ENVIRONMENTAL STANDARDS INCLUDING SCHEDULE FOR THEIR ENFORCEMENT
Guidelines for Prescribing Location Specific Standards The main aspects considered while developing environmental location specific standards are generally wastewater discharge and air emissions. The first aspect relates to achievability of limits of pollutants by incorporation of appropriate pollution control measures and the second relates to adverse effects on health & environment. The first approach aims at use of best achievable and economically feasible technology. Economically feasible technology assures that cost of pollution control measures will remain within the affordability of the industrial units. Standards developed on these principles are notified as MINAS (Minimal National Standards) and these standards are uniform throughout the country. The advantage of such an approach is that within a specific group of industries, minimum extent of pollution control measures is ensured. As the development of standards based on the local environmental conditions is not a practicable proposition to a central agency, it is logical to evolve industry-specific standards at the national level and to safeguard the local environment by making stringent standards and/or limiting pollution load, which is to be enforced by local authorities (i.e. making national standards stringent to protect local receiving environment). Through such exercise, these standards serve both industry-specific and location-specific requirements. Keeping this as the agreed model in the backdrop, the Central Pollution Control Board has been developing industry-specific standards, which are subsequently notified under the Environment (Protection) Act by the Ministry of Environment & Forests, Government of India. The second step, i.e. making the standards stringent by the local regulatory Boards depending upon the need, is a task, which demands multifaceted knowledge and cost-effective solutions, balancing technological choices, affordability and assimilative capacities. With this in view, the Central Board studied the facets concerned with the issue and a systematic approach has been established to guide the local regulatory Boards, in prescribing location specific stringent standards (LSSS). The main objective of the exercise is to bring residual pollution load after the treatment in compliance with the assimilative capacity of the receiving environment. As the strategy clearly states to control the pollution to the extent possible and then to explore the nature’s assimilative capacity, emphasis is always on further control. Keeping this as the main theme, an approach has been established detailing sequence of steps, which is presented in Fig. 10.1. Emission Standards for Pesticides Manufacturing Industries The Central Pollution Control Board after conducting extensive field studies and technology reviews, has developed National Emission Standards for the pesticides manufacturing industries, which have been endorsed by the Expert Peer & Core Committee and the Central Board. The Recommended standards and guidelines are as below:
Recommended Guidelines for Fugitive Emission Control
Enclosures
to chemical storage area, collection of emissions from loading of raw materials,
in particular, solvents through hoods & ducts by induced draft, and control
by scrubber/dust collector to be ensured.
Development/review of Effluent & Emission standards for oil refineries Standards for discharge of effluent and emissions from oil refineries were notified under Environment (Protection) Act in the years 1986 and 1990, respectively. These standards are same for old & new refineries and consider few parameters only. There was need to include additional parameters viz. Oxides of Nitrogen (NOx), Volatile Organic Compounds (VOCs), etc. Besides, many developments have taken place in the technologies for oil refining process and pollution control in this sector, particularly, during last one decade. New process units are also being added to meet the improved fuel quality standards, required for reducing vehicular pollution that is of concern in urban centers. In view of the above, the existing standards have been reviewed. The revised emission standards include additional parameters viz. NOx, Ni+V, PM, etc. and higher efficiency for Sulphur Recovery Unit. In addition, a Leak Detection and Repair (LDAR) programme and specific requirements for minimizing vapour losses from storage tanks & product loading/unloading facilities are also included. In the revised effluent standards, additional parameters have been added and limiting values for existing parameters revised. Revised standards were discussed in the 18th Peer & Core Committee and approved by the Board in its 132nd meeting held on January 04, 2005. Technology up-gradation in existing & new sulphuric acid plants to reduce and control oxides of sulphur & acid mist emissions in sulphuric acid plants Sulphuric acid (H2SO4) plants emit oxides of sulphur and acid mist in the atmosphere. Presently, emission limits are prescribed as 4.0 kg/tonne of concentrated (100%) acid produced for SOx and 50 mg/nm3 for acid mist. In recent years, some large sulphuric acid plants have been established, which require further reduction in emissions of these pollutants. In addition, improved process & pollution control technologies are also available. Therefore, a project on study the possibilities of technology upgradation in existing sulphuric acid plants and use of state-of-the-art technology in new plants so as to reduce and control oxides of sulphur & acid mist emissions was taken up. Based on the study, standards for SO2 and acid mist emissions are revised. Revised standards were discussed in the 18th Peer & Core Committee and approved by the Board in its 132nd meeting held on January 04, 2005. Emission Standards and Stack Heights Regulations for Brick Kilns Clamp kilns Bull’s Trench Kiln (BTK), and down draught kilns are primarily used for brick making in India. Clamp kilns of various designs are used for brick manufacturing in Peninsular India. BTKs are used mainly in Indo- Gangetic plains and down –draught Kiln are being used for brick manufacturing in Karnataka. Vertical Shaft Brick Kiln (VSBK), a Chinese technology has been introduced in 1996 in India. Vertical Shaft Brick Kiln is an energy efficient technology and can be an alternate technology for replacement of clamp kilns. The standards for Bull’s Trench Brick Kiln are already notified vide notification GSR No. 176 (E); April, 1996 under the Environment (Protection) Rules, 1986. Emission standards were to be evolved for VSBK. 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 the Central Board in association with The Energy & Resources Institute (TERI), New Delhi. Finding of the study were discussed in Peer & Core committee meeting in the Central Board on 20th and 21st April 2004. The observations of Peer & Core Committee were incorporated in the proposed recommendations. Minutes and proposal have been circulated to expert, NGOs and Association. The Emission standards for down draught kiln are already notified for Ceramic Industry. Same have been proposed for down draught brick kilns, as well. The recommendations were put up in the 132nd meeting of Central Board on 4th January 2005 for discussions and acceptance.
Table 10.1: Emission Standards for Bull’s Trench Brick Kilns (BTKs)
Table 10.2: Stack Height Regulations for Bull’s Trench Brick Kilns
Table 10.3: Emission Standards for Down-draught Brick Kiln
Table 10.4: Stack Height and Emission Standards for Vertical Shaft Brick Kiln
A
set of guidelines have been developed for environmental performance of VSBK which
would help in bringing down emission levels in VSBK are :Use
of internal fuel during brick moulding helps in reducing stack emissions, particularly
particulate matter (PM).Experiences in VSBK operation
in India show that fuels such as coal powder, boiler ash, Fly ash and biomass
fuels (rice husk, sawdust), etc. can be effectively used as internal fuel in VSBKs.The
amount of internal fuel addition in green brick during moulding depends
on the quality of soil and the desired quality of the fired product. It is generally
observed that addition of internal fuel in soil varies between 1% to 10% (by weight)
at existing VSBKs. Fly ash is used as internal fuel in one of the VSBKs (Nimbut
near Pune in Maharashtra) upto the extent of 8–9% by weight. Low
volatile content bituminous coal with low sulphur content is preferred. Coal of
lower calorific value can be used in VSBK as fuel. Use of fuel having volatile
matter more than 25% is likely to result in higher fuel consumption as well as
higher emissions (soot, unburnt carbon and CO) . The properties of coal, recommended
for use in VSBKs, are Table 10.5 : Properties of coal used in VSBK (on dry basis)
Use
of gaseous fuel shall be encouraged. Use of gaseous fuel such as LPG, LNG or CNG
shall help in reducing the fuel consumption and emission per unit of production.
