

Consent for operation (CFO) facility will be established as per the terms & condition given in the CFE and they will be strictly complied, Consent for Operating the E-Waste Facility will be taken from the west Bengal state Pollution control board (WBSPCB) will be taken to start the operation activities.

CPCB Registration The facility will be registered with central pollution control board (CPCB) as an authorized e-waste recycler in accordance with the procedures prescribed under Rule-13, The copy of the will be produced to WBPCB.

Make available all records to the central or state pollution control board for inspection

Ensure that residue generated thereof is disposed of in a hazardous waste treatment storage disposal facility.

Ensure filing annual returns in form 3, the west Bengal state pollution control board on or before 30th June following to the financial year to which that returns relate

Membership Certificate: Any industry/company disposing the E-waste should take the membership certificate and details of such industry and its application/source of generation will be taken such details will be submitted to WSPCB.

Six form Manifest : Manifest will be issued to the client at the time of lifting the E-waste the manifest will be maintained as follows:

1) White colour : Forwarded to WBSPCB by Generator2) Light yellow colour : Retained by the generator3) Pink colour : Retained by the E-waste facility4) Dark yellow : Retained by transporter5) Green Colour : Forwarded to WBSPCB after Disposal6) Light Blue : Returned to the generator after disposal

Annexure 2

The Technology

Flow ChartThe technology used in this facility will be a combination of both in-house and imported the complete E-waste recycling line is explained below.

Manual Dismantling

Pre Breaker Crusher

Hammer Mill

Pulverizer

Vibro sleve

Metals Non Metal

Various Type of Plastics

To Plastic Recyclers

Precious Metal Recovery through

Aqua Regia Method (Au, Pt, Pd, Ag)

Metals (Cu, Al, Iron, Steel etc.) will be baled and sent to

Authorized Recycler

Collection & Transportation: After receiving information form client, operator will send one officer to survey the type of e

waste based on the recommendations of the officer, arrangement will be made for collection of E-waste.

In this case, operator will provide an E-waste Help line, in which representatives will be available for any kind of queries related their e-waste and their letup of disposal also any kind of queries related to E-waste can be mailed to the operator. The person who mailed will get a response with a solution.

A Suitable Vehicle will he sent for collection depending on the quantity of E-waste.

The electronic waste generated will be collected through specially closed designed vehicle having a weighing machine and a mini shredder, inside.

The vehicle will be decorated with advertisement for creating awareness for proper E-Waste disposal

The waste collected will be weighed at the client’s premises and weigh receipt will be issued to the customer on the spot along with an acknowledgement

The total quantity & type at waste will be entered into the manifest along with the customer’s signature & stamp.

The type, weight and other details of the e waste collected will be entered in the CPCB pass book along with the client’s seal and signature.

The vehicle used for the transportation will follow the provisions of Motor Vehicles Act.

All the materials will be transported in good packing condition.

The people engaged for the process of collection will be qualities and shall provided all the benefit of labor laws, medical insurance.

The people engaged will be provided with all the necessary safety equipments.

The six copy manifest system will be competed at all the stages.

The safe transportation the E-waste should be ensured.

After reaching the recycling facility the material will be weighed once again for comparison

Storage of E-waste: Adequate storage space will be provided in the premises estimating the maximum quantity. Storage area will be designed to withstand the load of material stocked and any damage of

material. Automatic smoke, Heat detection system should be provided in the sheds. Adequate fire fighting

systems should be provided for the storage area, along with the areas in the facility. Loading and unloading of wastes in storage sheds will be done only under the supervision of the

well trained and experienced staff. Doors and approaches of the storing area will be of suitable sizes for entry of fork lift and

firefighting equipment.

The exhaust of the vehicles used for the purpose of handling, lifting and transportation within the facility such forklifts of trucks will be fitted with the approved type of spark arrester.

All the necessary records of storage shed will be maintained and will be made available for checking.

Smoking will be prohibited in and around the storage areas Good housekeeping will be maintained around the storage areas. The e-waste received from generator shall be stored at earmarked covered shed having

concrete floor and leak proof roof. Wooden or plastic pallets shall be provided to store the waste.

The whole facility will have only one main incoming entrance and one main outgoing exit for security purposes with sufficient CCTV 24 hours recording and card access coverage to ensure that goods are under tight security and monitoring.

Adequate lighting (both natural and electrical) will be provided in the storage shed. Bulbs, Wires, mobiles etc will be stored separately in individual carton boxes and with proper

labeling. It is ensured that no damage is caused on the environment during storage and transportation of

E-waste. The Dust generated due to the movement of the vehicles will be controller by frequent

sprinkling of water. All the sensible items like CRT Monitors, TVs and bulb etc will be stored at ear-marked area. Goods Receive note (GRN) for the gross weight will be issued upon receiving the material at the

warehouse. Material will be then sent to its segregation department under IDO (Internet Debary Order) for

Segregation.

Finished Goods Storage Shed: A separate shad will be provided for storing the finished goods having all the facilities as said

above. The segregated/dismantled/processed E-waste will be stored here for further Recycling/reuse/disposal. The dismantled waste will be stored here as ferrous metals, Non-ferrous metals, plastic, Glass etc separately for disposal.

