10.1 EMISSION STANDARDS/GUIDELINES NOTIFIED/REVISED

Emission limits for New Diesel Engines (upto 800 KW) for generator sets applications notied in Govt. of India Gazette GSR 371(E), May 17, 2002 at Serial No. 95, was amended vide Gazette Notification GSR 520(E), July 1, 2003. This amendment specified the emission limits for different ratings and presented in Table 10.1.

Table 10.1 Amended Emission Limits for Different Ratings of Diesel Engines

Noise Limits

The date of implementation of the noise limits for diesel generator sets notified vide GSR 371 (E), May 17, 2002, viz 1.7.2003 was extended by one year vide GSR 520, July 1, 2003 to 1.7.2004.

The regulation requires mandatory provision of acoustic enclosure, at the manufacturing stage, for all new generator sets run on diesel (upto 1000 KVA), effective from July 1, 2004. The maximum permissible sound pressure level for new generator sets (upto 1000 KVA) run on diesel according to this new regulation shall be 75 dB(A) at 1 m from the enclosure surface.

For diesel generator providing an acoustic enclosure or acoustic treatment of the DG room shall control sets, not covered by above noise from the DG set. Such acoustic enclosures/acoustically treated rooms, shall be designed for minimum 25 dB(A) insertion loss or for meeting the ambient noise standards, whichever is on the higher side.

Collection of Bank Guarantees and Affidavits

Bank Guarantees and Affidavits from diesel engine/genset manufacturers were collected as per the provisions of GSR 520(E), July 1, 2003 and GSR 92 (E), dated January 29, 2004. The bank guarantees and affidavits were required to be submitted by the manufacturers and importers desiring to obtain the benefits of extension of time by six months to one year, for emission limits of the diesel engines for genset application.

Compliance Procedure for Emission Limits for Generator Sets

Compliance procedure for emission limits for new diesel engines (upto 800 KW) for genset applications has been finalised and circulated among the certification agencies.

10.2 VEHICULAR POLLUTION CONTROL

Vehicular emissions are an important source of air pollution in urban centres of the country. Therefore, controlling vehicular emissions remained a major thrust area during the year. The focus was not only on the National Capital Region but has been on the entire country. Use of clean fuels like CNG, LPG, biofuels etc, for vehicles increased gradually. Following measures on vehicular pollution control were taken and as a result improvement in air quality was observed at various urban areas.

Vehicular Emission Norms

» From 1.4.2003 only Bharat Stage-II emission norms compliant new vehicles, except 2 & 3 wheelers, were registered in the cities of Hyderabad, Secunderabad, Bangalore, Ahemdabad, Kanpur, Agra & Surat
.
»From 1.6.2003, Bharat (Trem) Stage-II emission compliant new agriculture tractors and construction vehicles only were registered throughout the country.

» Emission norms for diesel vehicles fitted with LPG engine were made effective from 1-5-2003.

» Bharat stage-II norms for 2- & 3-wheelers were notified during September 2003.

» Draft emission norms for in-use vehicles effective from 1-10-2004 were notified during July 2003.

» For implementation of Bharat Stage-II emission norms to be effective from 1-3-2004 for all categories of vehicles in Sholapur and Lucknow were also notified during December 2003 .

Fuel Quality

» Fuel quality compatible with above emission norms were ensured in corresponding cities.

Alternate Fuel

» Gasoline with 5 % ethanol will be supplied in sugar producing States and Union Territories of Maharastra, Andhra Pradesh, Goa, Gujarat, Haryana , Karnataka, Tamil Nadu, Uttar Pradesh, Daman & Diu, Dadara & Nagar Haveli, Chandigarh & Pondicherry from January 2003.

» BioDiesel Specification has been finalized. Some trial run on biodiesel has also been completed.

» Use of Gaseous fuel is increasing. There are 115 CNG stations in Delhi (Table 10.2), 57 CNG and 15 LPG stations in Mumbai, 5 LPG stations in Chennai, 7 LPG stations in Hyderabad & 6 LPG stations in Bangalore. Action plan has been prepared to increase the LPG filling stations in Chennai, Hyderabad and Bangalore.

Table 10.2 CNG Stations and Consumption in Delhi

Other measures

» In Delhi number of flyovers have been constructed to ease traffic congestion and to reduce emissions from vehicles during idling at traffic lights. Delhi metro railway line has been extended to Trinagar from Tis- Hazari as Mass Transport Systems for catering more people.

» Interstate trucks which are not destined to Delhi are not allowed to ply within city limits.

Action Plan for Controlling Air Pollution

» Hon'ble Supreme Court directed Union of India and State Governments to prepare action plans for reducing RSPM level for cities of Kanpur, Ahemdabad, Sholapur, Bangalore, Lucknow, Chennai, Hyderabad, Mumbai and Kolkata. Hon'ble Supreme Court also directed respective State Pollution Control Boards to place the proposed action plans before EPCA (Environmental Pollution Control Authority).

» The action plans for the above cities have been received. MoEF, CPCB & EPCA are reviewing these action plans. Some of the actions proposed in the action plan have already been initiated during year 2003.
» Hon'ble Supreme had identified nine critically polluted cities namely Kanpur, Lucknow, Varanasi, Agra, Jharia, Patna, Jodhpur, Pune & Faridabad. The action plans for these cities have been received and being reviewed. Some of the actions proposed in the action plan have already been initiated during year 2003.

» The Hon'ble court has also asked the State Pollution Control Boards to prepare action plan and scheme for compulsory switch over to CNG/LPG as automotive fuels in the cities those are equally or more polluted than Delhi. Later, CPCB identified these cities as Ahemdabad, Kanpur, Kolkata & Pune. The action plans along with scheme for compulsory switch over to CNG/LPG in these cities have been received and reviewed by CPCB.

Volatile Organic Compounds in Delhi & Mumbai

The project on "Inventory of emissions of Volatile organic compounds (VOCs) in urban air of Delhi & Mumbai" is being conducted by CPCB through National Environmental Engineering Research Institute (NEERI), Mumbai Zonal Office. The objectives of the study are proposed to be achieved in two phase. Phase -I comprises of identification and measurement of VOCs in ambient air, whereas phase-II involves inventorisation of sources of VOCs in industrial estates. The study on phase-I has been completed during year 2003. More than 50 VOC compounds have been identified in Delhi & Mumbai. The results of source apportionment using CMB-8 reveals that in Mumbai the gasoline evaporative emissions are the dominant source of VOCs , while in Delhi vehicular exhaust are the dominant sources.

Evaporative Emissions of Hydrocarbons from various sources

A project on Inventory of evaporative emissions of Hydrocarbons from various sources in Delhi, Kolkata, Mumbai and Chennai has been taken up by CPCB. National Environmental Engineering Research Institute , Mumbai Zonal Lab will conduct the study. The study has commenced during January 2004.

Vehicular Emissions Inventory & Source Apportionment

As per MOU between MoEF & US-EPA a study on vehicular emissions inventory & source apportionment for the city of Pune have been planned.

a. International Vehicle Emission Model

Vehicle emission study was conducted by USEPA and James Lent University of California River side during March 2003. The study was designed to estimate the technology distribution of vehicles operating in Pune, measuring driving pattern and estimating time and number of vehicle engine start.

b. Training cum Demonstration Project

Training on air pollution monitoring , source apportionment and emission inventory was being conducted at Pune during September, 2003. SPCB's, CPCB, Research Institutes, Oil companies, Automobile manufacturers, universities and Municipal Corporations have attended the programme.

Project on "Auto- Rickshaw LPG conversion Demonstration in Bangalore & Kolkata"

Environment Canada is implementing Canada-India Environmental Institutional Strengthening Project with the Ministry of Environment and Forests in India. CPCB is implementing Air Quality Sub-component of the Project. The project on LPG Conversion of Autorickshaw has been initiated as sub-component of the Air emissions and Monitoring & Control component which includes transfer of Canadian technical expertise for conversion of autorickshaws to LPG in Bagalore and Kolkata city. In order to supervise the activities of the project , CPCB has constituted technical advisory committee under the chairmanship of Dr. H.B Mathur. The autorickshaws required for testing in Canada has been shipped to Environment Technology Centre, Canada, from India.

Air quality Monitoring and Source apportionment studies in metro cities

The project is sponsored by oil companies and will be executed by NEERI, Nagpur and ARAI, Pune. The selected cities are Delhi, Kolkata, Mumbai, Chennai, Bangalore and Pune. CPCB is the member of the technical and steering committee of this project and will be actively involved in the study.

