SUSTAINABLE ENVIRONMENTAL MANAGEMENT AND UTILISATION OF
SOLID WASTES FROM WORLD LEATHER SECTOR
Dr. S. RAJAMANI CHAIRMAN
International Union of Environment (IUE) CommissionChennai, India
E- mail: [email protected]
IUE COMMISSION OF IULTCSRepresented by 30 countries, UNIDO, UNEP,
European Union and Invitees
CHAIRMANDr. S. RAJAMANIIndia
SECRETARY- upto 2006Dr. CAMPBELL PAGESwitzerland
SECRETARY– 2007 onwardsMr Thierry PONCETFrance
IUE COMMISSION MEMBERS
COLOMBIAMr Juan Manuel SALAZAR
CHINAMr Chen ZHANGUANG, Mr Su CHAOYINGDr SHI BI, Madam Zhang Shuhua
BRAZILMs Katia Fernanda Streit
AUSTRIADr Hans ANDRES
AUSTRALIAMs Catherine MONEY
ARGENTINAMr Carlos CANTERA, Ms Patricia CASEY
IUE COMMISSION MEMBERS
GERMANYDr Heinz Peter GERMANN
FRANCEMr Thierry PONCET, Secretary (IUE)
CROATIAMr Jakov BULJAN
NORWAY, SCANDINAVIAMr Johannes O. Borge
EUROPEAN UNIONMr. Gustavo gonzales Quijano
CZECH REPUBLICProf Dr Karel KOLOMAZNIK
IUE COMMISSION MEMBERS
NEWZEALANDMs Ngaire Foster
MEXICOMr Ricardo Weiss
GREECEMr Pantelis PANTELARAS
INDIADr S Rajamani
JAPANDr. Keiji Yoshimura
ITALYDr Gianpiero Comite/ Dr Domenico Castiello / Mr Adolfo Izzo Renzi
IUE COMMISSION MEMBERS
TAIWANDr George Huang
SWITZERLANDDr Campbell Page
POLANDDr Maciej URBANIAK
ROMANIADR. LUMINITA ALBU
SLOVENIADr Anton GANTAR
SPAINMr Daniel Sanchez Esteve / Dr. Ms. Luico F. Cebeza
IUE COMMISSION MEMBERS
UNIDO, AUSTRIAMr Ivan Kral
URUGUAYMr Ricardo Hourdebaigt
UNITED STATESDr Nicholas CORY, Mr Elton Hurlow
TUNISIADr Abdessatar
TURKEYDr Volkan CANDAR, Dr Murat TOZAN
UNITED KINGDOMDr Wolfram SCHOLZ , Dr Tony Covington
Planning to include Pakistan, BanglaDesh, South Korea, Vietnam, Ethiopia, Kenya and other Countries.
ANNUAL IUE COMMISSION MEETING IN ONE OF THE HOST COUNTRIES
JUNE 2007, WASHINGTON DC
Rio de Janeiro, Brazil - October 2008 Beijing, China – October 2009
Proposed – Kolkata, India – Nov 2010 Valencia – Spain – September 2011
IUE COMMISSION ACTIVITIES
• Development of IUE Documents on Environmental aspects and Dissemination
Dissemination through IULTCS Website, Country Websites
Circulation among country members
Translation into other languages (Spanish, Turkish etc.)
Dissemination through UNIDO, UNEP, European Union etc.
Presentation in IULTCS Congress and Regional Conferences
Technical guidance/advice to Member associations / Countries
Publications through leather journals
IUE 1 - Viable Cleaner Technologies for Leather Production
IUE 2 - Tannery Solid By-Product Management
• Utilization of green fleshingsand trimmings
• Use of limed fleshings
• Methane production grease
• Grease and protein recovery
• Composting using waste sludge and other solid wastes
• Solid waste management aspects
IUE 3 - Total Dissolved Solids in Tannery Effluent
IUE 4 - Assessment for Chromium containing Waste from the Leather Industry
HOSEFLEXIBLE
COLLECTION
RECOVERED CHROM E
PROCESS FLOW DIAGRAM OF CHROM E RECOVERY AND REUSE SYSTEM
CHROME TANNING DRUMS
EXHAUST CHROM E LIQUOR
TANK
M OTOR M gO
stirrer
PLATFORM LEVEL
SU
PE
RN
ATA
NT
TO D
RAI
N
42H SO
REDISSOLVING TANK
LIQUORSTORAGE
TANK
CHROM E
TO TANNING DRUM S
SUPPORT
CHROM E SLURRYPUM P
PUM PScreen
IUE 5 - Typical Performance of Tannery Waste Water Treatment Systems
• Pretreatment units• Primary treatment
units• Biological treatment • Anaerobic / UASB• Membrane Bioreactor
and water recovery(Spain, India, Brazil, China etc.)
