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Non-Ferrous Metal Industries Present Status amp Proposed standards
Submitted by-
Sooraj Garg
P14EN009
Under the Guidance of-
Mr Ajay Aggarwal
Additional Director
Central Pollution Control Board New Delhi
Contentbull Company Profile
bull Introduction
bull Production of Non-Ferrous Metals in India
bull Primary Copper Industriesndash Manufacturing Process
ndash Environmental Concern
bull Primary Lead and Zinc Industriesndash Manufacturing process
ndash Environmental Concern
bull Proposed Standards
bull Ambient Air Quality Monitoring2
Company Profilebull Central Pollution Control Board New Delhi
Statutory organization under the Ministry of EnvironmentForests amp Climate Change (MoEF amp CC)
Established in 1974 under Water (Prevention and Control ofPollution) Act 1974
It serves as a field formation and also provides technical servicesto the Ministry of Environment and Forests of the provisions ofthe Environment (Protection) Act 1986
Head office of CPCB divided into 21 divisions and I workedunder the PCI-II (Pollution Control Implementation Division - II)division
bull Area of work Preparing a support document for drafting the proposed standards for Non-Ferrous metal Industries (Cu Pb amp Zn)
3
Introductionbull Metals that do not contain iron as principle constituent are
called non-ferrous metalsbull Non-ferrous metals have specific advantages over ferrous
metalsbull They can be fabricated with ease and have high electrical
amp thermal conductivitiesbull Non-ferrous metals find extensive use on account of their
desirable properties like low weight higher conductivitynon-magnetic property etc
bull Aluminium copper lead and zinc are the most prominentnon-ferrous metals in India which are produced throughboth primary and secondary routes
bull Primary non-ferrous metals production is energy intensiveand there are various avenues of pollution from suchindustries like mining refining smelting and casting
4
Contribution and rank of India in world production of principal non-ferrous metals
Metals Production (Kilo tonne) Indiarsquos Contribution ()
Indiarsquos rank in
order of
quantum
of production
World
(during 2011)
India
(during 2011-
12)
Aluminium 45200 1654 37 8th
Copper 19500 504 26 10th
Lead (refined) 10400 92 09 18th
Zinc (slab) 13000 783 60 3rd
5
Source Annual Report 2013-14 Ministry of Mines Government of India
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Contentbull Company Profile
bull Introduction
bull Production of Non-Ferrous Metals in India
bull Primary Copper Industriesndash Manufacturing Process
ndash Environmental Concern
bull Primary Lead and Zinc Industriesndash Manufacturing process
ndash Environmental Concern
bull Proposed Standards
bull Ambient Air Quality Monitoring2
Company Profilebull Central Pollution Control Board New Delhi
Statutory organization under the Ministry of EnvironmentForests amp Climate Change (MoEF amp CC)
Established in 1974 under Water (Prevention and Control ofPollution) Act 1974
It serves as a field formation and also provides technical servicesto the Ministry of Environment and Forests of the provisions ofthe Environment (Protection) Act 1986
Head office of CPCB divided into 21 divisions and I workedunder the PCI-II (Pollution Control Implementation Division - II)division
bull Area of work Preparing a support document for drafting the proposed standards for Non-Ferrous metal Industries (Cu Pb amp Zn)
3
Introductionbull Metals that do not contain iron as principle constituent are
called non-ferrous metalsbull Non-ferrous metals have specific advantages over ferrous
metalsbull They can be fabricated with ease and have high electrical
amp thermal conductivitiesbull Non-ferrous metals find extensive use on account of their
desirable properties like low weight higher conductivitynon-magnetic property etc
bull Aluminium copper lead and zinc are the most prominentnon-ferrous metals in India which are produced throughboth primary and secondary routes
bull Primary non-ferrous metals production is energy intensiveand there are various avenues of pollution from suchindustries like mining refining smelting and casting
4
Contribution and rank of India in world production of principal non-ferrous metals
Metals Production (Kilo tonne) Indiarsquos Contribution ()
Indiarsquos rank in
order of
quantum
of production
World
(during 2011)
India
(during 2011-
12)
Aluminium 45200 1654 37 8th
Copper 19500 504 26 10th
Lead (refined) 10400 92 09 18th
Zinc (slab) 13000 783 60 3rd
5
Source Annual Report 2013-14 Ministry of Mines Government of India