Expert Committee to Evaluate Policy and Guidelines to Prevent, Monitor and Control Fine Particulate Matter (FPM) in the Ambient Air

An expert committee to evaluate policy & guidelines to prevent , monitor and control fine particulate matter (FPM) in the ambient air has been constituted under the chairmanship of Prof.J.M.Dave. In accordance with the recommendations of the expert committee four Sub-committees have been constituted on following topics:

· Prevention control & air quality standards of FPM.
· Monitoring of FPM
· Health effects of FPM.
· Source apportionment studies of FPM

The sub- committees have submitted draft reports which were circulated to the members of the principal committee.

Committees related to vehicular pollution control in which CPCB has taken active participation

· Working group on adulteration of petroleum products constituted by Bureau of Indian Standards (BIS).
· Environmental Pollution Control Authority for NCR constituted by MoEF.
· Standing committee on emissions constituted by MoRTH.
· Petroleum products sectional committee constituted by BIS.
· The expert committee on Auto fuel Policy constituted by MoPNG.
· Expert committee to evaluate policy & guidelines to prevent, monitor and control fine particulate (FPM) in the ambient air.

National Report

» Report of the Expert Committee on Auto Fuel Policy was accepted by the Union cabinet during October 2003. The road map for controlling vehicular pollution from all categories of new vehicles is as follows. Apart from road map for new vehicles , the road map for in-use vehicles has also been recommended (Table 10.3).

Table 10.3 Road Map of in-use Vehicles as per Auto Fuel Policy

» Report of the Expert Committee on Development of Bio-fuels was submitted during July 2003. The committee recommended 5% bio-fuel blended diesel in the country by the year 2005 and 20% bio-fuel blended diesel by the year 2011-12.

10.3 INDUSTRIAL EMISSION STANDARDS

Emission Standards, Siting Criteria and Good Practices for Hot Mix Plants

There are more than 1000 hot mix plants of different categories operating in different parts of the country. Most of the plants are of stationary and drum- continuous type. The rated production capacity varies from 6-10 t/hr to 10-120 t/hr. The locations of these plants keep on changing. Burning of fuel, feeding of aggregate, direct heating of bitumen create environmental hazards especially `air pollution' due to dust and volatile organic compounds such as BTX, PAH, PCB's and VOCs.

Realizing the need to strike a balance between environment and economic development, the Central Pollution Control Board, with the help of Central Building Research Institute, Roorkee decided to prepare Comprehensive Industry Document (COINDS) on hot mix Plants in an effort to minimize the adverse environmental impacts by regulating emissions from these plants. Proposed emission standards, siting criteria and good practices have been circulated to manufacturers and other stakeholders for their comments and suggestions.

Review of Effluent Standards and Development of Emission Standards for Basic Organic Chemicals Manufacturing Industry

With respect to basic organic chemicals, the effluent standards have been developed and there is a need to develop emission standards and guidelines for hazardous waste management. It is also required to review the effluent standards in view of change in BPT. Therefore, the Central Board took up a study to review the existing effluent standards considering best practicable technology including waste minimisation techniques; to develop emission standards considering techno-economic feasibility within the domain of health and environment and also to develop guidelines for hazardous waste management.

Development of Emission Standards for Wheat Processing and Flour Mills, Pulse Grinding and Milling, Dry Rice Grinding and Rice Mills

There are large number of industrial units spread across the country engaged in pulse milling, dry rice and besan grinding, wheat processing, flour mills and rice mills. These units mostly use conventional production technologies and generate substantial pollution of air, water, noise, etc.

The objective of the study is the assessment of problem of noise, emissions and effluents, best available cost-effective technology to control pollution and to develop standards for noise, emissions and effluents including storm water disposal for wheat flour mills, pulses making mills, dry rice, pulses grinding mills and emission standards for rice mills. Study has been completed based on which recommendations are drawn.

Development of Environmental Standards, Stack Height Regulations and Good Practices for Producer Gas Plants and Biomass Gasifiers

Producer gas obtained by the process of gasification, can be employed in thermal application or for mechanical/electrical power generation. Like any other gaseous fuel, producer gas affords much better control over power levels when compared to solid fuel. This also paves the way for more efficient and cleaner operation.

Producer gas plants generate various pollutants and there are no pollution control norms for these plants presently. During the gas manufacturing, tars are generated and discharged into the environment, which are "non-aqueous" in nature. Coal tar is always co-mingled with other lighter oils, which are also waste products from producer gas plants. There are significant gaseous emissions containing certain volatile organic compounds along with other gaseous pollutants such as CO, NOx and SO2.

The producer gas plants and biomass gasifiers are energy efficient and environment friendly, but the local environmental benefits (such as reduction in particulate emission, CO, SO2 and NOx) have not been studied. The Central Pollution Control Board therefore, decided to study the environmental parameters systematically for producer gas plants and biomass gasifiers and recommended techno-economically feasible environmental standards following BATNEEC (best available technology not entailing excessive costs) and strategies for better environmental conditions in association with The Energy and Resources Institute (TERI), New Delhi.

Emission Standards, Stack Height Regulations and Siting Criteria for the Vertical Shaft Brick Kiln (VSBK)

The existing emission standards on brick kilns pertains to only annular kilns (BTKs and high draft Kilns) and were made before VSBK emerged as a potential technology for firing bricks in the country. With this background it has been considered to formulate the emission standards, Stack height regulations and Siting Criteria for Vertical Shaft Brick Kilns.

Vertical Shaft Brick Kiln (VSBK) is an energy efficient technology for firing clay bricks. It is particularly suited to the needs of brick production in developing countries - which is small scale and decentralized type i.e. clamps. Presently more than 30 VSBKs are in operation in Madhya Pradesh, Maharashtra, Kerala, Orissa and Uttar Pradesh. Several design modifications have been incorporated under the India Brick Project (IBP) in the original Chinese VSBK design to improve its performance in energy, environment and product quality aspects.

The main advantages claimed for VSBK technology are:

· highest energy efficiency among all types of kilns;
· lower emissions;
· small area requirement; and
· uniformity in the quality of the fired bricks

A study entitled "Development of Emission Standards and Stack Height Regulation for Vertical Shaft Brick Kilns vis-a-vis Pollution Control Measures" has been undertaken by Central Pollution Control Board in co-operation with TERI, New Delhi. The study has been completed and Draft Emission Standards, Guidelines and Siting Criteria have been evolved. Recommendations for emission standards and stack height are presented in Table 10.4.

Table 10.4 Recommended Emission Standards and Stack Height Regulations for VSBK

Performance Evaluation of Air Pollution Control System-Modification thereon and Review of Emission Standards for Bull's Trench Brick Kilns

India is the second largest producer of bricks after China. Brick is the common building material used in almost all parts of India. During the ninth five-year plan period, the annual bricks demand has been estimated as 170 million. Brick making is a traditional industry but has emerged as an important activity. There are around 150,000 kilns engaged in brick production in the country. Brick making is energy intensive process, with specific energy consumption varying from 1.2 to 1.75 MJ/kg of fired bricks for BTKs and 1.5 to 3.0 MJ/kg for clamp kilns. Coal is the major fuel used for firing bricks. It is estimated that brick industry consumes over 20 million tonnes of coal annually.

Some of the technological development in brick kilns firing, such as fixed chimney kilns, high draught kilns and vertical shaft brick kilns have resulted in reduction in pollution and increase in energy efficiency. The Aligarh Muslim University (AMU), The Central Building Research Institute (CBRI), Roorkee, The Punjab State Council for Science and Technology (PSCS&T), Chandigarh, etc. have designed fixed chimney and air pollution control device(s) basically to trap particulate matter from Bull Trench Kilns.

Of late, apart from coal, various fuels including vacuum residue/distillation cake of refinery, hazardous organic wastes, rejected coal of coal-washries and agriculture residue are being used as fuel at brick kiln industries. A Meeting of stakeholders, CPCB officials and TERI has been held to decide the monitoring protocol. Questionnaire survey has been prepared and circulated to all SPCBs and PCCs for collection of information.