AEROBIC – MEMBRANE BIOREACTOR – NO SECONDARY CLARIFIER SUITABLE FOR
WATER RECOVERY
IUE 6 - Pollution Discharge Values from Tannery processes Under Conditions of Good Practice
IUE 7 - Chargeable Effluent Parameters From 25 Countries
IUE 8 - Odour Control in Tannery and Treatment Plant
• Sources of odour
• Putrefaction
• Hydrogen Sulphide
• Wastewater treatment and sludges
• Volatile organic compounds
• Air treatment
• New Guidelines are being introduced in many countries for odour control
• H2S control in Effluent treatment plantBIO-FILTER FOR ODOUR CONTROL
IUE 9 - Special requirements for Sewers Adapted for Tannery Effluents
IUE 10 - Document for Restricted Products in Leather
IUE 11- Recommendations for Occupational Safety and Health in the use of Chemicals in Tannery, Process and Treatment Plants
WORLD ENVIRONMENTAL UPDATE –SLUDGE AND SOLID WASTE MANAGEMENT
World Leather Process and Waste Generation
• Leather process – 15 million tons / year
(50,000 tons/ day)
• Wastewater discharge – 1,500 MLD
• Tannery Solid waste – 6 million tons/ year
• Sludge generation – 5 million tons/ year
• Salt discharge – 7 to 8 million tons/ year
INDIA
LEATHER PROCESS AND WASTE GENERATION IN SELECTED COUNTRIES
0.4 million tons / year1.5 million tons / yearSalt discharge
0.3 million tons / year1.2 million tons / yearSludge generation
0.3 million tons / year 1.5 million tons / yearTannery Solid Waste
More than 120 MLDMore than 400 MLDWastewater discharge
Less than 2 tons / yearMore than 15 tons / yearAverage processing capacity
0.8 millions tons / year 3.5 million tons / yearLeather process
More than 2000About 700No. of tanneries
CHINA
MAJOR SOLID WASTE FROM ABATTOIRS TANNERIES
• Dusted salt• Raw hide / skin trimmings• Green fleshing• Limed fleshing • Pelt trimmings• Wet blue trimmings• Vegetable tan trimmings• Shavings • Buffings
SLUDGE / SOLIDWASTE FROM EFFLUENT TREATMENT PLANTS
• Limed sludge
• Chrome / chemical containing sludge from ETPs and CETPs
• Sludge from the biological treatment
• Salt from solar pans and evaporators
SLUDGE DRYING BEDS
MECHANICAL DEWATERING
SYSTEM
UTILISATION OF SOLID WASTE
• Disposal options of dusted salt
Can be reused for curing along with fresh salt. But pre treatment is required.
• Green Fleshing Recovery of grease and meat mealPet Chews
• Disposal of Limed FleshingsAfter cleaning, processed for Gelatin Substitute for fish meal Methane production - Composting
SOLID WASTE GENERATION FROM TANNING AND FINISHING OPERATIONS AND MODE
OF DISPOSAL
Chrome Tan and Vegetable Tan Shavings
• Leather Board Manufacture
• Thermal Treatment for Recovery of Chromium and Bio – Energy Generation
• Enzymatic Treatment
• Conversion in to fertilizer
ARGENTINA
Management of solid wastes
• Green Fleshing Recovery of grease and meatmealPet Chews
• Manufacture of quality leather boards from vegetable tan waste
• Disposal of chrome containing sludge is a major problem
ARGENTINAManagement of solid wastes
CHROME SHAVINGS CONVERTED IN TO PELLETS, BUENOS AIRES, ARGENTINA
BRAZIL
MANAGEMENT OF SOLID WASTES AND SLUDGE
• During the 2008 – 2009 recession. Major environmental problem of disposal of unsalted hides from slaughter houses due to restriction in salt application and no demand for hides.
• Conversion of chrome shavings into bio- fertilizer after chrome recovery.
• Disposal of chrome containing sludge is a major problem due to the refusal for disposal into centralized secure landfill system .
R&D Activity in SENAI Tannery School, EstanciaVelha
CHINA
• There are about 700 tanneries
• Recently, more than 400 small sized tanneries have been closed as per new regulations.
• Till now, 13 ETPs has been built in China’s leather industry.