Manual Dismantling Section: Waste which contains mainly electronic and electrical material and monitors of computer or

TV’s shall be shifted to manual dismantling section in hand trolleys. A set of 8 to 10 no of work stations are proposed with a suction hood for any dust particle

coming out of the dismantling process. A team of experts in dismantling shall be deputed for dismantling purpose with all the required tools and tackles. The tools and tackles shall be identified with the best available brand to ensure optimization in working and to avoid small accidents in the process. The employees at this section shall be provided with all required PPE's i.e. apron safety shoes, gloves dust mask etc. Fire extinguishers shall be provided in the working area.

The team deputed shall dismantle all the waste articles e.g. Computer CPU Box, hard drive, CD ROM, Cables, PCB's etc and monitor into back cover and picture tube. The hard drive, PCB's shall be further dismantled into components attached and naked PCB’s.

The dismantled PCB's will be kept sent to pre breaker crusher for further recycling. Both the products shall be stored in bags for disposal for recovery (metal part) and for making of toys and monuments (non metal part). In case the non-metal part fails to be recycled, the same shall be disposed through (Treatment, Storage and Disposal Facilities) TSDF as this consists of residue with high C.V.

The ferrous material i.e. cabinet, body of monitor etc shall be baled and disposed for recycling. Plastic shall be baled and sold out for recycling to authorized recyclers. The chemical process for recovery of PGM shall be done in the next stage. The waste generated from above process shall be stored at earmarked area with all the

provision by not allowing this waste to be exposed to the environment. The dust generated from the dismantling and crushing will be collected through a set of

cyclones followed by high efficiency bag filter. High efficiency bag house provided for manual dismantling area as well. All the Segregation/ Recycling process carried out at the site is Mechanical Dry process and no

water utilization for this purpose is envisaged at this stage. High efficiency bag house provided for manual dismantling area as well. All the employees working at Mechanical and manual separation of metal shall be equipped

with appropriate PPE's. The generation of noise shall not be significant as the operations do not include high noise

generating equipments at this stage. No chemical fumes or gases are expected since the process is only physical separation and

crushing. Therefore, no stack is envisaged. If there is any discrepancy, it will be discussed with customer at this stage and matter will be

rectified immediately. Upon data destruction completed, official destruction certificate will be issued to customer for

records. Segregated (or) crushed material will be then sent to next stage for suitable recycling process.

Pre-Breaker Crusher:The pre-crusher breaks material like WEEE, washing machines, LCD, TV,s, etc. One of the pre-crusher's advantages is that it does not cut the material, but breaks it which makes sorting afterwards easier to take out for example valuable, reusable materials, such as printed circuit boards. Its functionality is similar to the bag opener and bale breaker. The pre-crusher, however has a special design, such as hardox lining for extra resistance.

Constant material flow after opening or breaking to increase the capacity of a waste sorting line.

Can process high capacities and are multi-purpose machines. Large force per hammer, wear-resistant hammers. Directly driven by a planetary transmission.

The material falls on a drum, which is equipped with hammers that are arranged in a helical manner. The slow rotating drum takes the material along to an adjustable cam on which robust wear-resistant hammers are mounted, where the bags will be torn apart or bales will be broken.

Hammer Mill: The Hammer Mill is an important tool in the security. It is specially designed grinding

rotor – with engineered in such a fashion that it will be longest-lasting most durable components available.

The powerful and turbulent action within the mill renders the electronic components virtually unrecognizable and certainly unusable.

Scrap enters the steel grinding chamber and is attacked by a series of steel hammers that crush, rip and shred the material into small pieces.

At the same time the material is being reduced in size. It is also scraped and scoured rendering any remaining information on the components illegible.

Typical applications include the destruction of printed circuit boards (PCBs), lead frames, ICs and ink wafers.

Computer hard drives are completely destroyed thus eliminating the ability to retrieve any remaining imbedded data. The average hard drive is reduced to pieces that are less than 3/4"(19mm) after passing through the mill. Secondary processes can reduce these pieces to an even finer grind for which the pulverizer will be used.

Pulverizer:Pulverizers are normally used at the end of the shredding process to further reduce materials and improve the separation results between materials. This innovative concept is of dimensional reduction based mainly on the self-reduction of material caused by air whirls and the friction of parts and thus

highly reducing the use and consumption of the cutting parts, which main function is transport and acceleration of particles.

Unlike a shredder which can leave retrievable data, the pulverizing action will completely scour electronic media of data while simultaneously liberating the majority of components for easy separation and recycling independent testing of computer hard drives has proven that no retrievable data can be found after processing.

With the ability to process Computer hard drives at a rate of one per second, this can also process cellular phones, printed circuit boards, semiconductors, CDs and more all without any system reconfiguration along with the following advantages;

reduced consumption and maintenance; wear concentrated on small surfaces that be easily replaced; Easy to use and compact in size.

Vibro Separators: The Vibro Separator segregates the dry material into various particle sizes ranging from1 to 5

sizes with up to 4 screen decks incorporated in one Vibrowest separator. Noise reduction- No noise. Coarse mesh is provided beneath fine meshes to give proper support and reinforcement to the

fine mesh. Special heavy duty imported cylindrical and roller bearings are used in the motor for longer

running life. Motor is double flange mounted.