10.4 COMPREHENSIVE INDUSTRY DOCUMENTS (COINDS)

Comprehensive Industry Document: Development of Emission Standards and Good Practices for Arc Furnaces and Induction Furnaces in SSI sector

The electric furnace plays an important role in the recovery and recycling of waste iron resources. In areas where an abundant supply of scrap and electric power are available, the proportion of steelmaking via the electric furnace route is relatively high, because both energy consumption and equipment investment are substantially smaller in the integrated route using a BF and BOF process to produce steel from ore.

Electric furnaces are classified as arc furnaces or induction furnaces. The arc furnace is used far more extensively for steelmaking, because its capacity is large and production efficiency is high. In addition to melting, both oxidation refining and reduction refining are possible in the arc furnace. The arc furnace is used for decarburization, dephosphorization, and dehydrogenation, and the induction furnace for desulfurization and deoxidation. The arc furnace is also capable of melting higher fraction of alloy scraps.

With the rapid industrialization, the consumption of steel continues to grow and as a result scarp generation will also continue to increase. Increased scrap generation in India and import from foreign countries means increased use of such furnaces, which will require adequate emission control and collection methods.

The Project is undertaken in association with Punjab State Council for Science & Technology (PSCS&T), Chandigarh with the objectives

· To study and characterize fumes and emissions from electric arc furnace, induction furnace and inbuilt facilities (argon oxygen decarborizer, turning furnaces, pre-heater, etc.),

· To study fugitive emissions during raw material handling, additives handling and tilting of pot /crucible for molten metal testing or during transferring,

· To study noise pollution, minimization of fugitive emission and noise pollution, issues concerning generation, handling and disposal of slag (solid waste), suitable cost effective modifications for better performance, effluent handling for ETPs (i.e. provided for air pollution control system); and

· To evolve suitable environmental standards (emission, noise, effluent and solid waste) and good practice for electric arc and induction furnaces including inbuilt facilities.

Comprehensive Industry Document (COINDS) and Evolving Environmental Standards and Good Practices for Cashew Seed Processing Industry.

Cashew nut processing industry is one of the promising sector producing valuable commodity exported to Gulf and European countries. The industry is categorized as small-scale. There are about 300 units scattered in Nagercoil district, Tamilnadu. The density of these industries is also high at Cheerla and Palasa in Andhra Pradesh; Kollam, Pathanamthitta, Trivandrum districts in Kerala and in Goa. Even though there is cashew seeds cultivation in these areas, most of the production demand is met by importing cashew seeds from South Africa. There are two commonly followed methods of Cashew nut processing, viz roasting process and cooling process. In cooling process vegetable oil is extracted from the shells of the seeds, which has market in paint industry. Due to limited market demand for the oil, most of the industries are following roasting process.

The cashew seeds roasting process releases thick smoke from the roasting drum through the stack. The smoke has irritating odour and source of public nuisance for the neighbourhood. The process also discharges wastewater from the quenching operation of the roasted seeds. The industries are mostly in small scale and cottage sector with no conventional and techno-economically cost-effective pollution abatement systems. Though pollution load from individual unit is relatively low, but the magnitude of pollution problem from the cluster of units is substantial.

The environmental standards for cashew seed processing industry are yet to be developed. The Central Pollution Control Board is developing 'Comprehensive Industry Document on Cashewseed Processing Industry to evolve Environmental Standards and Cost Effective Good Practices' with the active co-operation of AIP- NPC, Chennai.

Comprehensive Industry Document (COINDS) on Bullion industry

Bullion refining is an important industry from economic view point. Importance of this industry is very well illustrated by the fact that India invests huge amounts in purchase of gold and silver as the demand for these metals is increasing. The operations and process involved in bullion refining industry are energy and water intensive, also generate emissions, effluents and solid waste in the environment. Environmental standards need to be developed to regulate these discharges. Also to suggest in-plant pollution control & resource conservation measures and other alternative pollution control, waste-handling measures including that of the treatment plants so as to meet the discharge standards. Services of M/s ENC Consulting Engineers have been hired to undertaken preparation of 'Comprehensive Industry Document for Bullion Industry'.

Comprehensive Industry Document on Electroplating Industry

The study has been undertaken to prepare a comprehensive industry document (COINDS) on electroplating industry. The information such as number of industries, their location, environmental problems and available pollution control technologies has been collected. The draft report includes detailed information on Electroplating Industry, processes & chemicals used, Environmental effects, In depth studies of 20 electroplating units, Recovery of metals, waste minimization & best available technology option, review of existing environmental standards comparison with environmental standards in other countries and suggestions for revision of effluent & emission standards emission.

Comprehensive Industry Document (COINDS) on Stone Crushers

Final report of the project including proposed environmental standards, code of practice for pollution prevention and the shifting criteria suggested in the report was placed before Peer & Core Committee for consideration. The matter was discussed and was decided that a sub-committee comprising Prof. J.M.Dave and Shri N.S.Tiwana may examine the issue along with officials of CPCB, SPCB and consultants.

Comprehensive Industry Document (COINDS) on Soaps & Detergents

Soaps and detergents are extensively used household products, which are indispensable to health, hygiene and cleanliness. So far, no industry specific emission / effluent standards have been stipulated by CPCB for the soaps & detergents manufacturing industry. It was decided to undertake the task of preparation of COINDS to provide necessary information on the status of Soaps & detergents industry in the country. CPCB entered into a 'Memorandum of Understanding' with Harcourt Butler Technological Institute (HBTI), Kanpur for the preparation of the document, which will include the minimal national standards and other relevant information needed for the prevention of environmental pollution from this industrial sector. The studies are in progress.

Comprehensive Industry Document for Sugar Mills (Revised)

The sugar industry is one of the major agro-based industries. The number of sugar factories in operation was around 139 in 1950-51 producing 11 lakh tonnes of sugar, while the total number of sugar factories have rose to 525 and the sugar processed was around 186 lakh tonnes. Though India ranks first in sugar production; per capita availability of sugar is very low as compared to other sugar producing countries. The industry has its base mostly in rural areas and playing important role in country's economy in the rural sector. The farmers find that sugarcane crop is highly remunerative and also robust which can sustain the natural calamities. Thus, it is very much essential to protect the interests of this industry in all respects. It is very important to address the industry and impress that the socio-economic and political considerations cannot override the interests of rural economy.

It is a general belief that sugar industry consumes considerable amount of water and also generate sizeable amount of liquid effluent. The suspended particulate matter (SPM) is a cause of concern, as it is felt that cost effective Air Pollution Control (APC) equipments are yet to be identified for bagasse fired boilers. With the realisation of the importance of water conservation and waste minimization concepts and indigenously developed APC equipment, the waste management and air emission control are now well within the reach of the industry. The solid wastes such as press mud, agricultural trash, fly-ash generated can be converted into useful bio-fertilisers to enrich micro and macro-nutrients of soil and improved crop yields.

The Central Pollution Control Board published a comprehensive document on sugar industry in 1980-81 and the present efforts are to upgrade this document to incorporate various aspects such as wastewater minimization & identification of appropriate technologies for reduction in emissions.

As per COINDS 1980-81, the industries have been following Double Carbonation and Double Sulphitation (DCDS) process and the conventional Double Sulphitation (DS) process. At present the DCDS process is being discontinued except at two units (Mawana Sugars in Uttar Pradesh and Saraswati Sugars in Haryana). It is reliably learnt that these industries may also switch over to double sulphonation process.

The sugar industry may be classified broadly into three categories, capacity wise, as given below:

· Small : Crushing capacity upto 2500 TCD;

· Medium: Crushing capacity greater than 2500 and upto 5000 TCD

· Large: Crushing capacity greater than 5000TCD

Recently many of the sugar units have installed co-generation units based on bagasse and many more are in the process of establishing the co-generation plants to ease the power crisis faced all over the country. The profitability of the industry would considerably improve if the co-generation plants are established. There can be another classification based on exportable power generation which is as below.

a. Co-generation sugar unit to export power

b. Conventional sugar units

Inplant Control Measures

· It shall be made mandatory to recirculate excess condensate, compressor cooling waters, sulphur burner cooling water, mill bearing and turbine cooling waters. If necessary, mini cooling towers may be installed to reduce temperature, to facilitate the recirculation and reuse of these streams. These measures are to be incorporated by the plant suppliers and also as the specifications of the plant machinery.

· Mechanical seals shall be used wherever applicable to avoid leakages from pump glands.