Firing of perforated bricks will help in reducing the fuel consumption and emissions per unit of production. It will also lead to reduced consumption of soil. Perforated bricks have been successfully fired in VSBKs. It is recommended
to use shaft lid with proper sealing arrangement at shaft top. This will help
in reducing the concentration of pollutants in the loading platform.The
peep holes are to be provided at regular intervals along the length of the shaft
for periodic monitoring of peek temperature, to control fire zone, reduction in
coal consumption and emission. The location of firing zone should be kept close to the middle of the shaft length. If the fire moves down, it would affect the product quality. If the firing zone moves up, it would lead to increase in level of CO, hydrocarbon emission. Proper ventilation arrangements by providing sufficient opening on all sides of the loading platform, monitor roof, limiting green brick stacking to a height of about 1.5 m at the loading platform ensures good ventilation at the loading platform and reduces the exposure of workers to pollution. Provide proper ventilation at cooling chambers. The cooling chambers are extended arrangements at the unloading side of VSBK. At least two persons are involved in the unloading operation, which is carried out for a period of 15 minutes. Upon cooling of fired bricks in the trolley, bricks are removed for stacking. Proper ventilation at this level is important. Paving of floors with overburnt bricks is recommended at the unloading side which will help in avoiding dust becoming air borne. Sprinkling of water shall be practiced in working area to suppress the dust. Removal of ash falling on the ground while unloading the bricks for cooling chamber and final taking out of bricks from cooling chamber will help in avoiding the dust level at the unloading side. Installation of Brick kiln shall be considered in sensitive area such as TTZ, Doon Valley, Dhahanu, etc. with LPG, Producer gas or Natural gas as fuel, in absence of notification from the concerned state pollution control board/pollution control committee. Distance between mango orchard and brick kiln shall not be less than 500 m when brick kiln is in the prominent up wind direction and 200 m in the other wind direction(s).The mentioned distances are applicable only for the mango orchard irrespective of variety (indigenous/hybrid) whose area individually or collectively should not be less than 2.5 acre. There won’t be any difference between a mango orchard and a joint nursery. Mixed orchards of 4.0 acre having 100 mango trees shall be treated at par with mango orchard. The distance between two brick kilns shall not be less than 500 m to avoid clustering of brick kilns in an area if a new brick kiln is being installed.Agro industrial wastes or agriculture residue shall be used as internal fuel to replace coal. The use of non-hazardous industrial waste such as stone dust, rice husk ash, red mud shall be encouraged to be mixed with top soil. Flyash shall be used in brick moulding in compliance of the notification under the provisions of the Environment (Protection) Act,1986 to manufacture soil-flyash bricks. Spent organic solvent, oily residue, pet coke, filter press cake (hazardous waste), etc. and other wastes (such as plastics,rubber,etc) shall not be used as fuel in brick kiln unless otherwise they are declared as one of the ‘approved fuel’ under the provisions of The Air (Prevention and Control of Pollution) Act, 1981 by the designated Authority. Multi layer and multi story Green belt of 10 m width, shall be developed along the periphery of brick kiln leaving two 10 m wide gaps in the boundary for entry and exit i.e. for movement of material and vehicles or a 3 metre wall shall be constructed on the sides where land is not available for green belt development to prevent fugitive emissions. Lightening arrestor as per the PWD norms or any other standard design shall be installed for Brick Kiln to avoid the damage to stacks/chimneys caused due to lightening attack.Paving of floors with over burnt bricks is recommended at the unloading side which will help in avoiding dust becoming air borne. Sprinkling of water shall be practiced in working area to suppress the dust. Regular cleaning of working area is recommended.Arrangements shall be made in the kiln for rainwater harvesting. Performance
Evaluation of Air Pollution Control System-Modification thereon and Review of
Emission Standards for Bull’s Trench Brick Kilns: There
are around 1,50,000 kilns engaged in brick production in the country. Different
types of kilns i.e. clamp, down draught kilns and bull’s trench brick kilns are
employed in brick making in India. However, Bull’s trench kilns (BTKs) are prevalent
all over the country. Brick making is highly energy intensive process and results
in stack and fugitive dust emissions due to inefficient combustion and ash covering
and handling of clay. Some of technological developments such as fixed chimney,
gravity settling chambers, introduction of vertical shaft brick kilns have resulted
in some reduction in pollution and increase in energy efficiency. The existing
emission standards for Bull’s Trench Kilns- BTKs) were notified on 2nd
April 1996. These emission standards banned use of moving chimney type BTKs which
were considered as a real issue to be addressed in BTKs. Switching over to fixed
chimney with stipulated height, individual units need to install gravity settling
chamber (GSC), a pollution control system to keep the SPM level below the prescribed
standard. It was realized to evaluate the performance of those technologies . The Central Board has entrusted the aforesaid project to The Energy & Resources Institute (TERI), New Delhi to carry out a performance evaluation of these designs adopted in different regions of the country . 12 kilns were monitored consisting both new and modified BTKs in different regions of the country in Punjab (mansa), U.P. (Agra-Fatehabad) and Tamil-nadu (Chennai) covering BTKs of all the four technology providers . Apart from these, soil, coal from kiln site and water samples are collected from village hand pump and village pond to test fluoride and mercury content. Study is in progress. The draft report is being prepared. Fly Ash Utilization by Brick Kiln Ministry of Environment and Forests, Govt. of India Gazette Notification, dated 14.09.1999 as a follow-up of the Hon’ble High Court of Delhi orders in CWP No. 2145/99; in the matter of Centre for Public Interest Litigation, Delhi Vs. Union of India and Others. An amendment,dated 27/8/2003 was notified for the said notification. Now, it is mandatory for brick kilns to use flyash, bottom ash or pond ash on weight. to weight. basis to the extent of 25 % in brick making if located within 100 km radial distance from any coal or lignite based thermal power plant w.e.f 27/08/2004. The Central Pollution Control Board compiled amended version of principle notification and circulated to all State Pollution Control Boards and Pollution Control Committees for information and implementation of the notification. Fly Ash Utilization Programme (FAUP), DST, Govt. of India in close association with the Ministry of Environment & Forest has organized training-cum -demonstration programmes for stakholders. The State Pollution Control Boards and Pollution Control Committees were suggested to insert advertisement in the leading newspaper for effective implementation of the notification. As a follow up 22 State Pollution Control Boards and Pollution Control Committees have inserted advertisement in newspaper till date . The use of fly ash is picking up since various construction agencies are now duty bound to use flyash bricks, blocks and tiles as the case may be in compliance of the notification. Emission Standards for Refractory Industry Refractories are products manufactured from raw materials like clay, silica, quartz bauxite etc. Refractories can withstand high temperature and used as structural materials in kilns etc. In refractory Industry the Air Pollution comprising particulate matter (PM), SO2, and NOx . It also generates wastewater, solid waste and hazardous waste. The study
has been completed by the Central Pollution Control Board in association with
National Council for Cement & Building Materials (NCCBM), New Delhi. The present
environmental scenario of the Indian Refractory Industry has been studied. In
depth at six refractory plant i.e. Rathi Ceramics (Faridabad), VRW Refractories
(Chennai), Eastern Refrcatory (Jhansi), ACC (Katni) , Carborandom Universal (Ranipet,
Chennai) and Tata Refractories Ltd. (Belpahar, Orissa). Emission Standards and Stack Height Regulation, Good practices and Siting Criteria for refractory industries were discussed in the 18th Peer and Core Committee meeting in the Central Board held on 20th and 21st April 2004. The observations of Peer & Core Committee were incorporated in the proposal. Minutes and proposal have been circulated to expert, Industry and refractory Association. The revised recommendations for emission standards and stack height on the basis of fuel and type of furnace were put up before 132nd meeting of Central Board on 4th January 2005 for discussions and acceptance. Table 10.6: Emission Standards and Stack Height for Refractory (down draught kiln) Category A : (Fuel :
Coal)
Note: Each stack shall be at least 2 metre above the top most point of the building, Shed or plant in the industry. Table
10.7: Emission Standards and Stack Height for Refractory (other than down draught
kiln)
Note:
Each stack shall be at least 2 metre above the top most point of the building,
shed or plant in the industry. Table 10.8:
Emission Standards and Stack Height for Refractory Category
B (Fuel: Oil / Natural Gas/ producer gas /LPG or including all, except Coal)
Note:
Each stack shall be at least 2 metre above the top most point of the building,
Shed or plant in the industry. Table 10.9: Emission Limit and Stack height for Rotary Kiln in Refractory IndustryCategory C : Rotary Kiln)
Trade EffluentWastewater overflowing from producer gas coal tar pits along with factory water may be let out from the plant till effluent standards for producer gas plants are separately notified or as per consent order issued by the concern State Pollution Control Board or Committee. The prepared standard are presented in Table 10.10. Table
10.10: Proposed Effluent standard for Refractory Industry
Solid
WasteThe ranges of solid waste depend on the
process and type of refractory product. It has been observed that most of the
solid waste product is recycled or sold out /utilized but in the case of waste
silica bricks, they are dumped and then utilized as building bricks for compound
walls/ flower bed. A separate study has been undertaken for coal tar waste from
producer gas plant. Even the solid wastes from electro- static -precipator (ESP),
from rotary kiln and the calcinated waste are used in some agricultural lands
for stabilization. However, each type of solid waste should be disposed of as
per the provisions of The Hazardous Waste ( Management and Handling) Rules, 1989
and The Municipal Solid wastes (Management and Handling)Rules, 2000, as applicable
. Dumping yards should be designed for each solid waste in such a way that solid
waste should not be spread all over the premises. Table 10.11: Handling of Hazardous Waste
Siting Criteria (For New Refractory Industry/ New ‘Green Field’ Units ) .If refractory plant is not located in any approved/notified industrial area but in isolation; Refractory plant shall be established at least 2.0 km away from the notified municipal limit of any town or city. The plant shall to be located 5 Km away from airport, 500 m away from the mid of railway track, National/ State Highway and 100 m from mid of any other road. Refractory plant should be established preferably at least 1.0 km away from residential areas/village (having population of 500 people at least), hospitals, schools, college, public building and/or a place from where flammable substances are collected, when plant is in prominent up wind direction and 500 m in other directions. Distance between mango orchard (with area 2.5 acres or more )and refractory plant shall not be less than 500 m when refractory palnt is in prominent upwind direction and 200 m in other direction. The mentioned distances are applicable only for that mango orchard irrespective of variety (indigenous/hybrid) whose area individually or collectively should not be less than 2.5 acre. There won’t be any difference between mango orchard and a joint nursery. Mixed orchard having 100 mango trees shall be treated at par. Good
Practices for Refractory Industry
Emission
Standards, Siting Criteria and Good Practices for Hot Mix Plants Construction
of roads plays a vital role in the socio-economic development of the country.
Ever since the Government of India declared infrastructure as the thrust area,
there has been predominant boom in the road sector. The construction and maintenance
of major portion of the road network is done by using conventional hot bitumen-mixes.