Winding of motor is done with thicker copper wire to withstand any minute fluctuation in current.

Specially designed round cross section springs are provided for better vibration and operating efficiency.

Arrangement for adjustment of the Top out of balance weight without removing the sieve Deck assembly can be provided if required.

Conveyor Belts:Flat conveyor belts are used to transfer the material from Hammer mill to pulveriser. This reduces man power and improves the work efficiency and reduces the time cost.

Magnetic Separator Conveyor Belts:

Magnetic conveyor belts are used shift the material from vibro separator to vibro Screens. They also separate Ferrous & Non- ferrous materials.

Similarly, they are used to transfer the material form manual dismantling section to Pre- Breaker crusher and Pre-breaker crusher to Hammer Mill.

Vibrating ScreensVibrating Screens are used to separate the Metals and non metals. For achieving the best separation results, the setting of the table inclination, the number of vibrations and the air flow, can be changed according to the needs.

It will also consist of the following:

Base. Fixed frame. Inlet of product. Suction fan (inlet of air). Suction of dust(outlet of air) Safety filter. Outlet heavy product.

Precious Metal Recovery:For the Precious Metal Recovery technology proposed is of AQUA REGIA Process. This system using is an innovation and the technology is proven and used in more than 24 countries worldwide.

This machine can recycle precious metals like gold, silver. For other precious metals of the Platinum Group Metals (PGM) like platinum, palladium and rhodium, the implementation team will develop process with in-house R & D, tie-up with leading consultants and technologists in Precious Metal Recovery in the next couple of years.

The e-waste fractions with precious metals are processed in a Titanium Reactor which is equipped with an agitator it dissolves in Aqua Regia and subsequently neutralized in tanks and washed and passed through a filter mesh of 50-150 micron size. The process is without any smell, or smoke. The process precipitates the precious metals of e-waste scraps. The final waste is Copper Sulphate which can be

disposed for pesticides/fertilizers. Sodium hydroxide (NaOH), missed with water, is used for filtering all fumes and gases at the reactor.

The entire process is Pollution free with no emission and the area remains as very clean.

After the recycling process, the water solution in this system is filtered. The water becomes clean and clear with a PH value of 8. It is suitable to be discharge into any drain or canal without having to install a water treatment plant.

Hydrazinium hydroxide (N2H5OH), Zinc powder and so on are used for purification and separating all kinds of precious metals.

The efficiency of the recovery of precious metals is 98 to 100%. Whatever spillages onto the floor will be fully recovered easily as there is a PVC tray underneath the machinery. The system is so clean that we can have our meals by the side of the machinery. There is no need for spending on additional safety devices or automatic water sprinkle system. Your money saved can be used for the investment of this system and machinery.

The operators of this system will not be in contact with any chemical or solution. All are done by vacuum suction. Same apply to the filling and emptying of all solution in this particular system. The operators just have to wear gloves for protection and avoid spillages of the solution into the eyes.

Cable Recycling:Cables comprises of at least 10 – 15% of the E-waste (both industrial & domestic). Cable stripper for cables ranging from 6mm to 100 mm without hydraulic shear. The cable wire stripper is designed to separate the cooper or aluminum part of electric wires from the sheath, whether this is in plastic, lead or other material of varying thickness. The new cable wire stripper machine, besides being quite versatile, now includes incorporated shears able to cut the electric cable up to 120 mm in diameter, as well as metal frames that are not very large, using a cutting power or approximately 250 BAR, maximum speed and safety guaranteed.

CRT Cutting Machine :The dismantled picture tube shall be sent to CRT cutting m/c which is a closed chamber attached with a hood connected to cyclone and bag house. The CRT shall be put into the control panel connected automatic CRT cutting frame. The CRT shall be cut into two pieces i.e. front glass and funnel glass.

The glass which is free from all coating etc. shall be crushed further and stored bags to be dispatched for recycling. The phosphorous coating in the CRT glass be collected in a tank will be disposed to the TSDF.

Plastic from cabinet, monitor shall be shredded in the shredder and will go granulation in the facility.

Similarly, other materials/metals which can be recycled and reused will be sent to authorized recyclers.

CFL/Tube Lights Recycling/Disposal :The CFL Premium Bulb Eater not only crushes spent fluorescent lamps of any size into 100% recyclable material, but also removes virtually all mercury vapor from the lamps.

The system, which is mounted to a 55 gallon container, can hold up to 1,350 4’ fluorescent lamps and 3,000 compact fluorescent lamps (CFLs).

A three-stage filtering process removes hazardous particulates and gases from bulbs while they are being crushed. The control panel provided along with it, gives additional security and make the operation easy.

The material after recycling will be disposed to TSDF.

Utilities :The following Utilities will be provided with in the facility.

R & D Laboratory DM Plant Security Room Weigh Bridge DG set Rain Water Harvesting Compressor etc.

Common Facilities :

Administrative Building:

An Office Block of area 10 x 10 mts double storied is planned to be constructed with Reception, offices for Operations and a lab. The offices will be furnished with computer with LAN and other functionaries required.

Roads

Well laid out internal roads to facilitate movement and material handling has been planned. Tentative size planned is road width 5 mts. Total length will be approx 500 mts.