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Company Profilebull Central Pollution Control Board New Delhi
Statutory organization under the Ministry of EnvironmentForests amp Climate Change (MoEF amp CC)
Established in 1974 under Water (Prevention and Control ofPollution) Act 1974
It serves as a field formation and also provides technical servicesto the Ministry of Environment and Forests of the provisions ofthe Environment (Protection) Act 1986
Head office of CPCB divided into 21 divisions and I workedunder the PCI-II (Pollution Control Implementation Division - II)division
bull Area of work Preparing a support document for drafting the proposed standards for Non-Ferrous metal Industries (Cu Pb amp Zn)
3
Introductionbull Metals that do not contain iron as principle constituent are
called non-ferrous metalsbull Non-ferrous metals have specific advantages over ferrous
metalsbull They can be fabricated with ease and have high electrical
amp thermal conductivitiesbull Non-ferrous metals find extensive use on account of their
desirable properties like low weight higher conductivitynon-magnetic property etc
bull Aluminium copper lead and zinc are the most prominentnon-ferrous metals in India which are produced throughboth primary and secondary routes
bull Primary non-ferrous metals production is energy intensiveand there are various avenues of pollution from suchindustries like mining refining smelting and casting
4
Contribution and rank of India in world production of principal non-ferrous metals
Metals Production (Kilo tonne) Indiarsquos Contribution ()
Indiarsquos rank in
order of
quantum
of production
World
(during 2011)
India
(during 2011-
12)
Aluminium 45200 1654 37 8th
Copper 19500 504 26 10th
Lead (refined) 10400 92 09 18th
Zinc (slab) 13000 783 60 3rd
5
Source Annual Report 2013-14 Ministry of Mines Government of India
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Introductionbull Metals that do not contain iron as principle constituent are
called non-ferrous metalsbull Non-ferrous metals have specific advantages over ferrous
metalsbull They can be fabricated with ease and have high electrical
amp thermal conductivitiesbull Non-ferrous metals find extensive use on account of their
desirable properties like low weight higher conductivitynon-magnetic property etc
bull Aluminium copper lead and zinc are the most prominentnon-ferrous metals in India which are produced throughboth primary and secondary routes
bull Primary non-ferrous metals production is energy intensiveand there are various avenues of pollution from suchindustries like mining refining smelting and casting
4
Contribution and rank of India in world production of principal non-ferrous metals
Metals Production (Kilo tonne) Indiarsquos Contribution ()
Indiarsquos rank in
order of
quantum
of production
World
(during 2011)
India
(during 2011-
12)
Aluminium 45200 1654 37 8th
Copper 19500 504 26 10th
Lead (refined) 10400 92 09 18th
Zinc (slab) 13000 783 60 3rd
5
Source Annual Report 2013-14 Ministry of Mines Government of India
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Contribution and rank of India in world production of principal non-ferrous metals
Metals Production (Kilo tonne) Indiarsquos Contribution ()
Indiarsquos rank in
order of
quantum
of production
World
(during 2011)
India
(during 2011-
12)
Aluminium 45200 1654 37 8th
Copper 19500 504 26 10th
Lead (refined) 10400 92 09 18th
Zinc (slab) 13000 783 60 3rd
5
Source Annual Report 2013-14 Ministry of Mines Government of India
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Major Producers of Non-Ferrous MetalsMetal Major Producer Production (tonne)
2013-14
Aluminium NALCO
HINDALCO
VEDANTA GROUP
316492
618286
75355
Copper Hindustan Copper Limited (HCL)
Sterlite Industries Limited
Hindalco India Limited
17005
294433
332842
Zinc Hindustan Zinc Limited (HZL)Binanipuram Zinc Limited (BZL)
78364738000
Lead Hindustan Zinc Limited (HZL) 185000
- Data is of 2011-12Source- Annual Report 2013-14 Ministry of Mines Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st amp 52nd Edition 6
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Primary Copper Industriesbull Copper is an important non-ferrous base metal having wide industrial
applications ranging from defence space program railways powercables telecommunication cables construction industries etc
bull Copper is mined from a variety of ores often containing less than one per cent copper
bull This copper is typically in the form of mineral compounds with sulphur iron arsenic and tin