The emissions from hot mix plants contain particulate matter, sulphur dioxide
besides poly-aromatic hydrocarbons. 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, drum-continuous type. The rated production capacity varies from 6-10 tph to 10-120 tph. Burning of fuel, feeding of aggregate, heating of bitumen from such a large number of plants is bound to create environmental hazards especially `air pollution’ due to dust and volatile organic compounds like BTX, PAH and PCBs. The Central Pollution Control Board interacted with three leading manufacturers of HMPs at international level namely:- M/s Speedcrafts Ltd., M/s Telco Construction Ltd. and M/s Linhoff Technological Pte Ltd., offering state-of –art technology with a claim of particulate matter level as low as 25 mg/Nm3 . Emission standards, siting criteria and good practices were drawn and discussed in the Peer and Core committee of the Central Board in March 2004. The committee desired to collect data on hydrocarbons in emission for new generation HMPs. The Central Board is taking steps to upgrade its monitoring facilities for hydrocarbons monitoring in stack emission. The leading private and Govt. laboratories also do not have facilities for monitoring hydrocarbons in stack . Development of Environmental Standards, Stack Height Regulations and Good Practices for Producer Gas Plants and Biomass Gasifiers Producer
gas is a derived gaseous fuel by gasification of various primary fuels like coal,
lignite, wood, agriculture residue and other biomass. Though, the bio-resource
base of India is substantial, its contribution to useful energy is low. Producer
gas can be employed in thermal application or for mechanical/electrical power
generation. There are no specific standards for producer gas units or bio-gasifiers.
The Central Board therefore, has taken up this study for formulation of environmental
standards for these units with the assistance of The Energy and Resources Institute
(TERI), New Delhi. The producer gas derived from gasification of coal continues to be the main fuel for the refractory industries particularly in the eastern part of India. Grade – E coal i.e. poor quality coal is available at a cheaper cost and refractory industries took advantage of it in eastern India. Similarly in western India, due to abundance of charcoal, Refractory industries are using charcoal-derived producer gas/bio-gas for kiln and furnace heating. Monitoring of biogasifiers was undertaken for the units utilizing gas for Ceramic industry at Morbi, Gujrat Industrial Carbon Dioxide production at Porbandar, Gujrat demo biogasifier at Savli, Gujarat and rice mill at Burdhwan, West Bengal Monitoring for producer gas units was carried in re-rolling mills at Raipur, Chattisgarh, refractory industry at Jharasguda, Orissa. limekilns unit at Paonta Sahib, Himachal Pradesh and Dankuni Coal complex in Kolkatta. West Bengal. Producer & biogasifier gas units were monitored for stack emissions (PM, SO2 & CO); ambient air quality (SPM, RSPM, SO2, & NOX); Work station air quality (Dust level, CO); Liquid effluents (pH, temperature, TS,SS,TDS, Oil & Grease, COD, BOD, phenols & Total Cyanide); solid waste (ash & tar) and energy performance. It
is derived that most downdraught and cross-draught power gasifiers can be equipped
with dry-gas clean-up systems, which drastically reduce the quantity of liquid
effluent produced. Some important industrial safety issues pertaining to exposure
to high temperature surfaces, exposure to CO emissions, and prevention (and control)
of explosions and backfires. It calls for good design of the insulating system,
good instrumentation and control. The compilation of report is under progress. Environmental Standards and Good Practices for Automobile Service Station, Workshop & Bus Depot (including disposal of waste oil, used batteries, used tyres and tubes etc.)" There are 28 States and 6 Union Territories with almost 600 districts in India. All the states and U.T.s have their own state transport corporations/roadways (STC/R). Many of mega and metro cities have their own transport corporations like BEST, DTC, etc. It is estimated that at least 2250 bus depots are owned by the STC/R. Bus depots are required for parking, night shelter, repair and overhauling works, washing, painting, repainting, servicing, fueling/refueling of buses and other related purposes. Apart from the STC/R, a number of private companies and individuals also have a fleet of buses, mini buses or maxi cabs. As per rough estimates, there may be more than 50,000- service stations through out the country owned by automobile manufacturers, their agents, individuals or STC/R. The current practices in service stations and bus depots are not oriented towards minimizing pollution by incorporation of implant pollution control measures. Of late, effluent treatment, emissions, noise control and implant pollution control measures are being given importance in this sector. Considerable changes in manufacturing processes, repair & maintenance schedule, practices of vehicles to improve upon the efficiency and to lower the cost of operation & maintenance in order to minimize the use of water, electricity, manpower, wastage of fuel reducing frequency of painting, replacement of battery, tyre and tubes and idling of vehicles; some of the technological developments have helped in prevention, abatement and control of pollution apart from increase in life of vehicles, better comforts to passengers, lesser operation & maintenance cost and fewer breakdowns. To assess the situation and to formulate storm water, effluent, solid waste management, noise and emission standards for bus depots, workshops and service stations the project has been initiated by Central Pollution Control Board. The information on the status (i.e. number, size and location) of automobile service station, workshop, bus depot etc. in the country: State wise & City wise have been collected. Appropriate pollution abatement and control systems based on ‘best available technology not entailing excessive cost’ (BATNEEC) concept needs to be adopted to evolve suitable environmental standards, guidelines which could be techno economically feasible for the automobile service station, workshop and bus depot; and to recommend good practices and better housekeeping for all operations. Development of Emission Standards and Good Practices for Arc Furnaces and Induction Furnaces in SSI sector Electric arc furnace (EAF) and induction furnaces (IF) are two principal melting/refining types of units in mini steel mills producing carbon, alloy and special steels for flat or products having long length, applications. The main raw materials in both the units, beside slag forming agents and additives for ferro-alloys are scrap and electricity. The proportion of steel making via electric furnace route is relatively high.The existing emission standards for Suspended Particulate Matter for arc and induction furnace, irrespective of capacity are 150 mg/ Nm3. With the rapid industrialization, the consumption of steel continues to grow and as a result, scarp generation will also continue to increase. The Central Board therefore, has taken up a study to develop environmental parameters systematically for EAF & IF and recommend techno-economically feasible environmental standards, and strategies for better environmental conditions with the help of The Punjab State Council for Science and Technology, Chandigarh. There are approx. 1000 induction furnace units and 85 electric arc furnace units, out of which 50 units have submerged arc furnaces. These furnaces are used for production of mild steel, special steel, stainless steel and various ferro-alloys in secondary steel sector. However, submerged arc furnaces are exclusively used for producing ferro-alloys (i.e. ferro- manganese, ferro- chrome, ferro-silica, etc.) The secondary steel process units ( i.e. induction and arc furnaces) are located mainly in clusters in India. These clusters are at Mandi Gobindgarh & Ludhiana ( in North); Coimbatore, Palaghat & Belgaun (in South); Durgapur and Hooghly ( in East); and Ahmedabad, Bhiwadi & Goa (in West) i.e. a total of 10 clusters in the country. More than 100 induction furnaces units are being installed in the country. Raw materials for secondary steel units remain sponge iron, scrap (imported and indigenous), own waste metal (i.e. riser and runners produced in the casting) apart from flux. The total slag generation from these 150 furnaces has been estimated as 3000 tonnes/day. In total, (approx). 18,60,000 tonne slag is generated in secondary steel sector per annum (Table 10.12). The slag from induction and arc furnaces contain silica (SiO2) in the range of 15-20%. Similarly, secondary steel slag contains more iron than blast furnace slag. This slag if used, as an admixture in cement could be a source of iron in cement. Ferric cement produced by using slag results in extensive saving of resource and energy. The slag from secondary steel units may be utilized in cement industry. Table 10.12 Estimated Slag Generation by Induction and Electric Arc furnace in Secondary steel Sector
tpa-
tonne per annum; tpd- tonne per day 10.2 INDUSTRIAL POLLUTION CONTROL Compilation of Material Safety Data Sheet (MSDS) for the 708 Hazardous, Toxic and/or Flammable Chemicals Material safety data sheet contains information on the potential health effects of exposure and how to work safely with the chemical product. These data sheets includes the information about the physical, chemical and toxic properties of the chemical (s). MSDS is widely used by manufacturers, dealers, universities, indenters, laboratories, etc. using various types of hazardous, inflammable and/or even corrosive chemicals. There 684 hazardous & toxic chemicals under Schedule 1 ( Part II) and other 30 and 179 chemicals under Schedule 2 and Schedule 3 (Part –I) of Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989 as amended to date. The list of 179 chemicals has been notified as part of Public Liability Insurance Rules, 1999. In total, there are 708+ chemicals for which MSDS are required as per existing Rules and Notifications. List of 708 chemicals has been drawn and 22 organizations, institutes, national and international publishers were contacted out of which 12 responded. The project is undertaken by Central Pollution Control Baord in Collaboration with National Chemical Laboratory, Pune. The objectives of this study to develop a database and a publication of Material Safety Data sheets in the appropriate format, as notified for all the 708 chemicals and formulations. (MSDS be compiled for additional chemicals and formulations, if required); to prepare master soft copy on CD and 100 copies on CD; and to prepare camera ready material for bringing out printed version of the compilation. Improvement in working of Aawas and Standardization of Vertical Bhatti Design for Earthen Wares The earthenwares such as pitchers, flowerpots, kulhar, etc. are