Drainage – underground and open

Each of the process plant will be equipped with adequate drains that converge into a storm water drain on either side of the roads. Water with utilized for green belt irrigation.

Water Distribution Network

Water for process requirement along with its distribution network planned with Bore wells and connected piping’s.

Security

A closed Circuit Camera with TV to operate in E waste area, stores, finish goods storage shed and main gate has been planned for surveillance.

Logistics

4 No. of collection vehicles are planned for the E-waste collection with different capacities.

Power

Power will be drawn from the WBSEB grid. The total connected load will 160 KVA DG set will also be provided for Back up.

4.13 List of Equipments :

Sr. No. Description Capacity Qty LoadDetailsKW5

5.5

3

100

a Conveyor 1 Nos

b Fe & Non Fe Separation 1 Nos

55

a Aspiration fan 1 Nos

b Polygonal air filter 1 Nos

c Discharging Cyclone 1 Nos

d Rotating valve 1 Nos

3

a grids 2 Nos

b exits 3 Nos

3.3

a Special Hopper

13

a Cyclone 1 Nos

b Rotating valve 1 Nos

c Polygonal air filter 1 Nos

10

a cyclone 2 Set 5

b Bag Filters 3 Set

a Refining and Recycling M/C 10kg/Batch 1 Nos

(1 batch=6Hrs)

Advantages with Technology: Any type of E-waste except refrigerators, cables can be recycled without manual

dismantling. No water requirement in the recycling process. Little water is required for Precious

Metal Recovery. No loss as entire dust is collected and treated in the precious Metal recovery line.

Recovery could be around 99%. No hazardous waste after process – Copper sulphate is left out after recycling which can

be easily disposed to pesticides, fertilizers plants. Area required is maximum 70 mts x 20 mts for the plant & machinery. The Technology as claimed is a proven one without any loss with maximum output of

different fractions including precious metal. No environmental concern envisaged due to the Recycling Process. The Pre-Crusher and Hammer Mill capacity is more initially to accommodate large sizes

of the E-Wastes without manual dismantling. Capacity easily scalable at any later stage with addition of Pulverisor and separators. The plant will be established in such a fashion that it can be easily further expandable

and can address the e-waste problem in the state for the next 20-25 years. The machineries/recycling line provided in the facility will be continuously updated

depending on the type of material, the facility receives.

The technology provided can be considered as Best Available Innovative Technology for recycling the E-waste.

Annexure 3

Environment management plan

Air pollution-No stack or chimney

-The dust generated due to the movement of vehicles is being controlled by frequent sprinkling of water

-The dust generated from the dismantling and crushing is being collected through a set of cyclones followed by high efficiency bag filter.

-High efficiency bag house provided for manual dismantling area will be provided.

-The dust particles collected in the cyclones/Bag filters will be disposed to CHWTSDF.

Water pollution-The entire process is a complete Dry process and water usage for industrial purpose is not envisaged.

-Water will be used only for domestic purpose (drinking, office use & green belt)

-Domestic waste water will be treated through septic tank followed by soak pit

Noise Pollution-No noise generating equipments

-All the employees working at mechanical and manual separation of metal equipped with appropriate PPE’s.

-CRT cutting done within closed chamber to minimize noise generation.

-Feeding hopper at shredder is enclosed for noise reduction.

-Regular maintenance of shredding and cutting systems is carried out to reduce noise generation.

Hazardous waste disposalSince the main purpose of the E-waste recycling facility is to dispose the Hazardous waste /particles in E-waste in scientific way, top most care will be taken for removal for Hazardous waste, storage and disposal.

-The hazardous collected from cyclones/bag filters etc will be stored in ear marked area within the premises.

-TSDF membership will be taken & then it will be disposed to the TSDF for further treatment.

Disposal of Metals & Non-metals:Plastics contribute one of the major portion of E-waste. The plastics generated will be baled and then sent to WBSPCB/CPCB authorities’ Recyclers only. The metals like Copper, Aluminum, Iron and steel will be baled into cubical and then sent to CPCB authorized recyclers/foundries etc where they; can be used as base metals. The records of their disposal will be maintained at the facility and will be made available for inspection/information to regulating authorities.

Environmental matrix:Type of pollution Quantity Method of disposal Remarks

air Nil nil NilWater 4kl/day(Domestic),

1kl/day(DM plant)Septic tank followed by soak pit

No industrial water usage

Noise 80-85 dB PPE’s Closed ProcessHazardous waste 3Mt/annum TSDF Dust from cyclones,

bag filter, CFL crushing machine, CRT cutting machine, etc,.

Non-Hazardous waste 30 Mt/annum To auth recyclers Packing waste, carton boxes, wood, rubber, etc.

Table Environmental Matrix.

Emergency preparedness & Safety Measurements: An emergency preparedness plan will be prepared, submitted & followed under emergency

conditions Sufficient no’s of fire extinguishers are provided at all the locations Sufficient water points will be provided all along the premises for water sprinkling, connected to

a pump Emergency no’s displayed at various places within premises Regular shop floor safety meetings are being g be conducted An independent HSE manager is appointed, directly reporting to unit head First Aid Facility will be provided On-site Periodical heath checkup for workers Any other as suggested by authorities.

