Module 5
Module 5
Environmental Policy
Environmental Impact Identification
Objectives and targets
Consultations
Operational and Emergency procedures
Environmental Management Plan
Documentation
Responsibilities and Reporting Structure
Training
Review Audits and Monitoring Compliance
Continual Improvement
BENEFITS OF EMS
An EMS can assist a company in the following ways:
1. Background information
Production processes, facility layout, waste stream generation, waste
management costs.
Source, type, quantity and concentration of waste
2. Plan Survey
Verify and fill gaps in background data.
Identify additional waste streams
Actual operation data and manufacturing practices
3. Sampling
Identify type of waste and point of origin.
Determine fate (e.g., waste treatment, storm sewer, and atmosphere)
Determine rate produced or emissions factors (amount produced per hour, per
production unit)
Determine variability (potential shock loading).
1)Process change: Process changes can reduce the inherent demand for water. An example is the
replacement of wet cooling towers by dry air coolers.
2) Water reuse: Wastewater can be reused directly in other water using operations when the level
of previous contamination does not interfere with the water using operation. This reduces both
freshwater and wastewater volumes but leave the mass load of contaminant essentially
unchanged.
4) Regeneration recycle: Wastewater can be regenerated to remove contaminants and then the
water recycled. In this case, regenerated water may enter the water using operations in which the
water stream has already been used. Also, recycle can sometimes create a buildup of undesired
WASTEWATER REUSE INTO THREE WAYS AS FOLLOWS
1) Internal wastewaters recycle: Depending on the manufacturing process, water
consumption can be cut down between 50% to 90% by adopting appropriate water
recycling techniques.
2) Reuse of treated industrial wastewater.
3) Reuse of treated wastewater for other activities such as irrigation, fire protection, dual
system etc.
POLLUTION PREVENTION IN VARIOUS INDUSTRIES
SOURCES OF WASTEWATER AND ITS CHARACTERISTICS
1. Sizing wastewater results from the cleaning of sizing boxes, rolls, size mixer, sizing area
and the drainage of sizing solution. Its volume is low but, depending on the recipe used,
can contain high levels of BOD, COD and TSS.
2. Desizing effluent results from additives used in the size technique, surfactants, enzymes,
and acids or alkaline as well as the sizes themselves. The generated wastewater can be the
largest contributor to the BOD and TSS.
3. Scouring wastewater characteristic is an organic and alkaline, contain fabric fragment
starch and sizing materials, caustic soda and chemicals used. It generates very high BOD
concentrations.
4. Bleaching wastewater usually has high solids content with low to moderate BOD levels include
alkaline and contain bleaching agents.
5. Mercerizing wastewater has low BOD and total solids levels but are highly alkaline prior to
neutralization. The low BOD content arises from surfactants and penetrating agents used as
auxiliary chemicals.
6. Dyeing wastewater depend upon the dyes used. It contributes high volume, color, low BOD,
high COD, high temperature and is sometimes toxic.
POLLUTION PREVENTION Pollution prevention programs should focus on reduction of water use and on
more efficient use of process chemicals. Process changes might include the following: Match process
variables to type and weight of fabric (reduces wastes by 10–20%).
Ozone-depleting substances should not be used, and the use of organic solvents should be minimized.
Use transfer printing for synthetics (reduces water consumption from 250 l/kg to 2 l/kg of material and also
reduces dye consumption).
Use water-based printing pastes, when feasible.
Use pad batch dyeing (saves up to 80% of energy requirements and 90% of water consumption and
reduces dye and salt usage). For knitted goods, exhaust dyeing is preferred.
Use jet dyers, with a liquid-to-fabric ratio of 4:1 to 8:1, instead of winch dyers, with a ratio of 15:1, where
feasible.
Avoid benzidine-based azo dyes and dyes containing cadmium and other heavy metals. Do not use
chlorine-based dyes.
CLEANER PRODUCTION OPPORTUNITIES 1) Good housekeeping: Good
housekeeping in textile industries is a program of maintenance, inspection, and
evaluation of production practices should be established.
2) Reduction in water use
Minimizing leaks and spills Maintaining production equipment properly
Identifying unnecessary washing of both fabric and equipment, and Training
employees on the importance of water conservation.