used in Indian society irrespective of rural and urban areas. The earthen wares are moulded from the clay using traditional potter’s wheel. The electricity is also used in moulding wares in urbanised villages, towns and cities to get more production. Earthen wares are dried in sun and fired using `Aawas’ using traditional method. Dry grass, leaves, agricultural residue and cow dung are pre-dominantly used in `Aawas’ as fuel for firing earthenwares. This activity is a nuisance in the vicinity and real problem during temperature inversions. Aawas used presently are triangular with 3 m – 4.5 metre base or circular with 3.0 m to 6.0 metre dia and used for better process. Generally, it is below the ground by 0.30 to 0.60 m. The disadvantage of such aawas/ bhattis is that these are not suitable for very big size and fancy pottery. The firing cycle extends over 3 days. It cannot be operated during rain and wet condition. Aawas are more popular in rural areas for a single family, since it is convenient. Of late, indigenous development have taken place and vertical bhattis are developed. These bhattis are circular in shape and firing cycle is over within 24 hrs. The vertical bhattis, a batch process can be used for making all kinds of potteries. These can be operated during monsoon, though sun-drying may be a problem. The kiln may cost Rs. 25,000/-(approx) each. Fuel used is generally rice husk, saw dust and/or cow dung. Such bhattis exists in town and cities. One entrepreneur is using LPG in box furnace for firing earthen wares at village Bindapur, Delhi. CNG can also be used as fuel for firing earthenwares provided kiln or furnace is developed and CNG is made available. The objective of the project is to standardize the design of traditional awas, and vertical bhatti for earthen wares; optimization of entry ports; provision of fire grates; to design the chimney and dampers; standardizing of stacking practices before firing; identification of clean fuels/less polluting fuels; better fuel feeding & firing practices or looking into possibility of looking into possibility of use of biogasifier; to develop good-practices and siting criteria.; and to provide design so developed, free of cost to users. Pollution Control in Tanneries The Central Pollution Control Board has undertakes inventorisation of tanneries located in Kanpur. The objective of inventory, apart from physically verifying the operational and closed units was also to assess the status of pollution control measures. The salient observations as emerged are as below: The pre-treatment provision are poorly operatedThe chrome – recovery plants are operated properly and recovered chrome re-usedThe sludge disposal from the tanning process is poorly managed mainly due to irregular lifting by Kanpur Municipal CorporationUntreated wastewater from tanneries in Sanjay Nagar area of Jajmau was observed to be discharged in trunk sewerThere have been about 10 cases of unauthorized tanneries operational in Jajmau areaExcept for stray cases in large scale units, cleaner operations are generally not practiced The conveyance system for tannery wastewater is in poor state and was observed clogged in several stretches ultimately resulting in lagooning in many areas    Fig. 10.2 Tanneries Scale of Operation at Kanpur  Chrome Recovery Plant  Pollution Control in Jajmau Treatment Plant Pollution due to Tannery cluster in Jajmau area of Kanpur came-up as a sensitive issue. Coupled with lack of sewage interception works and poor performance of CETP / STPs established, water quality of River Ganga at Kanpur is being affected. The Central Pollution Control Board has taken measures to ensure phenomenal improvement in overall scenario. The sequence of measures and observed impact are as below : Detailed investigation of the area, performance evaluation of CETPs and STPs in April 2004, July 2004 and December 2004Based on the investigations Directions under Section 5 0f EP(A) and the Section 18 of The Water Act were issued by Chairman Central Pollution Control Board made and communicated to CPCB HO In order to enforce the Directions issued by Chairman CPCB, ZO: Lucknow took –up detailed investigation and the issue was raised before The District Magistrate and The Divisional Commissioner Kanpur Series of interaction were made with GM, Ganga Pollution Control Unit Kanpur Municipal Corporation and Tannery Associations in KanpurThe matter was raised in CREP Subcommittee meeting and also at the National Task Force meeting for tanneries. Stress was given to ensure waste minimization measures by tanneries in Jajmau cluster
Pollution
Control Status of Distilleries and Paper mills Distilleries and paper mills have been identified as major source of pollution in the state of UP and Uttranchal. Special efforts have been done for control of pollution from these units, which are causing problem for river pollution, particularly responsible for Ganga River pollution. After surveillance distilleries have been directed to achieve zero discharge for spent wash being generated by adopting various techno-economically viable techniques like Installation of RO PlantInstallation of evaporatorBio-composting.Ferti irrigation Distilleries are in process of achieving the target of zero discharge of spent wash by December 2005.Agro based Small Paper mills operating in the catchment area of River Ganga have been directed either to install chemical recovery plant or switchover to waste paper in order to overcome the problem of black liquor discharge generating from the paper making process. Target date set for installation of Chemical recovery plant is March, 2006. Almost all the paper mills have submitted their action plan to comply with the directions. Economic Viability of Various Treatment Options for Distillery Effluents In
order to prepare perspective view of the present scenario of economics involved
in the treatment plants of distillery industries, the Central Pollution Control
Board has undertaken. Dry data collection, compilation, synthesis and interpretation.
The treatment system with primary, secondary treatment followed by reverse osmosis
and use of reject for composting was found as most cost effective, resource conservative
and eco-friendly method. Primary treatment of spent wash with bio-methanation
facility followed by composting seems to be economically lucrative, subject to
the availability of sufficient press-mud, land (for composting) and ample agricultural
land in the region for use of produced compost. Turbo Mist Evaporators Technology for Treatment of Distillery Effluents Assessment
of Enhanced Natural Evaporation System have been made at Vindyachal Distillery
Pvt. Ltd., Pilukhedi for disposal of distillery effluent. The industry has got
three turbo evaporators installed during Sept 2004. It has been confirmed by the
industry representative that 152 m3 of effluent could be evaporated
in 24 hours by each turbo evaporation machine. The evaporator is basically a turbine
fan installed at one end of the tunnel/barrel and driven by an electric motor.
It is capable of throwing the effluent into the atmosphere in the form of mist
and the mist gets evaporated before it reaches the ground. The organic matter
and the dissolved solids in the effluent remained in the atmosphere and could
be carried away with the wind to the surrounding areas. The efficiency of the
process depends on the atmospheric conditions and it could not be operated in
rainy season. Pollution Control in Slaughter House The Hon’ble Supreme Court while hearing the matter of Writ Petition ( C ) No. 309 on July 26, 2004, observed that the main question in the petition is about disposal solid waste generated at the slaughter houses. The Hon’ble Supreme Court directed CPCB to collect information from various State Pollution Control Boards/Committees as to the modes adopted in their respective areas for disposal of the solid waste. Accordingly, CPCB requested all the State Pollution Control Boards/Committees to supply requisite information in format. On receipt of information CPCB compiled and submitted the to the Hon’ble Supreme Court in November 2004. Pollution Control from Generator Set Emission Limits The implementation of emission limits for new diesel engines (upto 800 KW) for generator sets (Genset) applications notified, vide GSR 371(E), May 17, 2002 (and its amendments), has been rescheduled vide GSR 448 (E), dated July 12, 2004, as given below in the table. The emission limits for different ratings of diesel engines for genset application are presented under: Table 10.13 Emission Limits for Diesel Engines for Genset Applications
Noise Limits The implementation date of the revised noise limits for diesel generator sets (upto 1000 kVA) was re-scheduled vide GSR 448(E), dated July 12, 2004 and is now effective from 1.1.2005. The notification prescribes that the new generator sets (upto 1000 kVA) manufactured on or after 1.1.2005 shall comply with noise limit of 75 dB(A) at 1 m metre from the enclosure surface and shall be provided with integral acoustic enclosure at the manufacturing stage itself.However, for the existing (manufactured before 1.1.2005) generator sets (upto 1000 kVA), as well as, all generator sets more than 1000 kVA, the noise level shall be controlled by providing an acoustical enclosure or by treating the room acoustically at the users’ end. Further, the acoustic enclosure or acoustic treatment of the room shall be designed for minimum 25 dB(A) insertion loss or for meeting the ambient noise standards, whichever is on the higher side. Meetings of Sub Committee of National Committee on Noise Pollution from Gen-Set A
meeting of the Sub-Committee of the National Committee on Noise Pollution Control
was also held on 14.12.2004. The meeting was held to review the "System
and procedure for compliance with noise limits for petrol/kerosene gensets". Pollution Control in Aluminium IndustryMoEF has constituted a National Task Force for implementation of recommendations of the Charter on Corporate Responsibility for Environment Protection (CREP) in aluminium industry. The second meeting of the National Task Force for aluminium industry was held on October 5, 2004. The major decisions taken for control of pollution from aluminium industry are: Maximum capacity of aluminium production to be permitted at one location The environmental damage to the surrounding area should be the criteria for deciding the max. capacity that can be permitted at one location. The expansion of the plant must be permitted considering the assimilative capacity of surrounding environment. Sampling