· If the cleaning operation of the equipment is carried out continuously it would help to reduce shock-loads on Effluent Treatment Plant. Wherever monthly cleaning practice is followed at fixed intervals and the effluents are discharged directly into Effluent Treatment Plants, the performance is affected due to shock loads. Most of the industries are now constructing Washing Holding Tanks whereby, the effluent from equipment cleanings, leakages and process upsets are stored and pumped in controlled manner to Effluent Treatment Plants.

In the industries, where inplant control measures and water recycling techniques are followed, the targets of water consumption & wastewater discharge of <100l/tonne of cane crushed are already achieved.

Water and waste Management

· The water management practices are to be strengthened in most of the sugar units. It is observed that water consumption varies between 400 to 1000 litre per tonne of cane crushed (Table 10.5). Taking into account the availability of sixty percent water in sugarcane, it is suggested that there should not be any water abstraction from surface or ground. Spray ponds/cooling towers should be adopted for maximum utilization of water. The quality of water at the upstream and downstream side of the discharge point should be monitored for pH, Temperature, suspended solids, BOD and dissolved oxygen etc.

· The industry shall be advised to measure water consumption on a rational basis. Most of the industries estimate the water usage based on pump capacities and the number of hours of pumping. Most of the industries are of the opinion that water meters do not work properly. In such a case, the levels of reservoirs may be recorded and the water consumption per day can be estimated by multiplying the level difference and area.

The usual method of measuring the effluent quantity is through "V" notch. The mild steel "V" notch plates get corroded due to acidic nature of effluent. The industry shall be advised to use Brass or Stainless steel plates for "V" notch and calibrate every year during the off- season. It is suggested to use continuous flow recorders.

· The effluent quantity varies between 100 litre to 400 litre per tonne of cane crushed. The norms for effluent quantity may be fixed as 100 litre per tonne of cane crushed.

· In case of domestic effluent treatment plant, two methods of treatment are suggested as Root Zone treatment and the combined treatment for domestic and sugar factory effluents. However, there can be a number of alternatives, which the industry may like to choose.

Air Pollution

The industry is to be addressed on the adoption of efficient Air Pollution Control measures such as Wet Scrubbers and ESP (Electrostatic precipitators) systems. It is suggested to replace multicyclones with wet scrubbers / ESP units; as the Multicyclones do not provide more than 40-50% efficiency. Many sugar units have started replacing multicyclones with wet scrubbers. It is suggested to install ESP unit wherever a sugar unit has Co-generation plant. A few industries have already taken this step and the performance of these control measures have been found extremely good.

Table 10.5 National average for water requirement, raw material consumption and effluent generation

Minimum National Standards (as discussed in the 18th Peer & Core Committee meeting)

Even though some of the industries have mentioned that it is difficult to achieve the existing Minimum National Standards (MINAS), the detailed study of some of the industries reveal that it is not difficult to meet the standards. It is, therefore, suggested to continue the existing MINAS for sugar industry for discharge on land for irrigation as BOD<100 mg/l and S.S. <100 mg/l and BOD 30 mg/l and SS 30 mg/l for discharge into inland surface waters (Table 10.6). The industry shall be addressed on proper design, operation and maintenance of effluent treatment plants through training programmes and workshops. The permissible wastewater discharge shall be 100 liters per tonne of cane crushed. The SPM of the stack emission shall not exceed 150 mg/Nm3 irrespective of the type of furnace and shall be achieved as per CREP decisions for sugar industries.

Table 10.6 Suggested Minimal National Standards for Sugar Industry

10.5 INDUSTRIAL POLLUTION CONTROL

Performance Study of Tannery units situated in and around Delhi

About ten tanneries located at Delhi, Haryana and Uttar Pradesh were studied with the objectives to improve their pollution control performance. Some common problems were observed and the suitable remedial measures were suggested. Some of the suggested measures are as follows:

· Solid waste including chrome-bearing sludge to be stored properly in lined pits with a shed over it to protect from rains.

· The algae growth in the aeration tank indicates that aeration tank is not maintained and not been put to use. MLSS level is to be maintained as per design.

· Acoustic enclosures are to be provided for the DG set(s) for control of noise pollution, as per Notification under the Environment (Protection) Rules, 1986.

· Boron bearing salts are not to be used in the manufacturing process.

· Dry desalter machine should be installed to reduce load on the solar evaporation ponds.

· Sprinkler system for solar evaporation ponds to be provided for effluent from soaking and pickling unit.

Prevention and control of pollution in tanneries in Kanpur

Kanpur city has one of the biggest tannery clusters in the country with as many as 354 tanneries (Fig 10.1), as a result associated environmental problem have also been equally alarming. The pollution of surface and groundwater has been observed to acquire serious proportions. The high content of chromium in the tannery wastewater has been reported to render the sludge from treatment plant, as highly hazardous substance.

Fig 10.1 Scale of Operation and type of Tanning in Tannery Units of Kanpur

As a result of regular surveillance by the Central Pollution Control Board and follow up for enforcement the scenario has shown appreciable improvement. Some of the salient achievements are as follows:

v Feasibility study for Common Chrome Recovery Plant
v After a series of meetings with local authorities, Tannery Association and other apex agencies a proposal for cost mobilization for the plant prepared for Kanpur Nagar Nigam. The proposal is under active consideration of Ministry of Environment and Forest, Govt of India
v Identification of land for the plant
v The defaulting tanneries have been issued with closure orders
v Number of individual chrome recovery plant established by tanneries has increased from 8 in 1996 to over 80 in 2004 (Fig 10.2).

*As per the latest status, there are 80 individual plants already established

Fig 10.2 Individual Chrome Recovery Plants established over the years

Latest status of Common Chrome Recovery Plant at Kanpur

· A formal proposal has been submitted by KNN to NRCD with assured contribution of 15% of the capital cost by KNN and 15% by tanners. The rest of the capital cost is being considered by NRCD. .
· Land for the proposed plant has been identified

Problems observed in tanneries at Kanpur

· The primary treatment plant installed at individual tanneries are generally not operated / operated improperly
· Tannery conveyance system is choked at many places resulting into discharge of untreated effluent into river Ganga
· Lifting of solid waste and PETP sludge is highly irregular resulting in a big nuisance in the area

Proposed Leather Technology Park, Banthar, Unnao

In order to promote Export oriented leather industries in U.P., a Leather Technology Park is being established at Banthar, Unnao in U.P.. The proposal to establish was submitted by UPSIDC to MoEF and after a detailed scrutiny, a five-member Sub-committee including by the Central Pollution Control Board Officers, visited the project site on July 22, 2003 . In order to stress environmentally sustainable leather tanning process, CPCB ensured to include following issues as recommendation to be implemented by the project authorities:

a. Installation of separate flow meter and (intake) water meter by tanneries

b. Automatic monitoring equipments by CETP / large tanneries

c. Annual environmental auditing by all tanneries processing > 5 ton hide /day

d. Resource recovery from process sludge / ETP sludge by generating bio-gas. This option may be tried in-line with the re-use of fleshing from tanneries in " Bio-methenisation" process. Since such option is under full-scale operation in Tamilnadu with technical support of CLRI, it is recommended that techno-economical feasibility of this option be worked-out in consultation with CLRI. In case the option of " Bio-methanisation" is declared not-feasible, it is strongly suggested that the option of using them in glue manufacture shall be avoided in keeping with crude processing techniques and high potential of air pollution associated with such industries.

e. Restricting wastewater generation from individual tanneries to the tune of 28m3/tone hyde processed

f. Dispensing boron bearing chemicals by tanneries / CETP

Separation of Chromium from waste chrome shavings to minimize disposal problems of hazardous solid wastes in tanneries

It is estimated that about 20,000 tonnes of chrome shavings are generated per annum from tanning industry in the country. In this project, the technology for chromium separation from the leather shavings has been developed. The study has been carried out in collaboration with Central Leather Research Institute, Chennai. The important findings of the study are as follows:

» Concentration of the chromium varies from 1.9-3.8% as Cr on dry solid basis.

» Moisture content of the shavings and trimmings varies from 40-55% depending upon the storage period.

» 80-90% removal of chromium from shavings and trimmings with moisture content of about 50% was observed.

» Increase in the percentage of chromium extraction was observed for wetting back of the shavings and trimmings before detanning.

» Detanning process duration time of one hour is sufficient for chrome bearing waste with the moisture content of about 50%. More process duration time will be needed for low moisture content waste.

» 500% float volume is sufficient for effective detanning in drums for shavings and 800% float volume for effective detanning in drums for trimmings. No enzyme or heating is involved in detanning.