3) Reuse in mercerizing: On the mercerizing range, the scope for water
conservation and reuse lies in adopting a countercurrent flow pattern. The water
requirement can be reduced, if most of this water can be recovered as steam
condensate from the multiple effect evaporators of the caustic recovery plant
provided suction in the evaporations is carefully controlled to avoid boiling
overflow.
4) Reuse in dyeing: Small saving can be affected if running washes are replaced
by static ones wherever possible. Further, the batching or wetting water need not
be drained out. It can be retained for use in the next operation like dyeing .
5) Reuse in printing and finishing: Uses water for various cooling and washing operation and
reuse steam condensates in boilers.
6) Reuse of soaper wastewater: The colored wastewater from the soaping operation can be
reused at the buckeye washer, which does not require water of a very high quality. Alternatively,
the wastewater can be used for cleaning floors and equipment in the print and color shop
8) Counter current washing: Counter current washing is an employed frequently on
continuous preparation and dye range. It can be applied at desire washers, scour washers,
mercerizing washers, bleach washers, dye ranges, and print house soaper range.
9) Use of automatic shut-off valves: An automatic shut-off valve set to time, level, or
temperature will control the flow of water into a process unit. One plant estimated that a
reduction
in water use of up to 20% could be achieved with thermally controlled shut-off valves.
10) Use of flow control valves: A flow or pressure reduction valve can significantly reduce the
quantity of water used in a wash or clean-up step. These valves are particularly useful in
cleaning areas where operators are not always aware of the need for water conservation
Sugar industry:
Approximately 5.5 kilograms of fly ash per metric ton (kg/t) of cane processed (or
4,500 mg/m3 of fly ash) are present in the flue gases from the combustion of bagasse.
Reduce product losses to less than 10% by better production control. Perform sugar
auditing. Discourage spraying of molasses on the ground for disposal.
Minimize storage time for juice and other intermediate products to reduce product
losses and discharge of product into the wastewater stream.
Give preference to less polluting clarification processes such as those using bentonite
instead of sulfite for the manufacture of white sugar
Collect waste product for use in other industries—for example, bagasse for use in
paper mills and as fuel.Cogeneration systems for large sugar mills generate electricity for
sale. Beet chips can be used as animal feed.
Optimize the use of water and cleaning chemicals. Procure cane washed in the field.
Prefer the use of dry cleaning methods. Recirculate cooling waters.
AUDIT APPROACH
The typical audit comprises of three steps as Pre-Audit, onsite Audit and Post
Audit.
Onsite Audit: The onsite audit means to identify the water usage, raw material
consumption, by product produced, wastewater produced, solid waste, hazardous
waste generated and also analysis report is produced for all this waste as well as
air, noise and sound. The water used for all the purpose within the industry is also
taken into account.
Post Audit: The final draft is prepared for raw material, water and energy
consumption and also the waste generated on the action plan the recommendation
are given.
The wastewater is generated in a sugar factory from processing, domestic purposes and
some number of spent lees which is coming from distillery.
All these wastewaters treated in ETP of sugar factory treatment process. To achieve BOD
reduction from 1000 mg/lit i.e. 92% treatment efficiency.
There is two stage biological treatment plants. The first stage will comprises of an aerobic
lagoon equipped with surface aerator and second stage is provided with conventional
complete mix activated sludge process.
The second stage is activated sludge process which further provides 90% reduction in
BOD resulting into an effluent. An oil and grease trap are incorporated to remove all free
and floatable material.
SOURCES OF POLLUTANTS AND ITS CHARACTERISTICS
POLLUTION PREVENTION AND CONTROL
Prefer dry debarking processes.
Prevent and control spills of black liquor.
Prefer total chlorine-free processes, but at a minimum, use elemental chlorine-
free bleaching systems.
Reduce the use of hazardous bleaching chemicals by extended cooking and
oxygen delignification.
Aim for zero-effluent discharge where feasible. Reduce wastewater discharges to
the extent feasible.
Incinerate liquid effluents from the pulping and bleaching processes.
Reduce the odor from reduced sulfur emissions by collection and incineration
and by using
modern, low-odor recovery boilers fired at over 75% concentration of black liquor.
Dewater and properly manage sludges.
Where wood is used as a raw material to the process, encourage plantation of
trees to ensure sustainability of forest
WASTE AUDITING OF THE MILL
Unit Operation of The Mill
1. Main processing sections consuming water are washing, diluting pulp before pumped to
beaters, beating and paper making.