and Analysis of Poly Aromatic Hydrocarbons The Poly-aromatic Hydrocarbons (PAHs) are proven carcinogens. Therefore PAHs are to be monitored in anode baking ovens and pot room area of aluminium smelters alongwith secondary (fugitive) fluoride. Dry disposal of Red Mud and its Utilization It was decided that aluminium plants will follow the dry disposal method of red mud as per CREP recommendations. The utilization of red mud in cement plants is a viable option for disposal of red mud. Thus, aluminium plants should take measures for utilizing red mud by nearby cement plants. Handling and disposal of Spent Pot Line Spent Pot Lining (SPL) is classified as a Hazardous Waste under the HWM Rules 1989. Therefore individual aluminium unit should apply for permission to the concerned State Pollution Control Boards for handling & disposal of SPL. The experimentation to find new options for disposal should be encouraged and used in thermal power plants, cement plants, foundries, steel plants and brick industries should also be pursued. Besides MoEF has been requested to notify following revision of standards for aluminium industries: a. Revision of fluoride emission standards
Pollution
Control from thermal power plants There are 83 coal based thermal power plants in the country of which 4 thermal power plants are closed. 55 thermal power plants comply with emission standards & 23 plants are yet to comply with the emission standards. 63 thermal power plants comply with effluent standards & 15 plants are yet to comply with the effluent standards. Use of beneficiated Coal at Thermal Power Plants The Ministry of Environment & Forests, Govt. of India has promulgated a Gazette Notification (GSR 560(E) & 378(E), dated September 19, 1997 and June 30, 1998 respectively) on use of beneficiated/blended coal containing ash not more than 34 percent( an.av.) w.e.f. June 2001(extended to June 2002) in the following power plants :Power plants located beyond 1000 kms. from pit head; Power plants located in critically polluted areas, urban areas and in ecologically sensitive areas. The power plants using FBC (CFBC, PFBC & AFBC) and IGCC combustion technologies are exempted to use beneficiated coal irrespective of their locations Beneficiated/blended coal
having ash content 34% or less is used by 24 thermal power plants ( 85 units)
. The details of such Thermal Power Plants are presented in Table 10.14. Table
10.14 Thermal Power Plant using Beneficiated/Blended Coal
During the year 2004-05, CIL and SCCL supplied 268 million tones of coal to thermal power plants in the country. Of which 38.49 washed coal was supplied by the exiting 14 non coking coal washeries. There is still gap of about 49.51 million tonnes of washed coal to cover all 39 identified plants located either 1000 km from pit head or in critically polluted area, sensitive or urban area. Table 10.15 Status of Washeries Supplying Washed Coal to Thermal Power Plant
* Recently Lodna washery is also being used for beneficiation of non-coking coal
Coal
Cleaning involves reducing the ash component, which contains trace minerals including
mercury, as well as sulfur compounds, before the coal is crushed and introduced
into the boiler for combustion. This process is used to lower shipping, storage,
and handling costs per unit of heating value, and improves boiler output per unit
weight input of coal. Coal cleaning has primarily focused on removing sulfur to
reduce acid-rain-related emissions. Average mercury removal efficiency : 21% Percent of coal being cleaned ( non Coking) : 15%
Particulate
Emission Control Electrostatic Precipitators (ESPs) are used to reduce fly ash emissions by creating an ionized field that removes charged particles. Although they have low energy requirements and operating costs, ESPs have limited ability to remove mercury because mercury exists in a vapor form in flue gas and does not generally adsorb fly ash particles at typical combustion temperatures.Average mercury removal efficiency : 24%Percent of utility boilers equipped with ESPs: 99.5% (320 out of 325)Fabric Filter (Baghouses) also used to limit fly ash emissions, pass flue gas through a tightly woven fabric capturing particulates on the fabric by sieving and other mechanisms. The dust cake that forms on the filter can increase significantly the collection efficiency. Baghouses can potentially reduce both elemental and ionic mercury.Average mercury removal efficiency : 28%Percent of utility boilers equipped with baghouses: 0.6% (2 out of 325) Acid Gas Control Flue Gas Desulfurization (FGD) or Scrubbers are installed to remove sulfur dioxide from power plant flue gas. Scrubbers use sorbents to create the chemical reactions needed to remove SO2. There are wet and dry scrubbers, with wet scrubbers being more efficient (up to 95%) in removing SO2 than dry scrubbers. One of the waste products generated through the wet scrubber process is gypsum (calcium sulfate), which is sold commercially or disposed of. Already in place to help coal-fired boilers meet SO2 emissions regulations, there is significant interest in using these systems to simultaneously remove SO2 and trace metals, including mercury. Wet scrubbers are more efficient in removing ionic mercury from waste incinerator flue gas compared to utility boiler flue gas.Average mercury removal : 34%Percent of utility boilers using technology : 0.3% (1 out of 325)Selective Catalytic Reduction (SCR) SCR technology is used to reduce emissions of nitrogen oxides (NOx) by using low NOx burners to create a fuel-rich primary combustion zone. This reduces the amount of thermal and fuel NOx created during combustion. NOx, a main component of smog, can be reduced up to 90% using SCR. SCRs have also been found to increase the amount of oxidized mercury downstream. Since mercury in an oxidized form is more readily captured by scrubbers, the combination of these flue gas controls may effectively capture a significant amount of mercury. Emerging Power Plant Controls Although methods for mercury capture have been developed mainly for waste incinerators, new mercury control technologies are being developed for coal-fired utility boilers. Currently, none of these systems are being deployed commercially. Some of these technologies include:Carbon Injection is the mercury control technology closest to commercialization for power plants. It involves the direct injection of activated carbon into the flue gas stream of a utility boiler. The carbon is collected in downstream particulate control equipment. Mercury removal depends on the total amount of carbon used, temperature, mercury speciation, flue gas composition, and type and amount of activated carbon used, averaging about 80-98% reduction.Carbon Filter Beds are capable of removing high mercury concentrations from waste incinerators. In addition, several power plants in Germany and Japan use this technology for acid gas removal and achieve more than 90 percent mercury control as a co-benefit. However, carbon filter beds have not been tested for power plant flue gas mercury removal in the U.S. One pilot project measured at least 99% mercury removal on a municipal waste incinerator. Condensing Heat Exchangers have a tube-and-shell heat exchanger which uses water to extract the residual heat from flue gas. A pilot test showed mercury removal of 84% with a boiler slipstream in addition to 11-36% removal of other toxic metals. Mercury Capture using a Noble Metal Sorbent is based on the ability of some metals, gold in particular, to form alloys with mercury. This alloy formation is reversible and at elevated temperatures, the mercury revolatilizes. Lab tests of alumina-supported gold showed 95% removal of gaseous mercury, regardless of chemical form. Since gold can be continuously re-used and the mercury can be sold, the process generates no waste. However, if the captured mercury is not being retired, and rather is introduced into the market late, the mercury sold will likely generate waste elsewhere. Fuel Switching is switching from coal or oil to natural gas or renewable like wind or solar. The use of cleaner fuels would largely eliminate emissions of articulates, other metals, SO2, NOx, and carbon dioxide, as well as reduce by over 99% all mercury emissions. Assessment of feasibility to meet the emission limit of 100 mg/NM3 of particulate matter in existing Thermal Power stations A study to assess the feasibility for meeting the emission limit of 100 mg/NM3 of particulate matter emission limit was carried through Central Electricity authority, New Delhi under Corporate Responsibility for Environmental Protection (CREP)., the characterization was made based on the particulate emission data collected from 325 units from 74 thermal power stations. Of which, the particulate emission was within 100 mg/Nm3 in 25 thermal power plants (77 units), More than 100 and less than 150 mg/NM3 was in 42 plants (135 units ) , Between 150 to less than 350 mg/NM3 was in 25 plants (70 Units) and particulate emission was more than 350 mg/Nm3 was in 11 plants (28 units). The study includes the constraints in achieving the limit of 100 mg/NM3 and also assessed the impact of coal quality on reducing the particulate matter emission. Recommendations and Road map have been suggested to achieve the emission limit of 100 mg/NM3 . The recommendations are : Washed/ beneficiated coal containing ash less than 30% may be used along with upgradation of existing control systems Augmentation of existing ESPs by increasing Specific Collection Area (SCA) and replacing existing controllers with microprocessor based controllers wherever necessary. Old boilers may be renovated alongwith upgradation of ESPs which will reduce lead time of ESP augmentationAfter detailed indepth investigation and evaluation of performance, Flue Gas Conditioning may be adoptedInternal inspection and periodic monitoring and maintenance of ESPs Road Map for achieving the limit of 100 mg/NM3 of Particulate Matter Forty plants can meet the emission limit of 100 mg/NM3 by Increasing Specific Collection Area (SCA) and addition of more fields and replacing existing controllers with microprocessor based controllers wherever not replaced.24 plants can meet the emission limit of 100 mg/NM3 by replacing existing controllers with microprocessor based controllers wherever not replaced and Fine tuning and adequate maintenance of each ESP, Flue gas duct and Boiler.20 plants can meet the emission limit of 100 mg/NM3 by using beneficiated /washed coal alongwith Flue Gas Conditioning Performance of Electrostatic Precipitators in Thermal Power Plants in Rajasthan State Kota Thermal Power Station, (RSVUN), Kota Kota
Thermal Power Plant, located at the bank of Chambal river at Kota (Rajasthan),
has a power generation capacity of 1045 MW (2 x 110, 3 x 210 & 1 x 195) with
14076 MT coal consumption and 3591 MT fly-ash generation per day. The ash and
sulphur contents in coal was 28-30% and less than 0.5% respectively. Coal is being
supplied by SECL, Korba and NCL, Singrauli by rail. Approx 23584 m3
of water was drawn per day from Kota barrage on Chambal River at Kota. Once through
cooling system existed and the temperature difference between intake and outgoing
water varied from 50 C to 100 C. Sewage treatment plant
of 1.2 MGD capacity was provided in the colony for treatment of domestic effluent.