Entry Point at Xinji Leather
Industry Estate
CHINA
R & D on conversion of fleshing into polymer fibers
Manufacture of leather boards from chrome Shavings
Manufacture of bricks from sludge and buffying dust China Leather Research Industry
Association, Beijing, China
CZECH REPUBLICRecovery of Protein from fleshingsConversion of chromium containing sludge conversion by the Ceramic industry
• Environmental Regulations introduced in 1984
• Manufacture of leather board from chrome shavings mixed with vegetable tanned shavings
Leading tanneries have got IS0 14000
COLOMBIA
FRANCETallow extracted from fleshings converted into alternative
energy source.
Dusted salt is used for de-icing of roads.
New Biological Treatment Plant - Capacity of 1250 m3/day - 5 million USD with total aerobic digestion of sludge at high cost
Conversion of the fleshingsmixed with pig dungs for bio gas generation and electricity -Major plants are working
DENMARK, NORWAY, SWEDEN
INDIABiomethanation plant for 2 TPD Leather chrome Biomethanation plant for 2 TPD Leather chrome
shavings at M/s. TIL, Dewas, M.P. shavings at M/s. TIL, Dewas, M.P. 0.5 MWe•Many R & D activities on solid waste and Sludge management
•Implemented in pilot scales
•Limited number of organized solid waste managements meets such as leather board making conversion of fleshing into chickenfeed etc.
Many un organised small scale solid wastesConversion units.
Disposal of fleshing from goat and sheep,Buffing, chrome shavings etc. to be addressed
INDIA
MEMBRANE SYSTEM FOR RECOVERY OF WATER FROM TANNERY EFFLUENT UNDER ZERO DISCHARGE CONCEPT – (50 Individual Units and 15 CETPs – Investment more than 100 million
USD )Safe disposal of the saline stream / salt from evaporators
is one of the major issues to be addressed
INDIA
DECENTRALISED SECURE LAND FILL SYSTEM FOR DISPOSAL OF TANNERY SLUDGE IN CETPS
Capacities 20,000 - 150,000 m3Disposal Cost is less than 40 US Dollar / ton compared to 200 –
300 USD in Europe, South American countries
ITALY• Major units for
conversion of fleshing into animal feed and fertilizer
• Leather board units from chrome / vegetable tanning trimmings
• Disposal of the sludge is a major problem the CETPs is upgraded to aerobically digest the entire sludge in the treatment plant
DIFFUSED MEMBRANE SYSTEM -ITALY
POLAND
• Processing of organic materials and converting into fuel called as bio-coal
• Co-fermentation of chromium-free tannery wastes with municipal sewage sludge and conversion into fertilizer
SPAIN
Reverse Osmosis system with membrane bioreactor for
Recovery of Water for Reuse in a CETP, LURCA, SPAIN
Difficulties in disposal of salt and chrome containing sludge
SOUTH AFRICA• “Enzymatic saving unhairing process – Bio-transformation of
hair waste”• Research Focus: ‘Epidermis injury’ to promote the diffusion
process, through bovine epidermis of unhairing agents
• Shavings mixed with clay for brick making
TUNISIAIntegrated cleaner production for 12 vegetable tanneriesManufacture of leather board units Research & Development on sludge for composting
TURKEY
• Istanbul (Tuzla) and Izmir have been resettled to industrial estates in having centralized effluent treatment plants and bio diesel generation from fats and fleshings
• Chrome containing sludge disposal is a major problem
UNITED KINGDOM
• Bio-diesel from tallow• Bio-ethanol from protenised wastes
The conversion of the solid waste from small scale tanneries in countries such as India, Bangladesh is limited for want of required quantity and consistent quality.
Due to enforcement of environmental regulations the disposal of chrome containing sludge is a major problem in many countries. – Cost of disposal of sludge ranges from US Dollar 200 - 300 / ton in European and South American countries
,
Countries like United States export more raw hides – reduction in tanning process. There may be restriction in export of salted raw hides. Research and development will be restarted for cleaner production, utilization of solid wastes etc.
Sustainability of SMEs is a major problem due to enforcement of environmental regulations
Continued R & D on reduction of salt in the leather preservation, cleaner production, utilization of solid waste / sludge is required
FUTURE REQUIREMENT AND SUSTAINABLITY OF TANNING INDUSTRY
ACKNOWLEGEMENT
• IUE Commission Members from 30 countries of IULTCS especially from Argentina, Brazil, China and Spain
• United Nations Industrial Development Organisation (UNIDO)
• Central Leather Research Institute (CLRI), Chennai, India
• MOEF, MNRE, DIPP and other Govt. Organisations
• Council for Leather Exports (CLE), Chennai, India
• Chennai Environmental Management Company of Tanners (CEMCOT), India
• Ambur Economic Development Organisation Limited (AEDOL)
Thank You
DR.S.RAJAMANI