Indian Petrochemical plants have been studied in association with indigenous and expatriate consultants in respect of process technology, combustion emissions, process point source emissions, process fugitive emissions, control approaches and overall approach for emission management. The studies emphasized efficiency of pollution control equipment based emission limit values for point sources, equipment based norms for fugitive emission control in respect of hazardous air pollutants and general Volatile organic compounds; and norms for flaring systems. The fugitive emissions in petro-chemical plants are considerable and arise from various sources, the broad range of their shares are as follows:

The prevailing fugitive emissions have been enlisted and grouped into high, medium and low categories in order to focus & emphasize the control measures in terms of equipment changes i.e. pumps, valves, flanges, seals etc. To finalize this approach, there are number of other aspects need to be ensured such as economic feasibility of the suggested improvements without negotiating with health criteria, applicability of grand father clause i.e. phase-wise improvement programme for old process technologies & establishments, standardized methods for monitoring and analysis, adequacy of monitoring and analytical capabilities with the concerned state pollution control boards, thorough understanding of the processes & environmental concerns by the local regulatory officials.

The Central Board is in the process of finalization of the emission limits and also planned for strengthening of capabilities of the regulatory officials for implementation of pollution control programme in the petro-chemical units through training programmes.

Central Pollution Control Board studied pesticides industries for identifying the priority emissions requiring control measures, existing pollution control equipment, their efficiency, tail gas concentrations, health criteria in respect of the pollutants, achievable tail gas concentrations by adopting best practicable technologies etc. in association with the indigenous and expatriate consultant. Like any other comprehensive pollution control strategy development exercise, the approach covered exploration of cleaner technologies, process optimization measures, recycle/reuse potential, prevailing mass and concentrations of air emissions from various unit operations and technological review (indigenous and experiences of developed countries) and ascertained cost bearing due to pollution control by the industries in order to ensure affordability. The draft findings have been discussed and in the process of finalizing the feasible national emission standards in respect of point source combustion & process emissions and guidelines for fugitive emission control & incineration, for pesticides industries

The Central Board is involved in developing minimal national standards (MINAS), which are applicable for entire nation considering techno-economic feasibility of control equipment. However, considering the location specific sensitivity, the state pollution control boards can make the national standards stringent. For example, in critical areas, where single or cumulative effect of emissions/wastewater discharges exceed the ambient air/water quality requirement, a rational/ structurised approach shall be followed in order to avoid bias in granting permit conditions to individual industries, which are often challenged on the basis.

Under this programme, efforts have been made to set approach for assessment of assimilative capacity and fine tuning of the standards considering health protection, environment protection, availability of technology and economic feasibility. With the association of indigenous and expatriate consultants, an approach has been made which is being debated among the experts for finalization. Besides, the approach is being applied in selected study area for fine-tuning. These studies include Inventorization of air and water pollution sources, existing level of control technologies, application of air quality models (ISCST3) and concepts of zone of initial dilution and mixing zones in respect of water quality in surface water bodies.

There are many issues and choices being studied in managing the pollution from individual industrial unit or from a cluster. For example, In case of water pollution management, it is endorsed to control the pollution at source, however the Water Act has provision to explore the assimilative capacity of the receiving water bodies considering minimum dry weather flow. The control approach can be classified into levels depicted in Table 10.2:

The dimensions of this provision may be summarized as follows:

One of the common air pollutants emanating from the chemical industries is volatile organic compounds. As it is well known that if emissions are emanating from a point source can very well be controlled absorption, condensation, adsorption, thermal destruction etc. Whereas, due to volatile nature of various solvents and process fluids used in chemical sectors, the fugitive emissions will arise from valves, flanges, pumps, storing units, effluent treatment plants etc. In order to address these volatile organics, a project has been taken-up for studying oil refineries, petrochemical plants in India. Possibilities of application of general VOC’s and hazardous air pollutants on the lines of developed countries is being discussed and their adoptability in terms of monitoring equipment, control equipment, investment on equipment modifications, establishing emission factors etc. are being studied.