2. Beating unit operation is the process combining beating and washing.
3. Wastewater from office section
Solid Waste Generation from Production Process
1. Piths generated from depithing unit operation.
2. The amount of pith separated is accounted for 20% of the bagasse amount.
3. Cinder generated from coal burning from the steam boiler.
4. It is estimated that the cinder amount is accounted for 30% of the amount of coal consumed.
5. Waste paper (low quality product) come from finishing and cutting.
6. At present, this waste paper amount is about 15% of total paper amount from paper machine.
7. The amount of waste paper here seems to be high.
8. The reason leading this might be that the rolls in the paper machines were not clean
resulting in paper is broken.
9. Another reason might be the edge for cutting too large
Water Consumption
➢ River water from sedimentation unit is pumped to the production area of the mill.
➢ A part of the raw water is pumped to a tank where alum is added.
The two major energy forms consuming in the mill are steam and electricity.
1. Coal is used to produce steam.
2. team supply to the cooking and drying process is produced by a steam boiler
IDENTIFICATION FOR CLEANER PRODUCTION OPPORTUNITIES
1) Poor Housekeeping
• It was seen the spillage of the bagasse from the belt conveyors when transferring the
bagasse from the depther to a digestor.
• The leaking and overflow of water taps in the mill leading to water consumption amount
was increased.
• The insulation of steam pipeline has been in bad condition.
2) Poor Raw Material Quality
• It was easy to recognize when surveying the mill that depithed bagasse was still mixed
with fine piths after depithing process.
• Hence the input material contains amount of non-fibrous material leading to consume
more chemicals and energy.
3) Poor process and equipment design
• The concentrated black liquor from cooking operation have not been separated and
collected.
• The spillage of pulp in washing pulp operation was seen due to inadequate size of the
potcher (the tanks below the digestors)
• Time of beating was found to be too long (more than 2 hours).
• It was seen that edge cutter was too large.
• Consistency indicator was absence.
• Fiber recovery unit using for wastewater from paper machine was absence Cleaner Production Good
housekeeping
1. Installation of a screen to separate fine piths and dust in the depithed bagasse.
4. Installation of self-closing valves for the pressurized raw water to minimize water wastage
7. Cleaning the roll in the paper machines to avoid broke paper Better Process Control 1. Segregation of
initial concentrated black liquor 2. Installation of consistency indicator. 3. Adjustment of edge cutter to
reduce side trimming loss 4. Use of soft water as boiler feed water. 5. Installation fiber recovery unit
(saveall) for whitewater from paper machines. 6. Reduce beating time 7. Multiple loading of digestor
Better Process Control
second stage leather making, the tanning proper invoves the treatment of the hides to make them non putrescible and
soft even when dried .depending on the type of product either vegetable substance containing natural tannin.
Vegetable tanning used for heavy leather and chrome tanning used for light leather
The leather industry is one of the main examples of industries which play an important role in
the Indian economy in terms of exports and employment opportunities, while being blamed for
environmental pollution
The pressure to adopt cleaner technologies normally emanates from environmental imperatives such as
the need to meet specific discharge norms, reduce treatment costs or comply with occupational safety
and health standards.
The typical primary targets are: o lower water consumption, o improved uptake of chemicals, o better
quality/re-usability of solid waste, and o reduced content of specific pollutants such as heavy metalsand
electrolytes.
Waste Minimisation Measures
Systematic implementation of the waste minimisation measures in tannery sector can provide a
viable solution to the environmental problems faced by the tanners as well as assist the tanners in
improving their profitability. The following measures should be taken:
a) All the tanneries shall install water meters and flow meters to measure actual consumption
andwaste water discharged. Water consumption rates shall be brought down to less than the
prescribed limits per tonne of hides by taking water conservation measures.
b) Process-wise, some of the waste minimisation measures to be adopted by the tannery units
include the following:
i) Soaking: The waste minimisation measures for reducing water consumption inter-alia include: Use of
counter current system of washing to concentrate the salt and other soluble materials such as dirt and
blood.
ii) Reuse of the 2nd main soak for dirt soak: Soaking consists of dirt soak and main soak. The main soak is
retained and used for dirt soak for the following batch.
iii) Reuse of dirt soak: The dirt soak liquor may be collected and added polyelectrolyte to flocculate and
settle the suspended solids. Soak liquor thus treated and filtered can be reused partially in liming,
deliming washes and pickling.
iv) Drum soaking instead of pit soaking: This will not only reduce water consumption but will also bring
down the soaking time from 12 hrs to 3 hrs. This will enable the tanners to construct solar evaporation
pond in less area thereby using the open land for more productive use.
v) Addition of soaking enzymes: Soaking enzymes are added to achieve uniform and thorough soaking.