bull To facilitate transportation to smelters concentration to about 30 copper content is accomplished at the mine sites via crushing grinding and flotation
bull The resulting concentrate is processed in a reverberatory furnace an electric furnace or one of several relatively new oxygen enrichment flash smelting furnaces to yield matte of as much as 65copper content
bull The iron in this matte is oxidized in a converter to produce blistercopper of 97 to 985 purity which can then be further refinedPyrometallurgical andor hydrometallurgical
7
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Manufacturing Process
Source - Nonferrous metal US EPA archive Document September 1995 8
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Copper - Process Material Input and Pollution Output
Source - Nonferrous metal US EPA archive Document September 1995
Process Material Input Air Emissions Process Wastes Other Wastes
Copper Concentration Copper ore water
chemical reagents
thickeners
Flotation wastewaters Tailings containing waste
minerals such as limestone and
quartz
Copper Leaching Copper concentrate
sulphuric acid
Uncontrolled leachate Heap leach waste
Copper Smelting Copper concentrate
siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down Slurry
sludge (K064) slag containing
iron sulphides silica
Copper Conversion Copper matte scrap
copper siliceous flux
Sulphur dioxide particulate
matter containing arsenic
antimony cadmium lead
mercury and zinc
Acid plant blow down slurry
sludge (K064) slag containing
iron sulphides silica
Electrolytic Copper
Refining
Blister copper Process wastewater Slimes containing impurities
such as gold silver antimony
arsenic bismuth iron lead
nickel selenium sulphur and
zinc
9
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Environmental impacts of copper production
Source Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and assessment
10
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Treatment bull Fabric filters are used to control particulate emissions
Dust will need to be disposed of in a secure landfill orother acceptable manner
bull Effluent treatment by precipitation filtration and soon of process
bull Bleed streams filter backwash waters boiler blowdown and other streams may be required to reducesuspended and dissolved solids and heavy metals
bull Slag should be landfilled or granulated and sold
bull Modern plants using good industrial practices shouldset as targets total dust releases of 05ndash10 kgt ofcopper and SO2 discharges of 25 kgt of copper
11
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Sulphur Dioxide treatment
bull Sulphur that is not captured is usually present asSO2 and can be recovered as elemental sulphurliquid SO2 gypsum or sulphuric acid
bull Sulphur dioxide is produced during the dryingand smelting of sulphide concentrates and othermaterial
bull A distinction can be made between techniquesapplied to reduce SO2 emissions from off-gaseswith less than 1 SO2 and for gases with a higherSO2 content
bull Acid plants convert the sulphur dioxide inemissions to sulphuric acid (H2SO4)
12
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
SO2 Gas cleaning mechanism
13
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Sulphuric acid plants
bull Single contactsingle absorption (SCSA) plantsndash The gas goes through the system oncendash such plants average conversion (SO2 to H2S04)
efficiencies of 96 to 98
bull Double contactdouble absorption (DeDA) plants ndash maximize S02 capture by returning the gas stream to
the converters through an intermediate absorption tower
ndash These plants are capable of 997 to 998 conversion efficiencies
14
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Sulphuric acid plant
15
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Primary Lead and Zinc Industries
bull The most important and abundant lead and zinc minerals are Galena (PbS)and Sphalerite or Zinc Blende (ZnS) respectively
bull The worlds reserves of lead were estimated at 89 million tonne Australialeads with 40 of worlds reserves of lead followed by China (16)Russia (10) Peru (9) and USA amp Mexico (about 6 each)
bull The worlds reserves of zinc were estimated at 250 million tonne Australiaaccounts for 28 of worlds zinc reserves followed by China (17) Peru(7) Mexico (6) India (5) and USA and Kazakhstan (4 each)
bull Rajasthan is endowed with the largest resources of lead-zinc oreamounting to 60753 million tonne (8861) followed by Andhra Pradesh2269 million tonne (331) Madhya Pradesh 1484 million tonne (216)Bihar 1143 million tonne (167) and Maharashtra 927 million tonne(135) Resources are also established in Gujarat Meghalaya OdishaSikkim Tamil Nadu Uttarakhand and West Bengal