Feasible disposal specific TDS limits have been developed and same have been endorsed by the Expert Committee and are being considered by the Central Board. Under capacity building programme, five days training programme on "Management of TDS in Industrial Effluents" has been arranged through EPTRI, Hyderabad, for 15 States and Central Board officers.

Under this MoEF sponsored programme, 11 industrial sectors have been taken up for review of the environmental statements submitted to the respective State Pollution Control Board offices. Premier institutions and expert consultants have been engaged to review the statements to ascertain the existing status of pollution control and to derive a national programme for systematic improvement. The list of sector specific institutes engaged are presented in Table 10.3:

Table 10.4 Water Consumption, Volume of Production based grouping of Bulk Drug Industries

An extensive questionnaire survey has been conducted to collect information from the water treatment plants in various Indian cities and towns. Besides, 15 water treatment plants have been studied in the north and western parts of the country and visits to 15 more water treatment plants in east and southern parts of country are being planned. There are many interesting findings in the first phase of the studies, it is expected that the study will bring out scientific, engineering, operational and administrative observations and requirements to ensure proper operation and environmental management in the water treatment plants.

The implementation of action plan for pollution control in 1551 (which came into operation on or before December 31, 1991) medium and large scale units identified under the 17 highly polluting industrial sectors was continued. The follow-up of the action taken against the defaulting industries under Section 5 of The E (P) Act, 1986 was further intensified and as a result the number of defaulting industries has reduced from 67 in March 2000 to 25 in September 2001. The number of closed industries has increased from 164 to 177 and number of industries having requisite pollution control facilities increased from 1320 to 1349. The category-wise status of 1551 industries as on September 30, 2001 is presented in Table 10.5. The 25 defaulters mainly include thermal power plants of State Electricity Boards.

The follow-up programmes in respect of the 68 industries identified under Ganga Action Plan (GAP) Phase-I were initiated by CPCB soon after the introduction of GAP in 1985. The industrial pollution control programme further intensified with the launching of the Central Action Plan in August, 1997, for control of industrial discharges along the rivers and lakes in the country. This programme resulted in identification of 119 more industries along the river Ganga, which required priority attention for the control of their effluent discharges. The pollution control status of these industries as on September 30, 2001 is presented in Table 10.6 and 10.7.

851 defaulting grossly polluting industries located along the rivers and lakes in the country have been identified for priority actions under this programme, which was started in August 1997. The follow-ups for the implementation of the programme, was intensified and this has resulted into reduction in the number of defaulting industries from 93 in March, 2000 to 5 in September, 2001. The State-wise status of the 851 industries as on September 30, 2001 is presented in Table 10.7.

Non-recyclable slag is the solid waste from secondary lead smelters. This waste is hazardous in nature and poses major problem due to non-availability of safe and notified hazardous waste disposal site. Presently, all the industries are collecting these wastes in a secure dump yard within their premises, from where the possibility of mishandling and disposing of solid waste to low lying area is very high.

In an integrated steel industry, wastewater generated from Coke Oven By-product Plant (COBP) is a major polluting stream containing toxic chemicals like phenol, cyanide and ammonia. In recent times, COBP effluent is treated by biochemical oxidation of cyanide, ammonia and phenol at separate effluent treatment plants, commonly known as bio-chemical oxidation & dephenolisation plants (BOD plants). The treated effluent from BOD plant is recycled for use in quenching hot coke in coke-ovens. However, excess treated water has to be discharged into common outlet drain of steel plant. Almost all the integrated iron and steel units have installed BOD plants. Wastewater reduction in COBP involves reduction of pollution load in process wastewater and proper operation of BOD plant. Detailed study was conducted to evaluate the performance of BOD plants based on proper design, inlet concentration, type of treatment units, operation and maintenance and trained manpower.