» Intermittent mixing of 10 minutes per hour is sufficient for detanning and extraction for shavings. Continuous mixing is needed for trimmings. Lime at pH 12 is selected as a detanning agent.

» One time washing is sufficient. Washing is carried out in drum for a float volume of 500% for shavings and 800% for trimmings for a duration time of 30 minutes.

» Filtering of the shavings was done using a 2 mm sieve and filter bag.

» Detanned liquor and wash water can be reused for the next cycle, which will minimize quantity of the chemicals and process water. Formic acid at pH 3 is selected for chromium extraction.

» Two times extraction is needed for chrome shavings and three times extraction is needed for trimmings.

» Pulping occurs immediately after the addition of acid only in the case of shaving. Because of the pulping, the filtrate volume reduces and thereby reduces the percentage chromium extracted. The manual filtration process also takes more time due to clogging of the pores.

» Mechanical dewatering equipment are necessary for effective separation of liquor and solid for commercial scale operation.

» Drum with 12-15 rpm is sufficient for detanning and extraction process.

Sulphur Balance and Material Balance in Oil Refineries

In-depth study of four selected Oil Refineries located in western part of the country was carried out in association with IIT Kanpur. These refineries are - Reliance Industries Limited, Jamnagar; Indian Oil Corporation Limited, Vadodara; Hindustan Petroleum Corporation Limited, Mumbai and Bharat Petroleum Corporation Limited, Mumbai.

Distribution of sulphur in different stages of crude refining was studied and compared for all four refineries. The stack monitoring and wastewater quality monitoring was also carried out at all the refineries. The study highlights that sulphur content in products is only 29.7% at Reliance Industries Limited (RIL), but the same is high in other refineries. At RIL only 0.56% of sulphur contributed to the environment, but its concentration is quite high in other refineries. The sulphur recovery is also very high at this refinery as compared to other refineries, because of better technology and much larger sulphur recovery units.

Study of Dye Industries Located at Vatva Industrial Estate, Gujarat

As a mandatory requirement, 14 dye manufacturing units located at Vatva Industrial Estate had applied to the Ministry of Environment and Forests, Government of India, for ex-post facto environmental clearance during February 2002. While considering the proposal for environmental clearance, the EIA Committee had visited these industries and recommended suggestions to the Ministry of Environment & Forests. The committee suggested that each unit should ensure reduction of COD to 400 mg/l at their ETP, so that after treatment in the CETP, the COD remains well within the specified environmental standard of 250 mg/l.

Status of Pollution Control Measures in Ceramics units in West Bengal

The units namely ceramics are categorised under the small scale sector and the entire manufacturing process is undertaken in batches. The most important part of the manufacturing process is the kiln. There are two types of kilns used in the process - the tunnel kiln and the rectangular / dome shaped kiln, the former being the conventional one. However, with improvement in technology there is a gradual shift to the tunnel kiln for convenience, fuel efficiency and 'green product' management. In West Bengal most of the kilns have abandoned coal as the fuel. As of now the burners of the kilns use light diesel oil (LDO) as the fuel. The emission norms are not stipulated for SOx except for stack height. However, the stack monitoring results indicate that the emission norms have been complied with respect to other parameters.

Status of Disaster Management Plan at Haldia, West Bengal

There has always been an anxiety of the safety measures taken particularly at isolated storage sites of hazardous chemicals particularly fuels. The important statutes that cover these critical areas issued under the Environment (Protection) Act 1986 are:

· Chemical Accidents (Emergency Planning, Preparedness and responses) Rule 1996

· Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules 1989

· Hazardous Wastes (Management & Handling) Rules 1989.

Questionnaires were circulated to the three major oil companies located in the Eastern region namely Indian Oil Corporation, IBP and Hindustan Petroleum Corporation. It was observed that the major fuels stored are : superior kerosene oil (KO), Motor spirit (MS), ultra low sulphur high speed diesel (ULSHDS), mineral turpentine oil (MTO), aviation turbine fuel (ATF) and gases (like LPG, propane and butane). In this context major fuel storage sites were visited including Haldia in West Bengal. The plants have a detailed on-site emergency plan. In West Bengal, Haldia has been developed as major industrial estate dealing predominantly with hazardous chemicals. It was observed from the available reports that the District Administrator prepares the calendar for mock drills particularly for each units in the Haldia region. As per schedule, all the industries participate in the mock drill along with the unit which is demonstrating its on-site safety precautions. The outcome of these exercises is widely publicized. At Haldia, ships which anchor at the jetties - the precautions for the pipelines emanating from the jetty areas are also taken during movement of chemicals through pipes. At the bay stations i.e. lorry (tank) fuel filling yards, the filling was automated leaving any scope for manual handling. The effluent (if any) is being skimmed for oil before discharge into the municipal drains. The units are participating in the eco-development of regions in the vicinity and there are adequate provisions for the green belt.

Status of waste utilisation by industries

A project was initiated to identify industries among the 17 categories of industries which used to generate such 'waste / wastes' having potential usage in other industries. To begin with, the following industry categories (Table 10.7) have been considered, as the waste generated from these categories not only have the potential to be used by other industries but their quantity is also quite enormous creating 'waste management problems'. Questionnaires have been circulated to ascertain the waste load and the potential users.

Table 10.7 Solid Waste Generated from Selected group of Industries

Solid Waste Management at Slaughter House

Waste management in slaughter houses has special significance, because their wastes tend to form breeding ground for pathogenic micro-organisms. Burning or burying of wastes lead to the total loss of potential by-products. The waste processing and disposal has to be economical and environmentally acceptable. With a view to suggest proper waste management practices in slaughter houses, a study was undertaken. Recommendations on best practicable methods currently available for processing and disposal of different wastes and classes of slaughter houses have been identified and presented in Table 10.8. Incineration can also be used, which is one of the effective means for treatment of many wastes.

Table 10.8 Methods for processing, utilisation and disposal of Solid Wastes
from Slaughter House

*Should be considered as provisional measure.; TLWK/d- Tonnes of live weight killed per day

Environmental Guidelines for Control of Fugitive Emissions during Cement Manufacturing

During cement manufacturing, fugitive emissions are generated at various stages. The degree of fugitive emission and the type of controls adopted varies from industry to industry. A study on "Assessment of fugitive emissions and development of environmental guidelines for control of fugitive emissions from cement manufacturing units" has been undertaken in association with National Productivity Council (NPC), New Delhi and IIT Kanpur. The study includes identification of all fugitive emission sources, monitoring and quantification of fugitive emissions, characterization of dust and analysis of metals. Based on the study, the standards for fugitive emissions and environmental guidelines to control fugitive emission will be finalized.

There are a large number of hazardous waste generating units located in 373 districts of 21 states in the country. So far 11,138 units have been given authorization by State Pollution Control Boards under Hazardous Waste (Management & Handling) Rules, 2003 mostly for temporary storage of hazardous waste, within the plant premises. It is estimated that about 4.43 million tonnes of hazardous waste is generated annually, out of which 71,833 tonnes of hazardous waste are incinerable. The benefits of using hazardous waste as a fuel in cement kiln are as ahead:

· High temperature and residence time of 4-5 seconds in an oxygen rich environment, ensure the destruction of organic compounds found in the waste.

· Any acid gases formed during combustion are neutralized by the raw material being alkaline in nature and are incorporated into the cement clinker.

· Interaction of the flue gases and the raw material present in the kiln ensures that the non-combustible part of the residue is held back in the process and is incorporated into the clinker in a practically irreversible manner.

· No waste is generated that requires subsequent processing.

There is the need to promote utilization of hazardous combustible waste having higher calorific value in cement kiln as fuel. This will not only solve the disposal problem associated with hazardous waste but also conserve natural fuel resources. There is possibility of emissions of toxic metals, volatile organic carbon compounds and other toxic gases, which needs to be controlled. As a policy measure, several procedures and guidelines for utilization of hazardous waste in cement kiln as fuel has been suggested.

Pollution Control in Iron & Steel Sector

Iron and steel is one of the largest industrial sector in the country. Production of steel is the key factor denoting development, but is also a major source of water, air and solid waste pollution. Following major achievements have been made in the field of environmental management and pollution control from the integrated iron and steel industries sector.