Further, to improve the treatability of waste water, regular wetting agent should be substituted with
biodegradable wetting agents.
vi) Stop ''open washing systems‖ in drum washing. Use batch systems only. Batch washing involves washing
of hides and skins during processing by introducing the required quantity of clean water into the
processing vessel and using the action of the vessel to achieve the required agitation as opposed to
running water washes which use the inflow and outflow of large quantities of water.
ii) Liming: The following measures shall be adopted to optimise chemical consumption in this
process step.
These include:
Substitution of paste lime by 85% pure calcium hydroxide [Ca(OH)!]: This will bring down the
quantity of consumption of powdered lime to one third ofits original quantity. lt will also reduce
the frequency of cleaning the primary settling tanks which consisted mainly of the lime sludge.
Use of liming enzymes: Use of liming enzymes will reduce Sodium sulphide (NaS)
consumption by 40%. Provision of a slight slope in the pasting area: By providing a slight
slope in the pasting area the excess liming paste can be effectively collected and used which is
otherwise washed away in the drain by lime yard workers.
Reuse of relime liquor: 50% of relime liquor can be retained and reused for liming of
subsequent batches. This will also reduce water consumption in liming. In addition to
optimisation of the chemical consumption in liming section, fleshings can be used to produce
biogas, gelatine, glue and also high-grade protein. This will solve the problem of solid waste
disposal from the liming section.
iii) Deliming: Efforts should be made to reduce the water consumption in this section process by
implementing the following measures:
Use of deliming agents such as ammonium chloride/ ammonium sulphide.
Use of 2nd delime wash for liming.
Reduce the use of ammonium by the injection of carbon dioxide gas (mainly applicable for
large tanneries and /or the use of other substitutes deliming agents 10
iv) Pickling: In this process, the following measures should be adopted to reduce salt
consumption: a. Use of drained float for next batch or go directly to tanning. b. Controlling
pickle liquor to 6° - 7° to optimise use of sodium chloride (NaCl).
v) Chrome tanning: The following measures should be adopted to recover chrome from
chrome tanning process, if it is applicable for the tannery. It may be restricted by the need to
produce leather properties which meat the customer requirement in particular related to dyeing
(reduced fastnesss and less brightness of colours) and fogging. a. Collection of spent chrome
liquor after basification and recovery of chrome from the same. The recovered chrome can be
used along with regular Basic Chrome Sulphate (BCS) for chrome tanning.
vi) Dyeing: The waste minimization measures under this process include the following: a. Use of
soft water for dyeing process to reduce the dye consumption as well as syntans consumption, in
case, the fresh water quantity is not good enough (hardness). b. Use of automated water dosing
systems.
ELECTROPLATING INDUSTRY
Pollution Prevention and Control Plating involves different combinations of a wide variety of
processes, and there are many opportunities to improve on traditional practices in the industry.
The improvements listed below should be implemented where possible.
1. Changes in Process
Replace cadmium with high-quality, corrosion-resistant zinc plating. Use cyanide-free
systems for zinc plating where appropriate. Where cadmium plating is necessary, use
bright chloride, high-alkaline baths, or other alternatives. Note, however, that use of some
alternatives to cyanides may lead to the release of heavy metals and cause problems in
wastewater treatment
Use trivalent chrome instead of hexavalent chrome; acceptance of the change in finish
needs to be promoted.
Give preference to water-based surface-cleaning agents, where feasible, instead of
organic cleaning agents, some of which are considered toxic.
Regenerate acids and other process ingredients whenever feasible.
2.Reduction in Dragout and Wastage
Minimize dragout through effective draining of bath solutions from the plated part, by,
for example, making drain holes in bucket-type pieces, if necessary.
Allow dripping time of at least 10 to 20 seconds before rinsing
Use fog spraying of parts while dripping.
Maintain the density, viscosity, and temperature of the baths to minimize dragout.
Place recovery tanks before the rinse tanks (also yielding makeup for the process tanks).
The recovery tank provides for static rinsing with high dragout recovery
The collection, treatment, and disposal of waste material that, when improperly handled,
can cause substantial harm to human health and safety or to the environment.