There are 81 coal based thermal power plants comprising total installed capacity of 60263.5 MW. Thermal Power plants are mainly responsible for air and water pollution besides problems related to solid waste (flyash) management. Out of 81 thermal power plants in the country, 42 plants comply with emission standards, 3 plants are closed and remaining 36 plants are in the process of installation/augmentation of pollution control systems. As regards water pollution prevention measures, 49 plants comply with ash pond effluent standards, 3 plants are closed and 36 plants are in the process of installation/augmentation of ash ponds. The main factors affecting the performance of Electrostatic Precipitators are:

A National Task Force has been constituted to assess the progress made in the implementation of the environmental standards and Rules, use of beneficiated coal and utilization of fly ash.

Presently, beneficiated/blended coal is being supplied to Dadri (U.P.), and Badarpur (Delhi) Power Plants of National Thermal Power Corporation (NTPC), Dahanu (Maharashtra), of Bombay Suburban Electricity Supply (BSES) and Rajghat & Indraprastha (Delhi) Power Plants of Delhi Vidyut Board (DVB). However, other 26 plants have not yet indicated their plan for meeting the requirement of use of beneficiated coal. The implementation of provisions made under the above gazette notifications would be helpful in mitigating the problems of air pollution and management and handling of flyash disposal in environmentally acceptable manner in thermal power plants.

Sixteen percent of total flyash generation (80 million tonnes) in the country is utilized mainly for manufacturing cement, bricks and construction of roads and embankments. However, in advanced countries like Germany, China, USA, European Union and Japan, the extent of utilization of flyash is 100%, 42%, 65%, 80% and 85 % respectively.

The State Pollution Control Boards were required to identify the brick kilns located within 50 km radius of power plants and modify the consent conditions as per the directives. Though, Orissa and Gujarat Pollution Control Boards have identified the brick kilns but the status of flyash utilization by these kilns is not yet available. Out of 81 thermal power plants, 46 power plants have submitted their action plan to achieve hundred percent flyash utilization within the stipulated time period.

A study on stack height regulation: "A state of art review through computer simulations and development of spacially meaningful regulations" was conducted by IIT, Kanpur under a project sponsored by CPCB. The report includes basis for revision of stack height regulations, methodology for determination of minimum stack height and proposed stack height regulations for different zones of the country. The new stack height regulations will be finalized by a Working Group constituted by CPCB.

A study has been undertaken with the following objectives:

The project has been taken up in collaboration with IIT Delhi to study the following:

A study has been initiated to assess the prospects and status of natural dyes. The study includes availability of raw materials, process technologies, current demand, usage and problems in development/manufacture of natural dyes.

Sago industries in Tamilnadu (around 1000 units) are based on tapioca roots and mostly under small scale industries (SSI) sector. The treatment plants set up by individual units are not being properly operated. It is therefore proposed to set up a CETP for the sago industries located along Thirumanimuttar river. The wastewater from sago industries located along Thirumanimuttar riverbanks will be collected and treated at the CETP. Tamilnadu Pollution Control Board has been requested to carry out the inventory of starch and sago industries in Salem town.

In Jajmau area of Kanpur, more than 300 tanneries of varying capacity are in operation. Many of the large and medium tanneries have installed the chromium recovery plant at the individual level. For small tanneries, CPCB has taken up a project to recommend cost-effective possibilities for installation of common chrome recovery plant.

In order to prepare an inventory of lime kiln units, all the SPCBs/UTs were requested to provide the updated list of lime kiln units operating in their States/UTs as well as the information regarding implementation of pollution control measures taken up by these units. The information is required to finalize inventory of lime kiln units being operated all over the country and to assess the magnitude of pollution load generated from these units.

CPCB has initiated human risk assessment studies in asbestos industries in collaboration with the Industrial Toxicology Research Centre, Lucknow. The study includes environmental monitoring of asbestos based industries, detailed medical examinations of industrial workers, geno-toxicological evaluation of asbestos exposed population and recommendations for preventive measures in industrial units. The study at two asbestos plants has been completed.