· About 98% stacks are complying with emission standards;

· Ambient air quality is within the statutory norms;

· Discharge effluent quality for the plant/units are generally within effluent norms, except BOD plant for the cyanide;

· 62.5% of the solid waste generated in steel plants are being utilized either through recycling/reuse or commercial disposal; and,

· Tree plantation has been undertaken in and around steel plants with a target of plantation of one tree for the production of one tonne of steel.

The report on "Description of Clean Technology during steel making in Integrated Iron & Steel Industry, Development of Environmental Standards and Preparation of Comprehensive Document" has been prepared. National Environmental Standards and clean technology developed for blast furnace and steel melting shop is under finalization for their notification.

Environmental Management in Mining Sector

Draft report on "Description of Clean Technology for iron ore mining, development of Environmental Standards and Comprehensive Industry Document" has been prepared. The Ministry of Environment & Forests, Government of India, vide its notification on 7th May 1992 has restricted certain activities in specified area of Aravalli Range. A document on "Study of Environmental Problems of Aravalli Hills & Preparation of Action Plan for Restoration of Environmental Quality (Gurgaon and Alwar Districts)" has been prepared. Based on the data generated, the impact on environment due to the industrial activities and mining will be assessed. The environmental impacts of cluster of the proposed mines and processing units under the present environmental scenario will be addressed separately. The Central Pollution Control Board has decided to include two other districts of Rajasthan - Chittorgarh and Udaipur - within the purview of study.

Pollution Control in Copper Industry

The copper industries have agreed upon the following action points for protection of environment within the specified time bound targets:

· To meet the SO2 emission limits by Dec, 2005

· Installation of continuous SO2 monitoring system

· Proper operation and maintenance of tailing dams

· To achieve zero discharge through 100% recycle/reuse of treated wastewater

· To reduce fugitive emissions and overall housekeeping

· To develop canopy based greenbelt around the periphery of manufacturing unit and township

Pollution Control in Zinc Industry

The zinc industries have agreed upon the following action points for protection of environment within the specified time bound targets:

· To meet the SO2 emission limits by Dec, 2006

· Installation, proper operation, maintenance and calibration of continuous SO2 monitoring system

· Construction of secured landfill for disposal of hazardous waste such as jerosite cake, ETP cake and spent catalyst as per CPCB guidelines

· To achieve zero discharge through 100% recycle/reuse of the treated wastewater by Dec, 2004

· To reduce the generation of fugitive dust from vehicle movements and improve overall housekeeping

· To develop canopy based greenbelt around the periphery of plant and township

Pollution Control in Aluminium Industry

First meeting of the National Task Force constituted for implementation of the CREP recommendations deliberated on following important action points (Table 10.9):

· Phase II Fluoride emission limits for soderberg process as agreed in CREP shall be finalised after Phase I is implemented

· More information on fluoride needs to be collected before environmental standards are finalised
· Pot life of 2000 days for Soderberg technology was felt more practical and the same was recommended

Table 10.9 Action Points and Targets for Aluminium Industry

Pollution Control in Thermal Power Plants

There are 83 coal-based thermal power plants in the country, of which 5 thermal power plants are closed. A total number of 56 Thermal Power plants with the prescribed emission standards while 22 thermal power plants are yet to comply with the emission standards. As many as 63 plants comply with effluent standards while 15 plants are not complying in this regard.

A Task Force (TF) for implementation of recommendations of the Charter on Corporate Responsibility for Environment Protection (CREP) in thermal power plants was constituted. The Task Force met twice in the year and reviewed the status of non-compliant power plants. The Task Force decided that non-compliant thermal power plants shall prepare an action plan for installation/augmentation of pollution control systems in time-bound manner as per recommendations of CREP. The sub-committees comprising representatives from CPCB, SPCBs, MoEF and CEA, in the non-compliant power plants located in West Bengal, Jharkhand, Uttar Pradesh and Haryana conducted inspections. Emphasis was given on Bank Guarantee from all non-compliant plants, i.e. 10% of the cost of pollution equipment.

Study on the development of standards for trace toxic metals has been completed and proposed standards will be placed in the meeting of Peer & Core Group.

The study on "Leachability assessment of trace heavy metals from ash ponds to groundwater" is undertaken with association of IIT Kanpur. Field investigations have been completed and findings of the study will suggest extent of leaching of trace metals from ash ponds and its impact on groundwater quality. Guidelines for prevention and control of leaching of trace metals including better ash pond management practices will also be prepared.

The study on "Cost benefit analysis including environmental benefits of recycling of ash pond effluents in thermal power plants" was undertaken with association of IIT Kanpur. The findings of the study will suggest feasibility of recycling of ash pond effluent and its benefits in water conservation and mitigating environmental problems. Guidelines for better ash pond water recycling systems will also be prepared.

Use of Beneficiated Coal

It has been suggested that the Ministry of Environment & Forests should consider an amendment in the notification for effective implementation of directives related to use of beneficiated coal.

The Ministry of Power has set up two different committees to look into ways and means for meeting the requirement of beneficiated coal as per the notification. The latest committee under Adviser (Energy) with members from CEA, Ministry of Coal, CIL, BSES, BHEL, MSEB, APGENCO is deliberating on the installation of coal washeries as long term solution to meet the stipulations. Beneficiated/blended coal is supplied to 17 thermal power plants, however other 14 plants have not yet indicated their plan for meeting the requirement of use of beneficiated coal.

Utilization of Flyash

There are 108 power plants including 78 plants of utilities. About 242 million tones of coal and 20 million tones of lignite were consumed in these plants, as a result 92 million tones of ash is generated and only 25 percent is utilized. Indian Road Congress has issued directives to all agencies on 31st July, 2003 for use of flyash in road construction. CPWD is yet to introduce the flyash use in RCC, in road construction and related activities. With respect to backfilling of ash in abandoned mines, 169 mines are available for backfilling. To give further impetus in flyash utilization, following recommendations were made:

· SPCBs should ensure implementation of the provisions of the notification

· Thermal Power Plants should market the flyash and should have separate division

· Only service charge for facilitating the handling of flyash may be levied by the thermal power plants

· Thermal power plants should not encourage third parties/agencies for supply of flyash

· EIA studies should be must for Highway construction

· Ministry of coal should give subsidy for disposal of ash into the mines

Development of Technologies for Pollution Control from Selected Drugs Manufacturing Units - Paracetamol: A Case Study

Paracetamol is an important drug manufactured in India and is being used as an analgesic and antipyretic drug in a number of drug formulations. Its production is reserved for small-scale sector in India and present production capacity is estimated as 17,000 tonnes per year.

The Central Pollution Control Board took up a study with the association of the National Chemical Laboratory, Pune and in-depth studies are under way to arrive at affordable cleaner options for production of paracetamol bulk-drug.

Determination of Optimum Water Consumption Limit for the Bulk Drug Manufacturing Industry

A study has been taken up by the Central Pollution Control Board to review the existing patterns of water use by the bulk drug industry, options for optimisation and to arrive at optimum water consumption limit. Based on this study, optimum water consumption limit for selected 84 drugs has been arrived, which are being further reviewed to explore the feasibility to have common value.

Risk Assessment in Oil Refineries and Petrochemical Complexes

Safety, health and environment protection are the key concerns for the oil refineries and petrochemical industries. The Central Pollution Control Board took up a project to study some oil refineries and petrochemical complexes in detail and to establish and train the regulatory officers on the procedures and techniques for carrying out risk assessment in these industries.

Status of pollution control in sponge iron industries in Chhattisgarh

Sponge iron plants have installed capacity of 2.5 MTPA in Chhattisgarh. 60 kilns were in operation and may touch 100 in coming years. Concentrated in Raigarh, Bilaspur and Raipur Districts, these units generate large scale air pollution and huge quantities of solid wastes. Development of standards for sponge iron plants is in progress.

Sponge iron is a metallic product formed by the reduction of iron ore at temperature just below the fusion point of iron. This product has derived the name sponge iron due to its porous nature. It is also called as Direct Reduced Iron (DRI). Sponge iron has now succeeded in becoming a preferred raw material in secondary steel making. It is a substitute of steel scrap for the secondary route of Direct Reduction / Electric Furnace (DR/EF).

The main raw materials required are iron ore, coal and dolomite. The iron ore used is hematite with an iron content of 60-66%. The consumption of iron ore has decreased from about 1600 kg. per tonne of sponge iron to 1500 kg levels mainly due to a better understanding of the process, improvements of the equipment and increased levels of automation. In the initial days, the size of iron ore was kept at 5-20 mm and washed in a scrubber before fed into the kiln. But presently, it has become a standard norm to use 5-18 mm ore as feed without scrubbing or washing. This has resulted in reducing the cost of iron ore fed to the kiln.

