VEHICLE SCRAP YARD (PV–100%)
[EIRI/EDPR/4400] J.C.: 2598XL
INTRODUCTION
Vehicle recycling is the dismantling of vehicles for spare parts. At the end of their useful life, vehicles have value as a source of spare parts and this has created a vehicle dismantling industry. The industry has various names for its business outlets including wrecking yard, auto dismantling yard, car spare parts supplier, and recently, auto or vehicle recycling. Vehicle recycling has always occurred to some degree but in recent years manufacturers have become involved in the process. A car crusher is often used to reduce the size of the scrapped vehicle for transportation to a steel mill.
The process of recycling a vehicle is extremely complicated as there are many parts to be recycled and many hazardous materials to remove. Briefly, the process begins with incoming vehicles being inventoried for parts. The wheels and tires, battery and catalytic converter are removed. Fluids, such as engine coolant, oil, transmission fluid, air conditioning refrigerant, and gasoline, are drained and removed. Certain high value parts such as electronic modules, alternators, starter motors, infotainment systems - even complete engines or transmissions - may be removed if they are still serviceable and can be profitably sold on; either in "as-is" used condition or to a remanufacturer for restoration. This process of removing higher value parts from the lower value vehicle body shell has traditionally been done by hand. As the process is labour intensive, it is often uneconomical to remove many of the parts.
A technique that is on the rise is the mechanical removal of these higher value parts via machine based vehicle recycling systems (VRS). An excavator or materials handler equipped with a special attachment allows these materials to be removed quickly and efficiently. Increasing the amount of material that is recycled and increasing the value the vehicle dismantler receives from an end-of-life vehicle (ELV).
After all of the parts and products inside are removed, the remaining shell of the vehicle is sometimes subject to further processing, which includes removal of the air conditioner evaporator and heater core, and wiring harnesses. The remaining shell is then crushed flat, or cubed, to facilitate economical transportation in bulk to an industrial shredder or hammer mill, where the vehicles are further reduced to fist-sized chunks of metal. Glass, plastic and rubber are removed from the mix, and the metal is sold by multiple tons to steel mills for recycling.
Recycling steel saves energy and natural resources. The steel industry saves enough energy to power about 18 million households for a year, on a yearly basis. Recycling metal also uses about 74 percent less energy than making metal. Thus, recyclers of end-of-life vehicles save an estimated 85 million barrels of oil annually that would have been used in the manufacturing of other parts. Likewise, car recycling keeps 11 million tons of steel and 800,000 non-ferrous metals out of landfills and back in consumer use.
COST ESTIMATION
Plant Capacity 10 MT/Day
Land & Building (4940 sq.mt.) Rs. 5.91 Cr
Plant & Machinery Rs. 4.30 Cr
Working Capital for 3 Months Rs. 9.51 Cr
Total Capital Investment Rs. 20.15 Cr
Rate of Return 98%