Preliminary survey and inventorization of the oil-drilling units has been carried out in Upper Assam. The oilfields of Upper Assam, owned by Oil India Limited and Oil & Natural Gas Commission Limited, were visited to study the pollution aspects and also groundwater quality monitoring was conducted in the surroundings of injection wells.

A detailed survey and monitoring was conducted in 15 cement industries situated in eastern region of the country and capacities exceeding 200 tons per day. The salient features of the survey are as follows:

There are seven aluminium plants in India comprising total production of 5,91,621 tonne. Most of the aluminium plants are in the expansion process and production is expected to touch 8,80,000 tonne in 2005.

During the production of aluminium, significant amount of gaseous and solid wastes are generated. The major environmental problems are due to emission of fluoride and generation of spent pot lining and red mud.

Central Pollution Control Board has taken up enforcement of environmental standards since 1990. During the year 1999-2000, status of pollution control was compiled through questionnaire survey.

First meeting was held during December 20-21, 2001 followed by visits to NALCO, Angul & INDAL, Hirakud. Following major environmental issues have been identified. The NTF is examining these issues in detail, for final recommendations.

As a result of various measures taken to improve the ambient air quality in the country following changes has been observed in the ambient air quality during 2001 in comparison to 2000.

Environmental Surveillance Squad is an important project undertaken by CPCB as per the direction of Hon’ble Supreme Court. The main objective of the squad is to identify the willful defaulter through surprise visits. Suitable action is also being taken against the erring industries either directly by CPCB or through State Pollution Control Board under various Environmental Acts.

Under this project more than 50 industries have been visited and proposed suitable action accordingly. On the basis of the recommendations, the competent authority of CPCB has issued closure notice to three erring industries located in Aurangabad, Maharashtra. In Gujarat two industries namely, M/s. Excel Industries Ltd; Bhavnagar and M/s. Birla VXL, Jamnagar have been recommended for stringent actions on account of gross non-compliance to the pollution control norms. In Daman five industries namely, M/s. Lalitha Chem, Silvassa, M/s. KLJ Polymers, Daman, M/s. Plasticisers & Polymers, Daman; M/s. Meadly Pharma, Daman and M/s. Alcchem Industries, Daman have been recommended for most stringent action (including direction for closure) on account of non-compliance to the pollution control norms and/or illegal discharge.

The brief status of compliance of standards in respect of thermal power plant in southern part is summarized below:

The emissions from the Unit-4 and Unit-6 are found to be within the limiting standards as such monitoring was carried out in the ducts. The monitoring at Unit 1, Unit 2 and Unit 3 could not be undertaken, as sampling ports are not available.

Stack emission from Unit-1, Unit-2 and Unit-3 could not be monitored due to insufficient oxygen levels experienced in the stack and its staircase. Emission from Unit-4 was recorded much higher than the limiting standard. Unit-5 is very closely meeting the standard whereas Unit-6 marginally exceeded the limiting standard.

The units of both the stages are not meeting the limiting standard. The clouds of fly ash emission have been found emitting. The monitoring was carried out in ducts of the units in Stage-I and no provisions were existing as per Emission Regulation -III.

The concentration of particulate matter in Unit-1 is severely exceeding the limiting standard although the plant has commissioned of late.Unit-2 is also exceeding the limit although during the visit it is noticed that new ESP with appropriate design is provided.

Monitoring could not be conducted in Unit-5 as sampling probe could not be inserted into the sampling port being smaller in diameter and inclined thus not meeting the requirements. Emission levels in all other units are not conforming the limiting standards. Monitoring was carried out in the ducts of Unit-1 to Unit-4 as such no provisions were existing as per Emission Regulation-III and monitoring is required to be carried out in the stacks.

All the thermal power plants are required to have the facilities as per Emission Regulation-III in order to have proper monitoring. No power plant except NTPC, Ramagundam was found to be meeting emission standards thus necessary directions are required to be issued. An action plan in each case is required to be formulated in order to install suitable air pollution control devices and to improve upon existing control measures. Action plan may also include the time required , fund allocation and the identification of the officials responsible for its implementation.