Non-coking coal is used having certain important parameters considered as necessary for the direct reduction of iron ore viz. reactivity ash softening temperature, caking and swelling indices and sulphur content, etc. Initially, only 'B' grade coal was consumed. The industry has successfully adopted measures to utilize 'C' & 'D' grade coal through better process control, shale picking belts and coal washing plants. With these measures, the coal cost has come down by nearly 20-30%, when compared to the 'B' grade coal.

Dolomite is mainly used as a desulphurising agent to prevent the pick up of sulphur by the sponge iron from the sulphur released by the burning of coal inside the kiln. The 4-8 mm size dolomite is being used in place of the earlier 1-4 mm size. The loss of dolomite fines to waste gases has been reduced by 50% after the increase in size to 4-8 mm.

In the inclined rotary kiln, iron ore and coal are passed through in a counter current direction to the oxidizing flue gases. Fine coal is injected from the material end for uniform combustion. The temperature in the range of 900 to 1050o C is maintained in the kiln. Air fans are mounted on the kiln to force air inside the kiln to react with the carbon from the coal to form carbon monoxide. After material heating, ore reduction and carbon gasification take place in close association with each other. The volatile constituents of coal and carbon monoxide are burnt over the entire length of the kiln with a controlled amount of air. The metallisation process completes in the kiln and the discharge is cooled indirectly with water in a rotary cooler connected to the kiln, screened and subjected to the magnetic separation in order to remove the non-magnetics from the sponge iron.

In coal based sponge iron plants, depending on the quality of the coal used, about 60% of the total heat input is utilised in the reduction process. About 40% of the heat input is discharged with the kiln waste gases. The hot waste gas and the char produced thus contain considerable energy potential. The waste gas heat recovery boilers have become norm in the industry, as the cost of power generation is equal to the hydel power generation cost.

The sponge iron industry in Chhattisgarh is growing in unplanned hapazard manner, as it is seen as a quick money minting business proposition today. The liberal institutional financial support coupled with the low-cost technology has encouraged many people to establish a unit. A standard sponge iron unit may start with a kiln of 100 TPD. The normal kilns have capacities of 100, 300 and 500 TPD. Some units have installed 50 TPD and even 25 TPD kilns, which operate intermittently. The local fabricators and suppliers have modified the kiln, cooler and auxiliary equipment to produce 200 and 400 TPD capacities also.

Due to mushroom growth in sponge iron industry, the important aspect of pollution control has been neglected altogether. Many units have not even applied for consents from State Board. Some have started production without even obtaining required licenses from various departments. If not properly planned at design stage, the sponge iron industry is a highly polluting industry in nature. Huge quantities of gases containing dust concentrations of more than 50 gm/Nm3 will be released into the atmosphere. The coal and iron ore crushers were being operated without any control equipment. There is also very high number of fugitive emission sources in the plant area. The cooling water could get easily contaminated with the dust and fines in the plant. The solid waste materials generated in the form of char, dolchar, iron ore fines, coal fines and dust require careful and expert handling because of their quantities and size. After thorough study of these units the observations are as follows:

Most of the new units are coming up in Raigarh, Bilaspur and Raipur Districts. The best quality of iron ore mines are located in Orissa State and the coal in required quantities is available from Korba/Raigarh Districts in the State.

A standard sponge iron unit may start with a kiln capacity of 100 TPD. Readily available kilns normally have the capacities of 100, 300 & 500 TPD. The local fabricators and suppliers have modified the kiln, cooler and auxiliary equipment to produce 200 & 400 TPD capacities also. Some small-scale units have installed 50 TPD and even 25 TPD kilns, which operate intermittently. It is expected that the total units may go up to 100 kilns from the present estimate of 60 operating kilns of various sizes.

The industrial units are operated with one or two technical persons knowing metallurgical process in sponge iron. The person is made responsible for all aspects of the production, including pollution generated from the process. In view of the limited knowledge and time, the technical persons are unable to work for pollution control. The monitoring of ambient air quality and stack emissions has been entrusted to the local consultants. The necessary documents including consents and data records are also maintained by the consultants on behalf of the industries.

Sponge iron industry is a highly polluting industry in nature. Huge quantities of gases containing dust concentrations of more than 50 gm/Nm3 will be released from the kiln. At a time when Pollution Control Boards have been advocating and promoting cleaner technology, adoption of such dirty technology of production is a matter of concern.

Pollution control measures taken by most of the sponge iron plants are far from satisfactory. The status of pollution control in small units with production capacity below 30,000 TPA is further bad.

Installation of Waste Heat Recovery Boiler (WHRB) and power generation in the units with 100 TPD and above capacity may be made compulsory.

CECB may take extra efforts to ensure compliance of consent conditions in the existing plants. No industry should be allowed to operate without pollution control devices. Industries operating without control devices may be closed immediately.

It is observed that many of the existing sponge iron producing industries have expanded and increased their production without obtaining necessary approvals. SPCB have to exercise strict vigil to ensure that such plants should not come up without proper and adequate pollution control systems.

Mercury emission from Caustic Soda Industries

The Alkali Manufacturers Association of India (AMAI) has provided technical inputs to all the caustic soda manufacturing units for accounting mercury consumption/loss. The Association has also provided general mercury calculations for all the industries irrespective of the plant condition and processes adopted by them. For example, handling loss is assumed as 2% of mercury consumed. In spite of several recommendations, none of the units have actually started measuring mercury escaping into the environment.

It was observed that during cell cut outs and power failures, huge quantities of mercury were reaching in brine mud which is disposed in the landfill sites. All the units have provided calculation on the basis of 10 power failures, without stating the actual duration of power failure in hours. Similarly, while disposing the exposed activated carbon, FUNDABAC filters, residues from distillation units etc. were not measured for actual concentration of mercury in them before their disposal.

The emission, ambient air quality, surface and groundwater quality and sediments of effluent receiving water bodies were not monitored on regular basis by the industries. In the absence of reliable database, it is not possible to conclude with one short-term study, the actual mercury release into the environment.

Among the action points of CREP, the installation of continuous online mercury analyzer has been differed by all the units as they claimed that mercury bearing effluents are being 100% recycled after treatment. The Association has informed the National Task Force for Caustic Soda industry that the actual consumption of mercury for the year 2002-2003 had already been brought down to 78 gm/tonne and the target set in CREP, 50 gm/tonne will be achieved by December, 2005.

Bio -Composting in Distilleries

Treatment of distillery effluent has always been a problem for industry. Spent wash generated from distillation process has very high pollution potential and it is detrimental to the recipient environment to which it is discharged. Typical characteristics of spent wash is presented in Table 10.10.

Table 10.10 Typical Characteristics of Spent Wash

(All values are in mg/l , except pH)

So far distilleries has adopted various treatment options to treat the distillery effluent but none of them is adequate enough to meet the stipulated norms of discharge within affordable economical range of the industry.

Bio - composting of press mud with distillery effluent is one option through which distillery can achieve zero discharge and get valuable bio compost. Composting process is carried out by mixing distillery effluent with press mud to make compost. Thus liquid effluent is converted into solid compost, which is easier to transport for wider area use. Filler material is arranged in wind rows and composted with effluent .Some time microbial starter culture is used to expedite the composting. The quantity of effluent employed is controlled to maintain optimum moisture in the windrows suitable for composting but not to soak the filler material and leak out of composting heaps. Temperature and moisture content are rigidly controlled and enough air is provided for composting reactions. Exothermic humification reaction accelerated by microbial culture completely decomposes all organic matter of effluent. A distinctive black loamy, free flowing and baggable bio-compost is produced.

CPCB has developed guidelines for bio composting. Distilleries are now adopting this technology in order to reduce the effluent discharge and in due course of time they are supposed to be zero discharge industry. Information regarding bio composting from the units of UP were collected and some distilleries were inspected to assess the efficacy of bio composting. Bio composting scenario in some of the industries are summarized in Table 10.11.

Table 10.11 Status of Bio-composting in some industries

Limitations of bio composting

· Press mud availability is limiting factor.

· Less demand for bio compost. Efforts should be made for promotion of use of bio fertilizers.

· Availability of land as the process needs vast land.