Quality Health & Safety Measurements;Every employee’s health is given top priority and we will follow such procedures to give everyone a healthy life. Operator should preferably have health and environment related awards such as OHSAS 18001:19001, ISO 14001:2004 awards for out outstanding QHSE policies in their sites.

Health measurements:

-Each employee is covered under health insurance policy (Both in-site& Office)

-A medical examination will be conducted for every employee before taking him into the job.

-Regular health check up will be conducted for every 6 months

-Pollution free environment

-Strict adherence to health, safety and environmental policies.

Safety measurements:

-All employees to be covered under Employee Safety insurance (ESI) and other group insurance policies.

-Fire Extinguishers at necessary places in the sites.

-An ambulance (own) to be readily available in every site for safety purpose.

-All employees are strictly instructed to wear helmet, hand gloves, safety shoes, etc,.

-Regular inspection is carried out in sites to check k the safety measurements

-Training to employees on safety measurements

Annexure 4

Detailed Calculations

Table of Pre-Operation Expenses and other calculations in Owner’s view

Table-4 Pre-Operative ExpensesSl no Description Amt (lakhs) %A DPR cost 11.09 3.33B Design/Detailed engg 22.19 6.65C Trial run/3rd party inspection 22.19 6.65D Interest during construction period 167.04 50.10E Administrative expenses during implementation 44.37 13.31F Salaries & Wages 44.37 13.31G Commissioning 22.19 6.65

Total 333.44 100%

Table: Estimation of Working Capital Requirements

Table-5Estimation of working capital requirements

Holdings (In months) Description

Yr-1Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10

2 Raw materials (2 months) 68107.

1149.

9157.

4170.4

7179.0

0187.9

5203.3

3213.4

9224.1

7

1 Finished goods 70.9111.

7156.

4164.

2177.8

1186.7

0196.0

3212.0

7222.6

8233.8

1

2 Receivables141.8

5223.

4312.

8328.

4355.6

2373.4

0392.0

7424.1

5445.3

5467.6

21 salaries & wages 11.18 11.7 12.3 12.9 13.59 14.27 14.98 15.73 16.52 17.341 Utilities 5.07 5.2 5.3 5.4 5.53 5.65 5.78 5.91 6.04 6.18

Sub-total(A)297.0

3459.

1636.

7668.

4723.0

2759.0

2796.8

1861.1

9904.0

8949.1

2

1 sundry creditors 34 53.6 74.9 78.7 85.24 89.50 93.97101.6

6106.7

5112.0

8

Sub-total(B) 34 53.6 74.9 78.7 85.24 89.50 93.97101.6

6106.7

5112.0

8Working capital requirements(A-B)

263.03

405.6

561.8

589.7

637.78

669.52

702.84

759.52

797.34

837.04

35% Working capital margin 92.06141.

9196.

6206.

4223.2

2234.3

3245.9

9265.8

3279.0

7292.9

6

Working capital borrowings170.9

7263.

6365.

2383.

3414.5

6435.1

9456.8

4493.6

9518.2

7544.0

7Interest rate 12% 12% 12% 12% 12% 12% 12% 12% 12% 12%Interest payable 20.52 31.6 43.8 46.0 49.75 52.22 54.82 59.24 62.19 65.29Increase in Working Capital Borrowings

170.97 92.7

101.5 18.2 31.25 20.63 21.66 36.84 24.58 25.81

Table-6 E- Waste refining & recycling product output Installed capacity- 6000 MTASl no Description yr-1 yr-2 yr-3 yr-4 yr-5 yr-6 yr-7 yr-8 yr9 yr-10

Installed capacity 6000 6000 6000 6000 6000 6000 6000 6000 6000 6000 %a C&F electrical 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 20%

Plastic 720 720 720 720 720 720 720 720 720 720 60%Metal-Non-ferrous 480 480 480 480 480 480 480 480 480 480 40%

b Computer& peripherals 2400 2400 2400 2400 2400 2400 2400 2400 2400 2400 40%Plastic 600 600 600 600 600 600 600 600 600 600 25%Metal- Ferrous 528 528 528 528 528 528 528 528 528 528 22%Metal-Non-ferrous 288 288 288 288 288 288 288 288 288 288 12%PCB 168 168 168 168 168 168 168 168 168 168 7%Glass 816 816 816 816 816 816 816 816 816 816 34%

c Mobile phone w/o Battery 300 300 300 300 300 300 300 300 300 300 5%Plastic 210 210 210 210 210 210 210 210 210 210 70%Metal-Non-ferrous 75 75 75 75 75 75 75 75 75 75 25% PCB 15 15 15 15 15 15 15 15 15 15 5%

d CRT monitors/TVs 900 900 900 900 900 900 900 900 900 900 15%Plastic 117 117 117 117 117 117 117 117 117 117 13%Metal-Non-ferrous 225 225 225 225 225 225 225 225 225 225 25%Metal-ferrous 135 135 135 135 135 135 135 135 135 135 15%PCB 63 63 63 63 63 63 63 63 63 63 7%Glass 360 360 360 360 360 360 360 360 360 360 40%

e Laptops, electronics 1200 1200 1200 1200 1200 1200 1200 1200 1200 1200 20%Plastic 276 276 276 276 276 276 276 276 276 276 23%Metal-Non-Ferrous 180 180 180 180 180 180 180 180 180 180 15%Glass 360 360 360 360 360 360 360 360 360 360 30%Metal-Ferrous 300 300 300 300 300 300 300 300 300 300 25%PCB 84 84 84 84 84 84 84 84 84 84 7%