These paper industries use agricultural wastes, waste paper, Jute/ Jute waste, rice straw, waste paper, purchased pulp etc. as raw materials. The units have pulping and bleaching facilities and uses caustic soda, sodium sulfide, Chlorine, fillers, white & colored pigments. The analytical result of the Effluent indicate that most of the water quality parameters not meeting the stipulated standard.

The treated effluent is used for the irrigation or it is recycled in the process. The ETP sludge is used for land filling, for making fuel cake etc. The disposal practice of hazardous solid wastes has been adopted by the industries.

The pharmaceutical industry has made greatest strides with the development of health facilities. The growth rate of the pharmaceutical industry in UK and USA is quite high, rated fourth among the chemical process industries after plastics, petrochemicals, and synthetic fibre. The foundation of the modern Indian Pharmaceutical Industry was laid in 1901. At present there are more than 15000 drug manufacturing units in the country with a preponderance of small-scale units.

The pharmaceutical industry uses high quality intake water and produces strong and toxic effluent. The synthesis of organic chemical produces wastewater consisting of complex mixtures of organic and inorganic materials. The organic wastes involve solvents, salts, acids, impurities and derivatives. The waste is usually high in BOD, COD, and TDS. The pH is usually very low (acidic) or very high (alkaline) and frequently the wastes are coloured. These wastes are generally toxic to the fish and other aquatic life.

The studies have been carried out at selected industries to assess the various pollution control measures installed and also the performance evaluation of the effluent treatment plant. The major findings of the study are as follows:

The objective of the study was to ascertain the improvements made by the tannery units in terms of pollution control measures being adopted and also monitoring of individual units of the treatment system to assess the performance of ETP in general, and the individual unit operations in particular. The main pollution from a tannery is from effluent rather than chimney emission, and, therefore, the study emphasized on effluent management system and performance characteristics evaluation.

The ambient air quality status during the peak period of lime production was monitored in and around limekilns agglomeration in Katni District and in Satna & Maihar cities to ascertain the maximum air pollution due to lime production during October-November, 2001. During the study, 80-90% limekilns were in operation. The salient observations are as below:

The cement industries have installed pollution control devices in each of their production unit (Table 10.12) except one cement plant, which has no control in its packing plant:

In order to generate first hand information on environmental impact of silica sand mining and washing operations, CPCB sponsored this project to Directorate of Geology & Mining, Allahabad. The project envisaged inventory and detailed status of pollutants from industries located at Shankargarh-Bargarh area, Allahabad. As an extended activity during the project the status of Silica Sand Mining and Washing activity as undertaken in States of Haryana, Karnataka, Maharashtra, Bihar, Rajasthan, Gujarat, was also studied. It has been derived that there is no organised management of Silica sand mining and washing practices. There is significant pollution of groundwater in the area, which is further aggravated by excessive abstraction of ground water. The indiscriminate mining, lack of effluent treatment provision and improper disposal of high iron-sludge, are identified as some of the key factors responsible for environmental degradation.

The major findings of the study are as follow:

At present, there are more than 1,000 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 tphr to 10-120 tphr. The location of these plants keep on changing. Burning of fuel, feeding of aggregates, heating of bitumen from such a large number of plants create environmental hazards, especially air pollution due to dust and volatile organic compounds.

The Central Board has decided to prepare a Comprehensive Industry Document on Hot Mix Plants in an effort to minimise the adverse environmental impacts by regulating emissions. Information on plant and process details, pollution control technologies, emissions and plant locations etc. were collected through extensive field visits as well as detailed questionnaire surveys. The study has been completed with the help of CBRI, Roorkee. Environmental standards are being drawn.

The objective of the study is to assess various environmental problems related to these industries and to develop standards for noise, emission and effluent including storm water disposal for wheat flour mills, pulse making mills, dry rice and pulse grinding mills and emission standards for rice mills. This project is likely to be completed by March 2003.