The ash dyke overflow being discharged into Nantha nullah, which was being used
by the farmers in the downstream. There were two ash dykes of 158 Ha and 265 Ha
respectively. The pipeline carrying slurry was around 1.5 km long. Unit-III, IV,
V & VI have dry fly-ash storage silos of 200 MT capacity, fly ash was lifted
by the cement plants for their use. There were six units
having separate ESPs with an efficiency of more than 99%. ESP in unit-I &
II had 17 fields each, whereas Unit-III, IV, V & VI had ESPs with 28 fields
each. During visit, unit-IV was working with 25 fields. Unit-V & VI were shut
down for annual maintenance. Opacity meters have been installed in all the units
but were not in operation except for unit-VI, which displayed reading as 132 mg/NM3.
The industry had 500 KVA DG set for emergency. There are three stacks each of
180 meter height. The Thermal Power Plant has got a exemption for 180 meter height
stack due to aerodrome located about 3 km away from the plant. .Semi-pulse type
microprocessors are installed in all the units to control the operating parameters.
Based on the performance survey the following are the recommendations:Silos
should be constructed to collect dry fly-ash from all the units for fly ash users.The
industry should make proper pitching to give stability and strength to ash pond
embankments to avoid any breach. The ash-dyke overflow water should be reused
in the plant for slurry making and gardening. Vegetation cover on the ash pond-II
should be developed to prevent fugitive emission during summer. Groundwater quality
around the ash dyke should be monitored and fly ash should be analyzed for heavy
metals.Noise monitoring should be undertaken by Kota
Thermal Power Station regularly in plant and at township during day and night.Dust
suppression system should be installed at coal handling plant and at wagon trippler.
Dust extraction system should be in operation at coal crushing areas and water
spray should be done on roads, regularly. Number of fields in ESPs for the unit-I
& II should be increased to achieve the limits prescribed by RSPCB. Opacity
meters should be repaired and calibrated in unit I to V and should be kept in
continuous operation.Necessary monitoring facilities
may be acquired by the industry and the monitoring should be conducted regularly.
It will help capacity building and better understanding for pollution control.
The STP should be operated properly and regularly to
attain the prescribed limits of treated wastewater.The
industry should develop the SLF for hazardous waste as recommended in the authorization. Suratgarh Super Thermal Power Station (STPs) Rajasthan The power station has installed capacity 1250MW (5X250 MW) with a 16445 MT coal consumption and 6400 MT fly ash generation per day. Sulphur content and ash content in the coal are 0.4-0.5% and 35-40% respectively. Coal being supplied by SECL Korba and NCL Singrauli areas in Madhya Pradesh. The water has been drawn from Indira Gandhi Nahar Pariyojna canal which is 5 KM away from the plant. All the five units of Thermal Power Plant are connected to ESPs having 28 fields each, ESPs have been designed to discharge less than 100 mg/nm3 of particulate matter . There are three stacks of same height ie. 220m each. Opacity meters have been installed at ducts before ESPs in all the five units but these opacity meters are not calibrated since their installation. Fixed Automatic ambient air quality monitoring stations have been installed at three locations within the plant premises. Besides, two mobile stations installed on mobile vans. Source emissions are measured fortnightly, at four stacks except in unit V. Ambient air quality monitored daily at three fixed locations, both the SMK were not in operation, one mobile van was not in use during visit. The wastewater from the colony (housing around 5000 people) and erectors hostels has been treated through septic tanks and discharged through soak pits to the stabilization tanks. STPS has a very large area for dumping of dry ash slurry, it may be sufficient for next twenty years. There was no overflow from ash pond, entire water has been percolated into ground because of sandy substratum. The STPS has submitted time bound programme for 100% ash utilization as per MoEF’s notification and provided dust extraction and dust suppression systems at all the transfer points, wagon Tripler and coal stacking areas but these were not in operation. Fugitive emissions were observed at CHP area. Silo’s are not provided, dry ash collected through ESP hoppers. Fly ash is being taken by cement plants (M/s Laxmi Cement, M/s Vikram Cement, Birla Cement etc.) . Cement plants lifted 22.8% fly ash during 2003. M/s. Shree Cement Ltd. constructing its own silo for dry fly-ash storage at unit V inside the plant. The following are the recommendations based on performance survey.The industry should get the environmental clearance and consents under Air and Water Acts for unit V and comply the conditions mentioned therein a.Dust suppression and dust extraction systems should be operated effectively at CHP area to control fugitive emissions. Opacity meters, stationary ambient air quality monitoring stations and mobile station instruments should be calibrated, and the values should be validated with the actual monitoring data.The industry should construct the STP for treating the domestic effluent coming from the colony and erectors hostels.Plantation/green cover should be developed on the ash pond to control fugitive emissions during heavy wind. Piezoelectric point should be provided around the ash pond to check the changes in ground water quality due to percolation of ash pond effluent. Heavy metals should be analyzed in fly ash being discharged into the ash pond.The industry should make a fuel supply agreement between coal companies and RSVUNL for the use of beneficiated/washed coal.The industry should construct the silo’s for dry ash collection and its tranfer to cement plants. Pollution Control from Copper Industry The National Task Force has constituted for implementation of CREP recommendations for Copper Industries to monitor the progress on the following agreed action points for controlling various environmental degradation. To meet SO2 emission limit (2 kg/tonne of H2SO4 produced), 50 mg/Nm3 of acid mist by December 2005. SO2 emissions monitoring: Installation/Proper operation, maintenance and calibration of continuous SO2 monitoring system by 30th June 2003. Proper operation and maintenance of tailing dams. Wastewater treatment and disposal: To achieve Zero discharge through 100% recycle/reuse of treated wastewater by 31st December 2003. House Keeping: To reduce the generation of fugitive dust from vehicle movement and improve overall house keeping by 31st December 2003. Green Belt: To develop canopy-based green belt around the periphery of plant and township as per CPCB guidelines.The status of Implementation of CREP recommendations for Copper Industries are presented in Table 10.16.Table 10.16 Status of Implementation of CREP Recommendations for Copper Industries
Pollution Control from Zinc Industry The National task force has been constituted for implementation of CREP recommendations for Zinc Industries to monitor the progress on following agreed action points for controlling various environmental degredation. To meet SO2 emission limit (2 kg/tonne
of H2SO4 produced), 50 mg/Nm3 of acid mist by
December 2006. SO2 emissions monitoring:
Installation/Proper operation, maintenance and calibration of continuous SO2
monitoring system by 30th September 2003. Solid
and Hazardous Waste disposal : Construction of secured landfill for disposal of
hazardous waste such as Jerosite cake, ETP cake and spent catalyst as per CPCB
guidelines by 30th June, 2003. Wastewater
treatment and disposal: To achieve Zero discharge through 100% recycle/reuse of
treated wastewater by 31st December 2004. House
Keeping: To reduce the generation of fugitive dust from vehicle movement and improve
overall house keeping by 31st December 2003. Green
Belt: To develop canopy-based green belt around the periphery of plant and township
as per CPCB guidelines. The
status on Implementation of CREP recommendations for Zinc Industries are presented
in Table 10.17.