Estimation of Revenues

Sl. no Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr9 Yr-10

DTotal Revenue From 851.11 1340.49 1876.69 1970.52 2133.71 2240.39 2352.41 2544.88

2672.13 2805.73 100000

aElectronic waste refining &recycling 851.11 1340.49 1876.69 1970.52 2133.71 2240.39 2352.41 2544.88

2672.13 2805.73

Percentage

i Plastic 143.07 225.34 315.47 331.25 358.68 376.61 395.44 427.80 449.19 471.64 16.81ii Metal-ferrous 71.65 112.84 157.98 165.88 179.62 188.60 198.03 214.23 224.94 236.19 8.42iii Metal-Non-ferrous 232.13 365.60 511.84 537.43 581.94 611.04 641.59 694.08 728.79 765.23 27.27iv PCB 392.83 618.71 866.19 909.50 984.82 1034.06 1085.77 1174.60 1233.33 1295.00 46.16v Glass 11.43 18.00 25.20 26.46 28.65 30.08 31.59 34.17 35.88 37.67 1.34

Estimation of Expenses

Table-7

Estimation of ExpensesSl no Description yr-1 yr-2 yr-3 yr-4 yr-5 yr-6 yr-7 yr-8 yr9 yr-10

E Operating Expenses 618.46 897.08 1202.06 1260.39 1357.68 1423.72 1493.02 1607.53 1685.95 1768.26

1 Raw Materials 408 642.6 899.64 944.62 1022.85 1073.99 1127.69 1219.96 1280.95 1345.00

E-Waste Purchase 408 642.6 899.64 944.62 1022.85 1073.99 1127.69 1219.96 1280.95 1345.00E-Waste Purchase Quantity 2400 3600 4800 4800 4950 4950 4950 5100 5100 5100

Price Per Ton (17000) 17000 17850 18742.5 19679.62 20663.60 21696.78 22781.62 23920.70 25116.74 26372.57

5% 0 0 0 0 0 0 0 0 0 0

105% 0 0 0 0 0 0 0 0 0 0

6000 0 0 0 0 0 0 0 0 0 0

100000 0 0 0 0 0 0 0 0 0 0yr-1 yr-2 yr-3 yr-4 yr-5 yr-6 yr-7 yr-8 yr-9 yr-10

2 Salaries and Labour- Operations 82.56 86.69 91.02 95.57 100.35 105.37 110.64 116.17 121.98 128.08 5%a Salaries Operations 48 50.4 52.92 55.57 58.34 61.26 64.32 67.54 70.92 74.46 105%i CEO 0 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 75000ii Plant Head 9 9.45 9.92 10.42 10.94 11.49 12.06 12.66 13.30 13.96 25000iii Lab Manager 0 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00

ivWare Houses and Logistic Manager (2) 6 6.3 6.62 6.95 7.29 7.66 8.04 8.44 8.86 9.31 30000

v Plant Executive- 4 14.4 15.12 15.88 16.67 17.50 18.38 19.30 20.26 21.28 22.34 15000vi EHS Officer 0 0 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00vii Lab Chemist 1.8 1.89 1.98 2.08 2.19 2.30 2.41 2.53 2.66 2.79 10000viii Operators- 10 12 12.6 13.23 13.89 14.59 15.32 16.08 16.89 17.73 18.62 10000ix Filters-02 2.4 2.52 2.65 2.78 2.92 3.06 3.22 3.38 3.55 3.72 10000x Electricians-02 2.4 2.52 2.65 2.78 2.92 3.06 3.22 3.38 3.55 3.72 6000b Direct Labour- 48 34.56 36.29 38.10 40.01 42.01 44.11 46.31 48.63 51.06 53.61 105%

3 Consumables 48 75.6 105.84 111.13 120.34 126.35 132.67 143.52 150.70 158.24 2000

Electronic Waste Refining (2000) 48 75.6 105.84 111.13 120.34 126.35 132.67 143.52 150.70 158.24 100000.00

Consumable Cost 2000 2100.00 2205.00 2315.25 2431.012552.5

6 2680.19 2814.202954.9

1 3102.664 Utilities 60.84 62.17 63.53 64.93 66.36 67.83 69.34 70.89 72.47 74.10 100000

a Power total 59.94 61.22 62.54 63.88 65.27 66.68 68.13 69.62 71.14 72.71 5130000b Power Cost 51.3 52.58 53.90 55.24 56.63 58.04 59.49 60.98 62.50 64.07i Connected Power Load-HP 300 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00ii Maximum Demand- kVA 180 180.00 180.00 180.00 180.00 180.00 180.00 180.00 180.00 180.00iii Working Days per Annum- Days 300 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00 300.00iv Power Factor 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95 0.95v Number hours per days- Hours 20 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00 20.00vi Unit Cost- in Rs 5 5.13 5.25 5.38 5.52 5.66 5.80 5.94 6.09 6.24