Hazardous wastes can take the form of solids, liquids, sludges, or contained gases, and
they are generated primarily by chemical production, manufacturing, and other industrial
activities. They may cause damage during inadequate storage, transportation, treatment,
or disposal operations.
People living in homes built near old and abandoned waste disposal sites may be in a
particularly vulnerable position. In an effort to remedy existing problems and to prevent
future harm from hazardous wastes, governments closely regulate the practice of
hazardous-waste management
Hazardous-waste characteristics
Hazardous wastes are classified on the basis of their biological, chemical, and physical
properties.
These properties generate materials that are either toxic, reactive, ignitable,
corrosive, infectious, or radioactive.
Toxic wastes are poisons, even in very small or trace amounts. They may have acute effects, causing death
or violent illness, or they may have chronic effects, slowly causing irreparable harm. Some are carcinogenic,
causing cancer after many years of exposure. Others are mutagenic, causing major biological changes in the
offspring of exposed humans and wildlife.
Reactive wastes are chemically unstable and react violently with air or water. They cause
explosions or form toxic vapours. Ignitable wastes burn at relatively low temperatures and may cause an
immediate fire hazard. Corrosive wastes include strong acidic or alkaline substances. They destroy solid
material and living tissue upon contact, by chemical reaction.
Infectious wastes include used bandages, hypodermic needles, and other materials from
hospitals or biological research facilities.
Radioactive wastes emit ionizing energy that can harm living organisms. Because
some radioactive materials can persist in the environment for many thousands of years
before fully decaying, there is much concern over the control of these wastes.
1 Underground disposal
The only way this method is compliant is when the hazardous waste is brought to mines
that are either inactive or partially active (along with meeting additional geological and
technical specifications).
Many companies need to dispose of radioactive waste, whether from medical treatments,
laboratory experiments, nuclear fuel production, or radioactive ore mining. For those
cases, this method is considered a strong, cost-effective option.
These hazardous waste facilities will vary in their sustainability, per the EPA. The agency
is responsible for protecting people and the natural world by verifying that these units’
design, operation, and maintenance adhere to its standards.
Landfill disposal
Dumpsites and landfills are the most commonly used and oldest method of waste
disposal. Hazardous waste landfills are specially built and are NOT intended for liquid
wastes. They are engineered and excavated so that they are within the ground rather than
piling upward.
These landfills are lined with clay, HDPE, or other non-porous materials to prevent the
waste from leaching into the ground. Wind dispersal controls, leak protection systems,
and a double liner are additional protections so that humans and the environment come
into contact with as little of the waste as possible.
Recycling
A federal analysis revealed that 1.5 tons of hazardous waste were managed through
recycling in 2017. Recycling is preferable to disposing of hazardous wastes for numerous
reasons. It results in economic benefits, decreases our raw material reliance nationally,
conserves natural resources, prevents pollution, and cuts energy use.
Any movement of hazardous wastes or other wastes from an area under the national
jurisdiction of one State to or through an area under the national jurisdiction of another
State or to or through an area not under the national jurisdiction of any State, provided at
least two States are involved in the movement
Parties to the Basel Convention have the overall obligation to ensure that transboundary
movements of hazardous and other wastes are minimized and that any such movement is
conducted in a manner which will protect human health and the environment.
Parties are under an obligation to take the appropriate measures to ensure that
transboundary movements of hazardous wastes and other wastes are only allowed if one
The State of export does not have the technical capacity and the necessary facilities,
capacity or suitable disposal sites in order to dispose of the wastes in question in an
―environmentally sound manner‖.
The wastes in question are required as raw material for recycling or recovery industries in
the State of import; or
In all cases, the Convention requires that the standard of environmentally sound
management of hazardous wastes or other wastes is met. Environmentally sound
management means taking all practicable steps to ensure that hazardous wastes or other
wastes are managed in a manner which will protect human health and the environment
against the adverse effects which may result from such wastes.
In addition to these conditions, the Basel Convention specifies instances in which Parties
may restrict transboundary movements and instances in which Parties must restrict
transboundary movements.
Finally, the Basel Convention requires that only persons authorized or allowed to
transport or dispose of wastes undertake such operations and that wastes subject to a
transboundary movement be packaged, labelled and transported in conformity with
generally accepted and recognized international rules and standards.