16
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Manufacturing Processbull Beneficiation
ndash Separation of lead concentrates and zinc concentrates
ndash The compounds of zinc copper arsenic silica antimony bismuth etc are deleterious impurities in lead metallurgy
ndash Compounds of lead copper arsenic bismuth iron silica etc are the deleterious impurities as far as zinc smelting is concerned
bull Smeltingndash Pyrometallurgical process
ndash Hydrometallurgical process17
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Environmental ConcernLocation Impact
Mining Tailing water tail dumps creates water pollution
dust and gases during blasting transportation of
ores results in air pollution
Crushing grinding Fugitive emission solid and liquid effluents
tailings
Beneficiation Solid and liquid effluents tailings result in water
pollution
Roaster Dust gases acid mist fine zinc dust
Leaching plant Water pollution due to solid and liquid effluents
Electrolytic cell house Water pollution due to solid and liquid effluents
acid mist
Melting Dust and gases fine dust of heavy metals
Standard for SPM 150 mgNM3
Source VISWANATHAN PV et al 199818
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Existing Standards for Aluminium IndustriesSl No Source Parameter Standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crusher)
Particulate matter 150 mgNm3
(ii) Precipitation areas Calcination Particulate matter 250 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2
in kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 150 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 03 kgtonne of aluminium produced(iii) Pot room Particulate matter 150 mgNm3
Total fluoride For Soderberg
Technology
28 kgtonne by 31st December 2006
Total fluoride For Pre-baked
Technology
08 kgtonne by 31st December 2006
(c) Standards for forage fluoride Twelve consecutive months
average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm19
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Proposed Standards for Aluminium Industries
Sl No Source Parameter Proposed standards
(a) Alumina plant
(i) Raw material handling (Primary and
secondary crushers)
Particulate matter 50 mgNm3
(ii) Precipitation areas Calcination Particulate matter 50 mgNm3
Carbon monoxide 1 max
Stack height H=14 (Q)03 Where Q is emission rate of SO2 in
kghr and H is stack height in meter
(b) Smelter plant
(i) Green anode shop Particulate matter 50 mgNm3
(ii) Anode bake oven Particulate matter 50 mgNm3
Total fluoride (F) 001 kgtonne of green anode produced
Polycyclic aromatic
hydrocarbon (PAH)
0025 kgtonne of green anode produced
20
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Continuehellip(iii) Pot room Particulate matter 50 mgNm3
Total fluoride For
Soderberg Technology
Pot lines with Soderberg Technology does
not exist now The EC for new pot lines to be
given only with pre-baked technology
Total fluoride For Pre-
baked Technology
03 kgtonne of Al produced
Fugitive fluoride emission 03 kgtonne of Al produced
(c) Standards for forage fluoride Twelve consecutive
months average
40 ppm
Two consecutive months
average
60 ppm
One month average 80 ppm
(d) Fluoride consumption Fluoride 10 kgtonne of aluminum produced (as F)
(e) Discharge of effluent ------ No effluent shall be discharged outside the
premises
The existing aluminium manufacturing units shall achieve the limits whichever modified within a period of one year
from the date of notification of the standards
21
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Standards for Copper Lead amp Zinc IndustriesPlant segment Parameters Plant capacity for 100
convertible concentration
of sulphuric acid
Existing
unit
New
unit
1(a) Concentrator Particulate Matter ----- 100 mgNm3 75 mgNm3
1(b) Sulphur Dioxide Recovery
Unit
Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
1370 mgNm3
1250 mgNm3
1250 mgNm3
950 mgNm3
Acid Mist Sulphur Trioxide Up to 300 tday
Above 300 tday
90 mgNm3
70 mgNm3
70 mgNm3
50 mgNm3
Note
1 Capacity in above stipulation means the installed capacity of Sulphuric Acid Plant
2 Scrubbing units shall have on-line pH meters with auto recording facility
3 Plant commissioned on or after the date of notification shall be termed as New Unit
4 The height of the Stack emitting Sulphur Dioxide or acid mist shall be a minimum of 30 metres or as per the formula H = 14(Q)03 (whichever
is more) where H is the height of stack in meters and Q is the maximum quantity of SO2 in kghr expected to be emitted through the