Cost Escalation is taken2.50

% 102.50% 24c Maximum Demand Charges 8.64 8.64 8.64 8.64 8.64 8.64 8.64 8.64 8.64 8.64 100000

iMaximum Demand Rates- Rs/ KvA 200 200 200 200 200 200 200 200 200 200

d Water 0.90 0.95 0.99 1.04 1.09 1.15 1.21 1.27 1.33 1.40i Operating Days 300 300 300 300 300 300 300 300 300 300ii Operating Hours 20 20 20 20 20 20 20 20 20 20 5%iii Consumption per hour 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5iv Rate per M3 30 31.50 33.08 34.73 36.47 38.29 40.20 42.21 44.32 46.54

5 Other Operational Expenses 19.06 30.02 42.03 44.13 47.79 50.18 52.69 57.00 59.85 62.84 0.50%i Electronic Waste Purchase 2.04 3.21 4.50 4.72 5.11 5.37 5.64 6.10 6.40 6.73 0%ii Others- Purchase Price 0 0 0 0 0 0 0 0 0 0 2%iii Repair and Maintenance 17.02 26.81 37.53 39.41 42.67 44.81 47.05 50.90 53.44 56.11

6 Administrative Expenses 93.19 97.21 101.43 105.86 110.51 115.40 120.53 125.92 131.57 137.51 100000A Salaries- Administrative 51.60 54.18 56.89 59.73 62.72 65.86 69.15 72.61 76.24 80.05 25000i Marketing Manager-10 30 31.50 33.08 34.73 36.47 38.29 40.20 42.21 44.32 46.54 25000ii Asstt HR Manager- 1 3 3.15 3.31 3.47 3.65 3.83 4.02 4.22 4.43 4.65 30000iii Finance Manager- 1 3.6 3.78 3.97 4.17 4.38 4.59 4.82 5.07 5.32 5.58 20000

iv Executives- 04 9.6 10.08 10.58 11.11 11.67 12.25 12.86 13.51 14.18 14.89 15000v Accounts Officer- 01 1.8 1.89 1.98 2.08 2.19 2.30 2.41 2.53 2.66 2.79 15000vi Administrative Officer 1.8 1.89 1.98 2.08 2.19 2.30 2.41 2.53 2.66 2.79 7500vii Office Assistants- 02 1.8 1.89 1.98 2.08 2.19 2.30 2.41 2.53 2.66 2.79 100000

BAdministrative Expenses- Other than Manpower 41.59 43.03 44.54 46.12 47.79 49.54 51.38 53.31 55.34 57.46 10000

i Rent 1.2 1.26 1.32 1.39 1.46 1.53 1.61 1.69 1.77 1.86 5000ii Telephone Expenses 0.6 0.63 0.66 0.69 0.73 0.77 0.80 0.84 0.89 0.93 40000iii Conveyance, Tours and Travels 4.8 5.04 5.29 5.56 5.83 6.13 6.43 6.75 7.09 7.45 106543.1iv Insurance 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 12.79 20000v Security Expenses 2.4 2.52 2.65 2.78 2.92 3.06 3.22 3.38 3.55 3.72 25000vi Rates and Taxes 3 3.15 3.31 3.47 3.65 3.83 4.02 4.22 4.43 4.65 10000vii Printing and Stationary 1.2 1.26 1.32 1.39 1.46 1.53 1.61 1.69 1.77 1.86 10000viii Office Electricity Expenses 1.2 1.26 1.32 1.39 1.46 1.53 1.61 1.69 1.77 1.86 100000ix Business promotion Expenses 12 12.60 13.23 13.89 14.59 15.32 16.08 16.89 17.73 18.62 20000x Other Misc. Expenses 2.4 2.52 2.65 2.78 2.92 3.06 3.22 3.38 3.55 3.72 5%

Note: Cost escalation is taken 5%

Table-9CASH FLOW STATEMENT- OWNER (DEVELOPER) PERSPECTIVESl. No. Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10A Sources of Funds

Profit After Tax -283.63 -43.45 186.51 239.33 294.19 319.90 366.01 391.32 418.73 448.23Depreciation 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84Land Grant 200.00Equity 795.49 0 0 0 0 0 0 0 0 0Secured Loans 1856 0 0 0 0 0 0 0 0 0Increase in Bank Borrowings 170.97 92.67 101.51 18.16 19.07 20.02 34.45 22.74 23.87 25.06Increase in Current Liabilities 34 19.55 21.42 3.75 3.94 4.13 7.19 4.70 4.93 5.18

Un secured loans from Group Companies 115 190 0 0 0 0 0 0 0 0

Sub Total3067.6

8 438.61 489.30 441.09 497.05 560.89 624.49 635.60664.3

8 695.32

B Application of Funds Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10Capital Expenditure 2557.03 0 0 0 0 0 0 0 0 0Land Grant Utilization 200Increase in Current Assets 280.78 161.45 176.89 30.96 32.50 34.13 59.35 38.80 40.74 42.78Repayment of Term Loans 371.20 371.20 371.20 371.20 371.20 0 0 0 0Unsecured Loans Repayment 0 0 0 140 165 0 0 0 0 0

