Odisha/ Bhubaneswar: The Waste to Energy Plant in Mancheswar Carriage Repair Workshop at Bhubaneswar was inaugurated by Railway Board Member (Rolling Stock) Shri Rajesh Agarwal in presence of General Manager ECoR Shri Vidya Bhushan, Addl. General Manager Shri Sudhir Kumar and Principal Heads of the Departments of East Coast Railway.
INTRODUCTION TO THE IDEA OF WASTE-TO-ENERGY PLANT -This Waste to Energy Plant, a patented technology called POLYCRACK, is 1st-of-its-kind in Indian Railways and 4th in India. It is the world’s first patented heterogeneous catalytic process that converts multiple feedstocks into hydrocarbon liquid fuels, gas, carbon and water. Earlier, lots of non-ferrous scrap generated from the Carriage Repair Workshop had no efficient method of disposal. As a result, these elements were being disposed of by landfills, which had an environmentally hazardous impact.
WASTE MATERIALS FEEDING -Polycrack Plant can be fed with all types of Plastic, Petroleum sludge, Un segregated MSW (Municipal Solid Waste) with moisture up to 50%, E-Waste, Automobile fluff, Organic waste including bamboo’s, garden waste, etc., and Jathropa fruit and palm bunch.
FEATURES OF POLYCRACK TECHNOLOGY: Polycrack has the following advantages over the conventional approach of treating solid Waste —  • Pre-segregation of waste is not required to reform the waste. Waste, as collected, can be directly fed into Polycrack. • It has a high tolerance to moisture hence drying of waste is not required. • Waste is processed and reformed within 24 hours. • It is an enclosed unit hence the working environment is dust-free. • Excellent air quality surrounding the plant. • Biological decomposition is not allowed as the Waste is treated as it is received. • The footprint of the plant is small hence the area required for installing the plant is less when compared with the conventional method of processing. • All constituents are converted in to valuable energy thereby making it zero Discharge Process. • Gas generated in the process is re-used to provide energy to the system thereby making it self reliant of its energy requirement and also bring down the operating cost. • There is no atmospheric emission during the process unlike other conventional methods except for combustion gases which have pollutants less than the prescribed norms the world over. • It operates around 450 degrees, making it a low-temperature process when compared with other options. • The safe and efficient system with built-in safety features enables an unskilled user to operate the machine with ease. • Low capital cost and low operating cost. • The fully automated system requires minimum manpower.
Its process is a closed-loop system and does not emit any hazardous pollutants into the atmosphere. The combustible, non-condensed gases are re-used for providing energy to the entire system and thus, the only emission comes from the combustion of gaseous fuels. The emissions from the combustion are found to be much less than prescribed environmental norms. This process will produce Energy in the form of Light Diesel Oil which is used to light furnaces. This process has been awarded the Best innovation Gold Medal in 2007 by Lockheed Martin, Dept of Science & Technology, Govt. of India, FICCI; Best Innovation Gold Medal 2007; Best Innovation Gold Medal 2008; Best Innovation Gold Medal 2009; Nominated for Tech-Museum Awards 2008; Frost & Sullivan – Global Innovation and Leadership Award -2011 and IGCW-2011 – Best Green Chemistry Innovation Award. This Waste to Energy Plant has been constructed in 03 months and the target date of commissioning of this Plant was January 2020. About 02 Crores has been spent on the commissioning of this Polycrack Plant. Waste generated from Mancheswar Carriage Repair Workshop, Coaching Depot, and Bhubaneswar Railway Station will be feeder material for this plant. This plant will access 500 KG of waste materials per day. Brief Description of Waste to Energy Plant Total plant installation cost 1.79 crores commissioning 22 Jan 2020. Estimated income from the byproducts: 17.5 Lakhs/annually  Maintenance cost per annum 10.4 Lakh lacs The capacity is: 500kg/ Batch This is the first plant in Indian Railways and 4th in India. The first plant is a small one set up by Infosys at Bangalore in 2011 and the second one is at Moti Bagh, Delhi in 2014 with a capacity of 50kg per day/batch each. The third one set up at Hindalco in 2019 with 50kg capacity per batch.