· During rainy season it is very difficult to run the bio compost plant, for that period only option left is to store the effluent or shutdown the plant.
Chances of ground water pollution is always there if bio composting is done on unlined or poorly prepared surface.

Silk Screen Printing

Dyeing and Printing of textiles are made to convert the raw textile fibres into finished goods having better appearance. Printing is a process of decorating textile fabrics by application of pigments, dyes or other related materials in the form of patterns. Screen-printing may be a hand operation or an automatic mechanical process.

The major unit operations in Screen-Printing are: Image Preparation, Stencil (Printing screen) Preparation, Printing, Drying and Finishing. Colour in the effluents is the main problem alongwith the Organic Matters.

Serampore, District of Hooghly, West Bengal is famous for Silk Screen-Printing Units and reportedly about 100 Units of various sizes are operating and as all the Units are directly discharging their raw effluent into Sewer or Municipal/Panchayet Drain, the condition of the drains have become worsened primarily and due to colour of the waste aesthetically objectionable secondarily. The main problem in these types of Unit is that their discharge is not continuous and often intermittent depending on the number and time of washings.

It was observed and reported that about 40 Units are having capacities to print 100 or more clothes per day. 50 Units having capabilities to print 50-60 clothes per day and about 60 -70 very small units printing only 20 - 30 clothes per day. The process adopted in all the Units of Serampore are more or less same, only variation is in the Capacity or Quantity being produced per day.

The salient findings are as follows

· Colour solution for dying and printing purposes are prepared by mixing following constituents

Dry Colour - 300 Gm
Gum - 400 Gm
Water - 8 litre

· The dye used is primarily of Acid Colour (Azo free, Non Benzodine) type. The dyes of Ciba, Clariant, IDI, Nerolac are being frequently used. The Local made dyes are also in use have been reported by the Units.

· The dye/colour is used in two processes: for Dyeing the clothes; requirement varying in the range of 5-15 gms per cloth depending on Shade (Light, Dark etc.) whereas for Printing purposes, the requirement is more or less uniform and varies between 15 -20 gms per cloth.

· In general, it was observed that water requirement for washing is in the range of 10 -15 litre per Unit cloth.

· Only 3 Units have installed Effluent Treatment Plant (ETP) which rest Units are directly discharging their polluted coloured effluent to nearby Municipal / Panchayet/ Low lying lands. Only 4 units have changed their Boiler to Oil Fired till date

· From the analytical results, it is evident that the Chemical Oxygen Demand (COD) of the wastewater is in general 2-5 times the Biochemical Oxygen Demand (BOD). However, in some cases the COD/BOD ratio of the effluent was found as high as 21 and even 50. The very low BOD in comparison to the COD (high COD/BOD ratio) with some cases might be due to the presence of higher non-biodegradable organic matters or presence of some other substances, which interfere, in the analytical results. However, the exact reason behind it, is yet to be established by investigation and analysis of various components.

The heavy metal concentration in the effluent and the corresponding discharge standards are presented in Table 10.12.

Table 10.12 Heavy Metal concentrations in Effluent and discharge Standards

It is evident that the effluent of the Silk Screen Printing are gross violators in terms of discharge of various metals such as Lead, Zinc and Chromium. The Metal concentration in the Dyes frequently used for Screen Printing are presented in Table 10.13.

Table 10.13 Heavy Metal concentrations in frequently used Dyes

Pollution Control at Large and Small Pulp & Paper Industries

Central Pollution Control Board published comprehensive industry document for large pulp & paper industries and small scale pulp & paper industry during the year 1991 and 1986 respectively. These reports were comprehensive and findings were based on in-depth studies carried out in selected pulp & paper mills using diversified raw materials, pulping processes, different waste treatment systems. Based on the findings in these reports, environmental standards for discharge of effluent and emissions were notified.

The scenario of pulp & paper industry has been under considerable change since then with respect to process technology, raw material and environmental technology. Looking into the changed scenario, increased environmental awareness, choice for ecofriendly products, cost competitiveness, recently emerged environmental issues, increased concept of recycling of water and also limitations of pulp & paper mills, Central Pollution Control Board has decided to review and revise the COINDS of pulp & paper mills.

Eight industries from each group i.e. large pulp & paper industries and small pulp & paper industries have been selected for carrying out in-depth studies. The indepth study has been completed and report is under preparation. Based on the findings from the present studies, the discharge standards for effluent and emissions shall be recommended.

Development of Guidelines for Water Conservation in Pulp & paper industry

Pulp & Paper industries have been considered as high water intensive industry using high volume of water in paper making. The water consumption ranges between 100-200 Cum/tonne of paper depending upon the process technology employed and water management practices followed by the paper mills. Indian paper industry lags behind with respect to water conservation in comparison to pulp & paper industries in developed countries where water consumption is very low ranging between 50-70 cum/tonne of paper. Considering the poor practices of wastewater recycling and reuse followed by Indian Pulp & Paper Industries, CPCB has taken up a project on framing guidelines for water conservation in pulp & paper mills. Under the project, section wise water balance is being undertaken in selected pulp & paper mills to assess the actual use of water in paper making. Different technological options for water reuse and recycling shall be suggested to minimize water consumption.

The water consumption/discharge pattern in different category of pulp & paper mills is presented in Table 10.14.

The activities in various sections of pulp & paper mill that consume water are briefly described below:

» Raw material preparation: Raw material preparation involves depithing in case of Agro based raw material like Bagasse, while washing and chipping of logs in case of wood based plant.

» Pulping section: Pulping section involves digestion of the wood or agrobased raw material, followed by brown stock washing and bleaching operations, pulp cleaning equipments etc. In addition, water is used for pulp dilution and also for non process purposes like pump gland cooling and sealing, floor washing, etc.

» Wastepaper pulping: Waste paper pulping involves hydro pulping, followed by centricleaning, thickening. Mostly recycled water is used in the hydropulper. Fresh water is mostly used in decker thickner showers.

» Stock Preparation and Paper machine: Water is required for chemical preparation, in wire and press section showers, vacuum pump sealing, etc.

» Chemical Recovery Plant: Chemical recovery Plant does not require any fresh water for the process. Fresh water is required for non process operations like pump gland cooling & sealing, slaker roller bearing cooling, floor washing, etc.

» Utilities: Utilities include Water treatment Plant, DM Plant, Softner Plant, Boiler House, Cooling tower.

10.6 NOISE POLLUTION

Meetings of the National Committee

11th & 12th Meetings of the National Committee on Noise Pollution Control were held on April 22, 2003, and January 30, 2004, respectively in New Delhi. Some major issues discussed during the meetings were:

· Amendment in Noise Rules/Regulations

· Noise limits for motor vehicle horns

· Noise limits for in-use motor vehicles

· Aircraft noise

Compliance Testing of Fire-crackers

Compliance testing of fire-crackers for noise limits was carried out in March 2004, in association with the National Physical Laboratory, New Delhi. The objective of the project was to study whether the noise levels of fire-crackers available in the market meet the prescribed noise limits. The test results of the present study are presented in Table 10.15.

Table 10.15 Noise levels produced by a variety of Firecrackers under free-field condition, at 4 m distance from the point of bursting

Stationary noise level measurement of motor vehicles

The project was carried out in association with Automotive Research Association of India, Pune. Pass-by-noise as per IS:3028 and stationary-noise as per IS:10399 for 91 new vehicles and 61 in-use vehicles were tested.

10.7 BIO-MEDICAL WASTE MANAGEMENT

Bio-medical Waste Management in Bangalore

A total of 31 hospitals and 2 Common Waste Treatment Facilities were inspected and monitored in Bangalore. Hospitals, both Government and Private, with and without incinerators were selected based on the number of beds and their contribution of waste. The study was focused on incinerators, combustion efficiency, autoclaving, segregation of waste, treatment of liquid effluent, disposal of waste and sharps etc. It was observed that out of 31 hospitals, 12 have their own incinerators and others are sending their waste either to CWTFs or to own landfill sites. The stack monitoring at 12 hospitals and both the CWTFs were carried out. Based on a multi-parameter based indexing system, grading of hospitals is in progress.

Bio-medical Waste Management in Madhya Pradesh & Rajasthan

Many hospitals in Madhya Pradesh and Rajasthan have provided incinerators to treat the bio-medical waste. Most of them were found violating the required specifications and were not operating regularly. Incinerators installed by the Common Treatment Facility (CTF) providers and the incinerators in eight hospitals were monitored.