Break Even Point 23%
CONTENTS
INTRODUCTION
VEHICLE SCRAPPAGE POLICY
SOME INCENTIVES FOR SCRAPPING OLD VEHICLES AND BUYING NEW ONES ARE AS FOLLOWS:
CHALLENGES
RTO RULES FOR SELLING OF CARS AS SCRAP IN INDIA
SOME POINTS TO NOTE ABOUT THE SCRAPPING PROCESS ARE AS FOLLOWS:
VALUATION OF OLD CARS:
CHALLENGES FOR INDIAN ECONOMY
IMPORTANT DEFINITION REGARDING SCRAPING OF VEHICLE
POWERS AND OBLIGATIONS OF RVSF
CONDITIONS OF ELIGIBILITY OF RVSF
ELIGIBILITY CONDITIONS
REGISTRATION OF RVSF
CRITERIA FOR SCRAPPING OF VEHICLE
CERTIFICATE OF VEHICLE SCRAPPING
APPLICABLE RULES/ACTS
BENEFITS OF SCRAPING POLICY
DISINCENTIVES FOR KEEPING OLD VEHICLES:
USES AND APPLICATION
ENVIRONMENTAL BENEFITS
WILDLIFE PROTECTION
REUSE OF VEHICLE PARTS
CONSERVATION OF ENERGY AND RESOURCES
MAKE SPACE
BIS SPECIFICATION
FOR MORE INFORMATION CONTACT AT:
OPERATION OF VEHICLE SCRAP YARD
HANDLING:
THE COLLECTION/DISMANTLING/DE-POLLUTING/SHREDDING FACILITY SHALL TAKE ALL THE STEPS TO:
STORAGE:
PRE-CONDITIONS FOR STORING ELVS
AN ELV SHALL NOT BE STORED WITHOUT REMOVING THE BATTERY, ADDITIONAL SALIENT POINTS ON STORAGE OF ELVS:
TRANSPORTATION
DE-POLLUTION PROCESS
DE-POLLUTION SEQUENCE
A. BEFORE LIFTING VEHICLE
B. LIFT THE VEHICLE ON DE-POLLUTION FRAME OR LIFTING DEVICE
DRAIN FUEL TANK
C. REMOVE VEHICLE FROM DE-POLLUTION FRAME OR LIFTING DEVICE
FOR LIQUID HAZARDOUS SUBSTANCES
A. WASTE OILS
B. TRANSMISSION OIL
C. BRAKE FLUIDS & CLEANERS
D. FUEL AND FUEL FILTERS
E. COOLANT (ANTIFREEZE)
FOR SOLID HAZARDOUS SUBSTANCES
A. LEAD ACID BATTERIES
B. AIR FILTER
G. RUBBER PARTS
H. GLASS PARTS
I. ELECTRONIC PARTS
J. REFRIGERANT GASES
K. AIR BAGS
L. CATALYST
DISMANTLING & SEGREGATION
IN THE CASE OF M1 CATEGORY VEHICLES:
IN THE CASE OF LL AND L2 CATEGORY VEHICLES:
SHREDDING AND SEPARATION AND PROCESSING OF RESIDUES
TECHNOLOGIES FOR THE ELV RECYCLING PROCESS
THE TECHNOLOGIES REQUIRED IN THE RECYCLING PROCESS OF ELVS ARE PRESENTED BELOW:
TECHNOLOGIES FOR PROCESSING RESIDUES - SEGREGATION OF NON-FERROUS METAL FRACTIONS:
OTHER TECHNOLOGIES
TECHNOLOGIES FOR TREATMENT OF SEGREGATED MATERIALS
INPUT/OUTPUT DATA
PROCESS FLOW CHART
RECOMMENDED TOOLS & EQUIPMENT FOR PRE-TREATMENTS:
UTILITIES PER MONTH (ESTIMATED)
SUPPLIERS OF PLANT AND MACHINERY
SUPPLIERS FOR VEHICLE RECYCLING PLANT
SUPPLIERS OF DG SETS
SUPPLIERS OF EOT CRANE
SUPPLIERS OF POWER TRANSFORMERS
SUPPLIERS OF ELECTRICAL PANEL
SUPPLIERS OF AIR POLLUTION CONTROL EQUIPMENTS
SUPPLIERS OF AIR COMPRESSORS
SUPPLIERS OF PLATFORM WEIGHING MACHINE
SUPPLIERS OF MATERIAL HANDLING EQUIPMENTS
SUPPLIERS OF FIRE FIGHTING EQUIPMENTS
PROJECT CYCLE
PRINCIPLES OF PLANT LAYOUT
MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
PLANT LOCATION FACTORS
PRIMARY FACTORS
RAW-MATERIAL SUPPLY:
MARKETS:
POWER AND FUEL SUPPLY:
WATER SUPPLY:
CLIMATE:
TRANSPORTATION:
WASTE DISPOSAL:
LABOR:
REGULATORY LAWS:
TAXES:
SITE CHARACTERISTICS:
COMMUNITY FACTORS:
FLOOD AND FIRE CONTROL:
GENERATION & MANAGEMENT OF WASTES/GREEN BELT
WASTE WATER (ESTIMATED)
WASTE (ESTIMATED)
HEALTH SAFETY AND ENVIRONMENT
ANTICIPATED ENVIRONMENTAL IMPACTS
CONSTRUCTION PHASE
OPERATION PHASE
MITIGATION MEASURES (PROPOSED)
HSE REQUIREMENT
PROPOSED IMPLEMENTATION SCHEDULE
PROJECT FINANCIALS
BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
PRELIMINARY PLANT LAYOUT
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)