Sub Total3409.0

1 532.65 548.09 542.16 568.70 34.13 59.35 38.80 40.74 42.78

C CASH FLOWS- Surplus/ (Deficit) -341.33 -94.03 -58.79 -101.06 -71.66 526.76 565.14 596.80 623.64 652.54Income Tax Calculation

Sr. No Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10A Normal Rate of Tax 33.99% 33.99% 33.99% 33.99% 33.99% 33.99% 33.99% 33.99% 33.99% 33.99%B MAT 19.54% 19.54% 19.54% 19.54% 19.54% 19.54% 19.54% 19.54% 19.54% 19.54%C PBT -283.63 -43.45 215.90 289.34 364.26 403.75 467.20 503.97 542.62 583.24

DAdd: Depr under companies act 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84

E Sub Total -103.78 136.40 395.75 469.19 544.12 620.59 684.04 720.81 759.46 800.08F Less: Depr under IT Act 325.57 282.53 245.37 213.26 185.51 191.47 166.18 144.33 125.46 109.14G Sub Total -429.35 -146.13 150.38 255.93 358.61 429.12 517.86 576.48 634.00 690.94H Exemption u/s 80 IA -429.35 -146.13 150.38 255.93 358.61 429.12 517.86 576.48 634.00 690.94I Income chargeable to Tax 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00 0.00J Regular IT 0 0 0 0 0.00 0.00 0.00 0.00 0.00 0.00K MAT -83.89 -28.55 29.38 50.01 70.07 83.85 101.19 112.64 123.88 135.01L IT Payable (Maximum of 0 0 29.38 50.01 70.07 83.85 101.19 112.64 123.88 135.01

regular IT & MAT)

Banker’s View Financials- The rows marked in purple colour below will not be considered in Banker’s view

Table-8Calculation of Earnings

Earning Before Interest, Tax and Depreciation 139.46 346.21 573.20 604.28 636.94 671.28 770.36 811.43 854.60 899.96EBITDA (%) 16.39 25.83 30.54 30.67 30.78 30.90 31.78 31.88 31.98 32.08Depreciation 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84Note: Cost escalation is taken 5%Earning before Interest and Tax -40.39 166.36 393.35 424.43 457.09 454.44 553.51 594.59 637.76 683.12Financial Expenses (Interest) 243.24 209.81 177.45 135.08 92.83 50.69 56.43 59.24 62.19 65.29Interest on Working Capital 20.52 31.64 43.82 46.00 48.28 50.69 56.43 59.24 62.19 65.29Interest on Term Loan 222.72 178.18 133.63 89.09 44.54 0.00Earning before Taxation -283.63 -43.45 215.90 289.34 364.26 403.75 497.08 535.35 575.57 617.83Income Tax (MAT) 0.00 0.00 29.38 50.01 70.07 83.85 107.03 118.78 130.32 141.77Earning After Tax -283.63 -43.45 186.51 239.33 294.19 319.90 390.05 416.57 445.24 476.06

-33.32% -3.24% 9.94% 12.15% 14.22% 14.72% 16.09%16.37

% 16.66% 16.97%LOAN SCHEDULENominal Interest Rate 12%Year yr-1 yr-2 yr-3 yr-4 yr-5 yr-6 yr-7 yr-8 yr9 yr-10Beginning Debt 1856.00 1484.80 1113.60 742.40 371.20Interest Accrued 222.72 178.18 133.63 89.09 44.54Loan Repayment Interest Paid 222.72 178.18 133.63 89.09 44.54 Principal Paid 371.20 371.20 371.20 371.20 371.20Ending Debt 1484.80 1113.60 742.40 371.20 0.00

Table-9CASH FLOW STATEMENT- BANKER'S PERSPECTIVESl. No. Description Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10A Sources of Funds

Profit After Tax -60.91 134.72 294.03 311.01 330.03 319.90 366.01 391.32 418.73 448.23Depreciation 179.85 179.85 179.85 179.85 179.85 216.84 216.84 216.84 216.84 216.84Land Grant 200.00Equity 795.49 0 0 0 0 0 0 0 0 0Increase in Bank Borrowings 170.97 92.67 101.51 18.16 19.07 20.02 34.45 22.74 23.87 25.06Increase in Current Liabilities 34 19.55 21.42 3.75 3.94 4.13 7.19 4.70 4.93 5.18Un secured loans from Group Companies 115 190 0 0 0 0 0 0 0 0Sub Total 1434.40 616.79 596.82 512.77 532.89 560.89 624.49 635.60 664.38 695.32

B Application of Funds Yr-1 Yr-2 Yr-3 Yr-4 Yr-5 Yr-6 Yr-7 Yr-8 Yr-9 Yr-10Capital Expenditure 2557.03 0 0 0 0 0 0 0 0 0Land Grant Utilization 200Increase in Current Assets 280.78 161.45 176.89 30.96 32.50 34.13 59.35 38.80 40.74 42.78Unsecured Loans Repayment 0 0 0 140 165 0 0 0 0 0Sub Total 3037.81 161.45 176.89 170.96 197.50 34.13 59.35 38.80 40.74 42.78

C CASH FLOWS- Surplus/ (Deficit) -1603.41 455.34 419.93 341.82 335.38 526.76 565.14 596.80 623.64 652.54