stack at 110 per cent rated capacity of the Tail Gas plant(s) and calculated as per the norms of gaseous emission
5 Tail Gas plants having more than one stream or unit of sulphuric acid at one location the combined capacity of all the streams or units shall
be taken into consideration for determining the stack height and applicability of emission standards
6 Tail Gas plants having separate stack for gaseous mission for the scrubbing unit the height of this stack shall be equal to main stack or 30
metres whichever is higher
2 LoadMass Based Standards Sulphur Dioxide (SO2) Up to 300 tday
Above 300 tday
25 kgtonne
20 kgtonne
20 kgtonne
15 kgtonne22
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Air Quality Monitoring
bull On 1st July 2015 I visited ambient air quality monitoring station located at Pragati Maidan New Delhi
bull Under NAMP four air pollutants viz Sulphur Dioxide(SO2) Oxides of Nitrogen as NO2 and SuspendedParticulate Matter (SPM) and RSPMPM10 have beenidentified for regular monitoring at all the locations
bull The monitoring of pollutants is carried out for 24 hours(4-hourly sampling for gaseous pollutants and 8-hourlysampling for particulate matter) with a frequency oftwice a week to have 104 observations in a year
bull National air quality standards given by CPCB Delhi hasbeen applied on these monitoring stations
23
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Monitored ParametersS
No
Parameter Testing method Absorbing media Sampling
time in
Hours
1 Sulphur dioxide Modified West
amp Gaeke Method (IS 5182 Part 2
Method of Measurement of Air
Pollution Sulphur dioxide)
Potassium
tetrachloromercurate (TCM)
4
2 Nitrogen oxides as NO2 Modified Jacobs amp Hochheiser Method
(IS 5182 Part 6 Methods for
Measurement of Air Pollution Oxides
of nitrogen)
sodium hydroxide and sodium
arsenite
4
3 Ozone Method 411 Air Sampling and Analysis
3rd Edition (Determination of oxidizing
substances in the atmosphere)
(1 KI in 01 m Phosphate
Buffer)
1
24
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
ResultS
No
Parameter Concentrati
on in
Ambient Air
1 Sulphur dioxide microgm3 10
2 Nitrogen dioxide microgm3 52
3 Ozone microgm3 18
These values were monitored at 4 hour interval for Sulphur dioxide and Nitrogen dioxide and
averaging the values for 8 hours and 24 hours
values for Ozone were monitored at 1 hour interval
All the parameters monitored at ambient air monitoring station were within the limit it may be due to the monsoon season in Delhi during the monitoring period
25
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
Discussionbull For Aluminium Industries major concern is
Fluoride CPCB also included the fugitive fluorideemission limits in standards
bull For Copper Lead and Zinc Industries SO2 is amajor concern in CREP Report it is mandatory tocovert SO2 in to H2SO4
bull Standards of H2SO4 plant apply on these plants
bull Due to water scarcity Zero liquid dischargeconcept also included in these standards
26
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
References1 Annual Report 2013-14 Ministry of Mines Government of India
2 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 52nd Edition copper (advance release) Government of India
Ministry of mines Indian bureau of mines December 2014 5-21
3 Background Report AP-42 section 123 ldquoprimary copper smeltingrdquo US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 27711
4 Nonferrous metal US EPA archive document September 1995
5 Annual Report 2013-14 Hindustan Copper Limited
6 AP 42 Fifth Edition Volume-I Chapter 12 Metallurgical Industry section- 123 primary copper smelting final section
October 1986
7 An overview of environmental issues and protection measures in Indian non-ferrous plants Viswanathan PV and Sankaran
C 1998 Environmental and Waste Management ISSN 0971-9407 pp 197-208
8 Copper Technology and Competitiveness September 1988 congress of the United states office of the technology and
assessment
9 Pollution Prevention and Abatement Handbook World bank group July 1998
10 Best Available Techniques (BAT) Reference Document for the Non-Ferrous Metals Industries October 2014 joint research
centre European IPCC bureau
11 Market survey on lead amp zinc Mineral Economics Division Indian Bureau of mines Nagpur June 2011 market survey
series No MS-34
12 Indian Minerals Yearbook 2013 (Part- II Metals amp Alloys) 51st edition ldquolead and zinc (final release) Government of India
Ministry of mines Indian bureau of mines January 2014
13 Background Report on ldquoPrimary zinc smeltingrdquo AP-42 section 127 US Environmental Protection Agency
OAQPSTSDEIB Research Triangle Park NC 2771127
28
28