The study includes identification of all fugitive emission sources, monitoring of fugitive emission, quantification of fugitive emission, characterisation of dust and analysis of the samples for metals. The study will suggest the standards for fugitive emission and develop environmental guidelines to control fugitive emission. Co-incineration of high calorific value hazardous waste in cement kiln The Environmental Policy for co-incineration of high calorific value hazardous waste in cement kiln was prepared by CPCB and discussed in Chairmen and Member Secretaries conference held on March 8-9, 2004. So far this has been a thrust area in India, while internationally high calorific Value hazardous waste is being co-incinerated in Cement Kiln. The advantage being that at a high temperature of 1400°C the organic compounds are likely to be destroyed. Further, 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. It also helps in energy saving, CO2 emission reduction and carbon trading. The cement industries have expressed their interest in the matter and have come forward for co-incineration of high calorific value hazardous waste in cement kiln. M/s Rajashree Cement located in Distt. Gulbarga of Karnataka State has been granted permission by Karnataka Pollution Control Board and Central Pollution Control Board to conduct trial run for co-incineration of ETP Sludge generated from BASF India Ltd., Mangalore. The trial run has been initiated from 16th January, 2005 during which ETP Sludge is being used in different proportions. Intensive monitoring of expected air pollutants (pollutants identified for hazardous waste incinerator) during the trial period is being conducted. Monitoring was also being conducted to cover one week before trial run and one week after trial run to generate the background / reference data. The VOC, hydrocarbon, TOC, PAH, heavy metals are being monitored besides the routine parameter i.e. particulate matter, SO2, NOx, HCl, HF, CO. The dioxins and furans which is considered as the most important and critical parameter have also being monitored. The ambient air quality also being monitored during the trial period. Even soil samples are being collected before and after the trial run to assess the impact of dust emission during co-incineration on soil quality. More over, the product i.e. clinker is being tested for its quality as per BIS norms including leachability and heavy metals content by the National Council for Cement and Building Materials. Two more cement industries have also been given permission for trial run by concerned SPCBs and CPCB. M/s Grasim Cement Industries (Cement Div.), Reddipalayam, Tamilnadu will co-incinerate refinery sludge, paint sludge and used tyre chips. M/s Laxmi Cement, Sirohi, Rajasthan will co-incinerate the CETP Sludge generated at Pali, Rajasthan. These trials will be undertaken after the first trial at M/s Rajashree Cement is over. The issue of co-incineration of hazardous waste in cement kiln on trial basis needs to be given momentum. As cement industries are located all over the country, therefore, there is an urgent need to identify high calorific value hazardous wastes available in the proximity of the cement plants which may be co-incinerated in cement kiln (subject to clearance after trial run). Table 10.18 Emission monitoring schedule during trial run of co-incineration of hazardous waste in cement kiln
Ambient Air Quality Monitoring SPM, RSPM, SO2, NOx Clinker Quality Testing Composition as per BIS requirement Leachability test Heavy Metal contents Compliance of Standards in Cement Plants : Andhra Pradesh The Cement plants located in Andhra Pradesh were monitored with respect to particulate matters from source emission and verification of other conditions stipulated in consent order issued by the SPCB and environmental clearance granted by MEF. The salient observations are as below .The Continuous Monitoring System (CMS) is yet to be provided in respect of monitoring of dust concentration in the stacks attached to different sources. , Therefore condition of interlocking, laid down in the Environmental Clearance not met. Further no action plan for installation of the CMS is yet prepared by the industry.Although the ambient air quality monitoring in respect of SO2, Nox, Suspended Particulate Matter and Noise is carried out by the SPCB, industry and by a third party, but no interpretation of these data is yet carried out.Although source emission monitoring was conducted by CPCB team, it has been noticed in most of the cases the provisions are not provided as per the norms stipulated in Emission Regulation. Thus, the source emission monitoring results provided by the SPCB and the third party may be far from the reality.The industry has provided Water Spraying and Dust Collecting Systems in the crusher and other transfer points yet deposition of dust in and around the plant indicates inefficient operation of these Air Pollution Control Devices. Table 10.19 Status of Inspection/Monitoring of Cement Plants : Andhra Pradesh
Based on the inspections and monitoring the recommendation we have been made, which are as follows. The industries shall be asked to prepare an action plan with allocation of fund for installation of Continuous Monitoring System and interlocking the same with the production and process equipment.The industries should also look into the data of air quality monitoring and draw the interpretation of them in regard to assess the performance of Air Pollution Control System. The ambient air quality monitoring in respect of noise appears to be unrealistic as such during the visit to the plan high level of noise found generated due to having not provided acoustic system specially near coal mills and its pumping station.The stacks attached to the source emission shall be modified by the industry in order to meet the norms as stipulated in the Emission Regulations.The industry should create a wind barrier around the plant in order to contain the dust within the plant area in addition to development of extensive green belt as per CPCB guidelines inclusive of plantation and bio-indicators.The fugitive emission from the transfer point should be contained specially from clinker hopper and clinker transport point. It requires to introduce the system of rubber curtain and wind barrier so as to prevent the dust suspension. Performance Study of ETP’s in Pharmaceutical Industries in Central Zone
Lupin
Pharmaceutical, Mandideep It is large-scale bulk durg manufacturing unit with production facilities as below : Ciprofloxacin & salts - 48 MT/year Emmofloxacin & salts - 06MT/year Intermediates - 36MT/year Acictovir & salts - 70MT/year Etadolac - 36MT/year Citalopram - 24MT/year Statins simvastatin - 12MT/year Macrolides - 50MT/year The industry has to optimize the operation of effluent treatment plant and achieve desired treatment. In fact, at 60 % loading, better efficiency of treatment could be achieved. Proper air pollution control devices are required to be installed for incinerators for chemical waste as well as garbage incineration. The incinerator for chemical waste should not be operated without air pollution control devices. Record for generation of hazardous waste from each production unit and ETP unit may be prepared along with the details of its storage and disposal. The inventory of hazardous waste should tally with the quantity of hazardous waste available on ground. The industry has to provide garland channels around the area handling hazardous waste to ensure that no run-off find its way into general storm water drains. The size of garland drain should be kept accordingly. The industry should establish its own facilities for monitoring of ETPs and air pollution quality in stack as well as in ambient environment. Thick green belt has to be provided on all the sides at premises treriphery and ensure its survival. Entire wastewater generated in effluent treatment facilities may be utilized and the use of solar evaporation pond may be eliminated. Ranbaxy Laboratories Ltd. It is a large scale bulk durg manufacturing unit located in Dewas industrial area producing following bulk drugs. The unit has provided comprehensive effluent treatment facilities comprising of equalization tank, anaerobic lagoon, 2 stage aerobic treatment facilities and clarifiers. The treated effluent is used for gardening. Ciprofloxacin & salts – 48MT/year Emmofloxacin & salts – 06MT/year Intermediates – 36MT/year Acictovir & salts – 70MT/year Etadolac – 36MT/year Citalopram – 24MT/year Statins simvastatin – 12MT/year Macrolides – 50MT/year
The
unit should improve the performance of anaerobic lagoon by desilting and submit
the action plan for safe disposal of sludge and explore for provision of equalization
tank of detention period 24-hour capacity to have homogenized flow. The effluent
from scrubbers provided with the incinerator facilities collected in solar evaporation
tank shall also be treated by controlled pumping into ETP, as this is a highly
concentrated waste with BOD of 11408 mg/l and COD of 34877 mg/l. The unit shall
restart the incinerator after replacing the corroded chimney and maintain the
records of the type of hazardous waste and quantities incinerated on Form 3 and
will submit the return annually on Form 4 to SPCB. Detailed inventory of hazardous
waste material stored, sold and reused has to be maintained with action plan for
making proper storage arrangement item-wise. Secured land fill for the disposal
of incinerated ash, chemical sludge and other hazardous waste has to be provided.
Also unit shall identify exactly the hazardous waste, which are to be incinerated,
sold, reused or disposed into secured landfill. Segregation of waste streams from
bulk drug and formulation unit need to be examined. The unit shall provide piezometers
in the areas wherever the treated effluent is applied for gardening. The unit
shall make arrangement for the closure of nullah in the backyard by diverting
the flow permanently. IPCA Laboratories Ltd, Ratlam The unit is manufacturing bulk drugs with production capacity of 1202.5 MT/year of various products and also involved in formulation of tablets, syrups and injectables.The unit has provided comprehensive effluent treatment facilities comprising equalization tank, 2-stage aeration tanks, clarifiers and tertiary treatment plant comprising of activated charcoal treatment and dual media filters. The entire water is used for irrigation facilities. Raptokas Brett & Company Ltd., Alwar It is a medium scale unit engaged in manufacturing of pharma-peptone and proteolysed liver extract, amounting to 196.67 tonne per year with meat extract as raw material. The wastewater generated is around 20 cubic meter per day and is treated by anaerobic, chemical and biological process. The operation and maintenance of effluent treatment plant at the unit are not proper. The anaerobic digester has been found working as a holding tank. There was no MLSS in aeration tank and secondary clarifier was not working as per design. The disposal of sludge from ETP was not adequate. Dallas Bio-tech Ltd., Bhiwadi The unit is engaged in manufacturing bulk drugs like amoxycillin, cephalexin etc., amounting 304 tonne/year. The wastewater quantity generated is around 40 cubic meter per day and treated in comprehensive effluent treatment plant comprising holding tank, chemical dozing, tubes settler, aeration tank, dual media filtration and treated effluent is discharged into RIICO drain. There was no flow measurement device, settling facilities after post-aeration. The sludge drying beds are of lesser capacity 10.3 COMPREHENSIVE INDUSTRY DOCUMENT (COINDS) AND EVOLVING ENVIRONMENTAL STANDARDS AND GOOD PRACTICES FOR CASHEW SEED PROCESSING INDUSTRY Cashew seeds processing industries are existing in a few coastal states in India. Even though there is cashew seed cultivation in the country, most of the product demand is met by importing raw cashew seeds from South Africa. The processed cashew kernel are exported to Gulf and European countries. There are about 1500 units,categorised under SSI category, scattered in Nagercoil (Tamilnadu), Cheerla & Palasa (Andhra Pradesh), Kollam, Pathanamthitta & Trivandrum (Kerala) and in Goa. It is a labour intensive industry. Female workers constitute 90% of the work force. These units generally operates in the morning i.e. from 6.00 to 12.00 O’ Clock. Cashew seeds are processed by two methods viz roasting and cooking process. The cashew seeds roasting process releases thick black smoke from roasting drum through the stack. The smoke has irritating odour and causes nuisance in the neighbourhood. The process also generates wastewater from the quenching operation of the roasted seeds. However, roasting process is preferred by the manufacturers. In cooking process, steam is generated in baby boiler and steam is supplied in kettle (Cooker) for cooking of seeds. In cooking process, cashew nut shell liquid (CNSL) vegetable oil is extracted from the shells of the seeds which has a market value in paint and resin industry. When the cashew seeds is roasted or cooked, it is sent to the cutting section and red skin, called testa is removed from the cashew seed through Borma Operation. Borma is done at 80-900 C which again releases a thick smoke. Quenching is not required in Cooking process. Not much has been done to update the technology used by cashew seed processing industry. Though pollution load from individual unit is relatively low but the magnitude of pollution problem from the cluster of units is very high. Keeping in view that industry is mostly in small scale and cottage sector, it was felt to study the industry in detail and to develop techno-economically viable environmental standards for cashew seed processing industry in India before evolving environmental standards with the help of various concerned state pollution control boards, pollution control committees, Dr. Ambedkar Institute of Productivity and National Productivity Council, Chennai. Monitoring of cashew seed processing industries for air, water and noise has been completed in Nagercoil (Tamil Nadu), Kollam (Kerala) and Kassibagga- Palassa (A.P.). Monitoring was carried out for Roasting, Cooking and Borma operations. Ambient Air Quality was also studied at Palassa (A.P.) . Water samples were collected and analysed for pH, COD, BOD, oil & greese and phenolic compounds. The information have been collected from various State Pollution Control Boards/Committees and compiled.There is a possibility of employing cleaner technology in Cashew Seed processing Industry. Instead of Roasting or use of cashew shell fired baby boiler in cooking process, bio- gasifire can be employed, using cashew shell as fuel, to done away with direct firing of cashew shell. Cashew nut shells, a waste product of the industry, are converted into combustible gas in the biomass gasifiers. The clean technology of employed by cashew seed processing industry will reduce smoke and dust nuisance resulting in improvement in ambient air quality in the vicinity.
Pulp and Paper industry falls under 17 identified categories of highly polluting industries defined by the Ministry of Environment and Forests. Pulp mills require enormous amounts of water for debarking the trees, washing the wood chips, bleaching the pulp which creates a significant interdependence with available water supply invariably has a serious impact on the local ecosystem. BOD and COD levels are very high in pulp mill effluents failed to achieve prescribed discharge standards causing pollution of surface water bodies. Though large pulp and paper mills installed chemical recovery plant (CRP) colour problem still persists. Smaller mills do not have CRP causing severe environmental pollution of soil and ground water. Considering the risk of water pollution problems, it is desirable that the wastewater may be disposed on land, which would help in harnessing their irrigation potential in agriculture. This has been demonstrated that productive crop irrigation programme introduced with wastewater disposal facility yielding revenue and wastewater disposal cost. To eliminate the problems of colour due to lignin and in this regard, clay loam soils are most effective for colour removal followed by silt and sandy loam. However, sodium build up was noticed in the continuously irrigated soils with the wastewater, which could be overcome by using gypsum for reclamation.Under one of the CPCB sponsored project "utilization of treated effluent form paper mills for crop irrigation and its impact on crop productivity and soil health", IARI has extensively studied the process for crop irrigation and the studies have revealed promising results in reducing the overall pollution loads with respect to lignin, color, COD, BOD including toxicity. Agricultural field of representative pulp and paper mills will be selected in association with CPCB for carrying out spot and field experiments with three categories of paper mills viz. Large Paper Mills, Small Paper Mills with chemical recovery unit and Small paper mill without chemical recovery unit. 10.5 RECOMMENDATIONS ON FAECAL COLIFORM DISCHARGE STANDARDS FOR SEWAGE IN DELHI A high-powered committee has been constituted in pursuance of orders of the Hon’ble Supreme Court in CWP No. 725/1992 for preparation of an Integrated Action Plan for cleaning the Yamuna River at Delhi. This High Powered Committee in its meeting dated 24.08.04 constituted a sub committee chaired by Chairman, CPCB to determine norms for permissible coliform level in treated sewage and the process required for achieving the same keeping in view techno-economic feasibility. This Committee, after detailed deliberations on various aspects and after consulting experts on the subject, prepared a report on Fecal Coliform discharge standards and possible technological options. Maximum permissible Fecal Coliform standards notified under EPA for bathing water quality is 2500 MPN/100 ml. Considering the facts that there is negligible dilution available in Delhi stretch of river Yamuna, the discharge standards for Fecal Coliform levels in treated sewage is recommended 2500 MPN/100 ml, the same as quality of bathing waters because the Delhi stretch of river Yamuna is desired to be maintained as bathing water. However CPCB has emphasized that to achieve the maximum removal of pollution load with the funds available, it would be proper to make arrangements for treatment of the entire sewage up to secondary level to achieve BOD<20 mg/l and SS<30 mg/l on priority basis rather than treating part of sewage to tertiary level to achieve FC<2500 MPN/100 ml and BOD<10 mg/l while leaving significant part of sewage untreated. Afterwards, when secondary treatment facility for at least 90 % of sewage is installed, all STPs need to be augmented with tertiary treatment facilities for removal of FC to a standard 2500 MPN/100 ml as well as for further removal of organic matter to BOD<10 mg/l so that the main objective of maintaining quality of Yamuna river may be fulfilled. In Delhi, existing STPs based on ASP and Trickling Filter (TF) technologies require augmentation with tertiary treatment units to achieve the recommended Faecal Coliform standards of 2500 MPN/100 ml discharge into Yamuna. Following are the possible tertiary treatment schemes which can be adopted after conventional treatment units (ASP or TF) to achieve the recommended FC standards.Chemicals aided tertiary sedimentation (after flocculation)Chemicals aided tertiary sedimentation (after flocculation) + Granular media (Sand) filtration Chemicals aided tertiary sedimentation (after flocculation) + ChlorinationChemicals aided tertiary sedimentation (after flocculation) + Granular media (Sand) filtration + ChlorinationInstallation of treatment facilities for secondary treatment of sewage generated in Delhi will take time meanwhile, CPCB proposes to take up experimental studies on treated sewage in Delhi to investigate effectiveness of above suggested tertiary treatment technologies in terms of faecal coliform removal. 10.6 PERFORMANCE EVALUATION OF ROOT ZONE TREATMENT FOR DOMESTIC WASTEWATER Root
Zone Treatment processes effectively purify domestic and industrial wastewater
according to the law of nature. The term "root zone" encompasses the
interactions of various species of bacteria, the roots of the reed plants, soil,
air, sun and water. Central Pollution Control Board has taken-up the project on
"Assessment of Root Zone Treatment technology for treatment of domestic wastewater".
The project is being undertaken at Sewage Treatment Plant, Jagjitpur, Haridwar.
The objective of the project was to assess the efficiency of Root Zone Treatment
plant for treatment of domestic wastewater and polishing of treated wastewater
under Indian condition and to optimize the system parameters. Two
Root Zone Treatment Horizontal beds, one each for receive raw wastewater (Raw
bed) [4.90m(L) x 3.1m(B) x 0.08m(H)] and other for receive treated wastewater
(Polishing bed) [4.35m (L) x 2.25m(B) x 0.04 m(H)] were constructed. The sand
of the bed of river Ganga (0.8 mm and Porosity 29%) is used as filter media. The
plant Phragmites Karaka is planted at the contructed wetland site. The
performance of the bed has been tested for various hydraulic and organic loading
with different hydraulic retention time (HRT). The performance of the Root Zone
Treatment with raw sewage & treated effluent (polishing treatment) are presented
in Table 10.20 & 10.21.
Table 10.21 Average Percent Removal of Various Parameters in Polishing Bed at Various Hydraulic Loadings
10.7 POLLUTION
CONTROL IN INDUSTRIAL ESTATES OF ANKLESHWAR, NANDESARI IN GUJARAT STATE AND TALOJA,
TARAPUR IN MAHARASHTRA STATE The
inspections have been undertaken in 18 out of 297 Red Category industries of Tarapur
(Maharashtra) & 42 out of 71 Red category industries in Nandesari (Gujarat)
to review the status of environmental management system. The findings are as below: The industrialists in this estate are least aware or pretend ignorance of concepts like Energy Conservation, Waste Minimisation/ Pollution Prevention. Since the common facility takes care of the wastes generated, no efforts are carried out to reduce or minimise the wastes. The gross violation of this principle of Pollution Prevention can be gauged from the fact that high COD load is first created (may be due to production process inefficiencies or otherwise) and then diluted with fresh water to meet the inlet norms of CETP. A base quantity of wastewater generation can be worked out theoretically and then compared with the quantity actually sent regularly to CETP for treatment. This measure may deter the industry from diluting and look for water conservation measures. All the industries are sending their effluent to CETP through tankers. The arrangement for filling the tankers outside the industry premises is also inadequate in most of the industries. Consequently, spillage and spread of effluent on earthen surface and natural drain takes place at many areas in the industrial estate. This kind of tanker filling arrangements is adversely affecting the environment & aesthetics of the industrial estate.Inventory work is in progress for MIDC-Tarapur, MIDC-Taloja, GIDC- Nandesari and GIDC- Ankeleshwar. Methodology adopted includes dry data collection, inspection of EMS and monitoring in selected industries. Table 10.22 : Red category of Industries Inspected at Industrial Estates of Gujarat & Maharashtra
10.8 MERCURY RELEASE INTO ENVIRONMENT BY CAUSTIC SODA INDUSTRIES The
evaluation has been undertaken by Central Pollution Control Board at M/s.Grasim
Industries (Chemical Division), Nagda , M/s.Hukumchand Jute Mills, Amlai and M/s
Shri Ram Vinyle & chemicals, Kota to assess the progress made by the industries
in controlling mercury release into the environment. Isotope studies indicated
that mercury consumption per tonne of caustic soda produced has been reduced gradually
during past three years. However, it has been observed that there is substantial
mercury still unaccounted. Industries have targeted year 2020 for converting existing
mercury cell process into membrane cell technology.
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