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POLLUTION CONTROL IN INDUSTRIES

PRESENTED BY TINU VALSA PAUL Reg. No: ETALCCH017 S2 M Tech CPC

CONTENTS

Pollution control in Cement industries Pollution control in Electroplating and Metal Finishing industries

POLLUTION CONTROL IN CEMENT INDUSTRIES

INDUSTRY DESCRIPTION
The preparation of cement involves mining; crushing, and grinding of raw materials (principally limestone and clay) Calcining the materials in a rotary kiln; cooling the resulting clinker Mixing the clinker with Gypsum and Milling, storing and bagging the finished cement. The process generates a variety of wastes, including dust, which is captured and recycled to the process Gases from clinker cooler are used as secondary combustion air.

SOURCES OF POLLUTION
Main source of pollution is Dust Emission. Approximately 10 -20% of the kiln feed can be suspended in the kiln exhaust gases, captured, and returned to the feed. Other sources of dust emissions include the clinker cooler, crushers, grinders, and materials - handling equipment. Grinding mill operations also result in particulate emissions.

Other materials-handling operations, such as conveyors, result in fugitive emissions. Ambient particulate levels (especially at sizes less than 10 microns) are harmful. Gases such as nitrogen oxides ( NOx ) and sulfur oxides ( SOx ) are formed from the combustion of the fuel (oil and coal) and oxidation of sulfur present in the raw materials, but the highly alkaline conditions in the kiln can absorb up to 90% of the sulfur oxides.

Heavy metals may also be present in the raw materials and fuel used and are released in kiln gases. The overflow from slurry concentrating equipment (i.e. thickeners) constitutes the main waterpollution problem. For new plants that process slurry, closedcycle water systems are used to return the overflow water to the process

POLLUTION CONTROL
The principal aim of pollution control in this industry is to avoid increasing ambient levels of particulate by minimizing the loads emitted. Minimize the increase in ambient particulate levels by reducing the mass load emitted from the stacks, from fugitive emissions, and from other sources. Collection and recycling of dust in the kiln gases

NOx emissions should be controlled by using proper kiln design, low -NOx burners, and an optimum level of excess air. Precalcining with low-NOx secondary firing can reduce nitrogen oxide emissions. SOx emissions are best controlled by using low-sulfur fuels and raw materials. Mechanical systems such as cyclones trap the larger particulates in kiln gases and act as preconditioners for downstream collection devices.

Electrostatic precipitators (ESPs) and fabric filter systems (baghouses) are the principal options for collection and control (achieving over 99%removal efficiency) of fine particulates. ESPs are sensitive to gas characteristics, such as temperature, and to variation in voltage; baghouses are generally regarded as more reliable. The choice of system will depend on flue gas characteristics and local considerations.

A. Raw material acquisition The primary air pollutant emitted is particulate matter. Methods used to control particulate emissions are: i. Fabric filters (pulse-jet or reverse-air/shaker) ii. Equipment enclosures iii. Water sprays (with and without surfactants) iv. Silos (with and without exhaust venting to wind screens fabric filters) v. Foams vi. Mechanical collectors vii. Bins viii. Chemical dust suppressants ix. Paving x. Material storage buildings

B. Raw Milling The following devices are used to collect particulate matter in the raw mill and raw mix storage areas: I. Mechanical cyclones (usually used in series with another control) II. Fabric filters (pulse jet or reverse air/shaker) III. Electrostatic precipitators (rarely used) C. Pyroprocessing The main pyroprocessing system emissions are Nitrogen, Carbon dioxide, Water, Oxygen, Nitrogen oxides, Sulfur oxides, Carbon monoxide, Hydrocarbons and Cement kiln dust.

The following methods are used to control particulate emissions from the kiln system: I. Reverse-air fabric filters II. Electrostatic precipitators (esps) III. Acoustic horns (sometimes used in conjunction with the two devices above) D. Clinker Cooling Reciprocating grate clinker coolers most often employ fabric filters E. Clinker Storage The devices used to control dust emissions from clinker storage areas are similar to those used in the raw milling process.

F. Finish Milling Particulate matter is emitted from mill vents, air separator vents, and material-handling system vents. The cement dust collected by the fabric filter is restored to the system G. Packing and Loading In the shipping department particulate matter is emitted from the silos and the handling and loading operations. Active and passive fabric filters are used to collect this dust. During loading of the product, particulate emissions are controlled by a fabric filter connected to the transport vessel; collected dust is restored to the shipment.

ELECTROPLATING AND METAL FINISHING INDUSTRIES

Some of the principal industries that use metal finishing processes are : 1. The motor car industry 2. The aircraft industry 3. The kitchen and domestic ware industry 4. The heavy electrical industry for the manufacture of electrical components 5. Non-ferrous and ferrous parts for the building industry; 6. Ornaments and fancy goods such as ladies' handbags 7. Industries concerned with the treatment of steels such as stainless steel, tubes or steels meant to withstand very high temperatures.

INDUSTRY DESCRIPTION

Pretreatment, using solvents for degreasing and cleaning, chemical cleaning, pickling with acids, phosphating by dipping steel or zinc base alloys in a solution of acid phosphates, chromating, sodium hydride descaling, abrasive cleaning, shot blasting, ultrasonic cleaning, barrelling and polishing Finish polishing using mechanical, barrelling, electropolishing or chemical processes

Electroplating using vat, barrel, automatic or reverse current processes to plate copper, nickel chromium, cadmium, tin, speculum (a tin-copper alloy), silver, palladium and other precious metals Anodising in sulphuric or chromic acid; Metal coating by galvanizing, sherardizing (heat treatment of cleaned articles in the presence of zinc dust and aluminium or sand), Peen plating (non-electrolytic method of applying metal coatings to hardware articles), calorizing (heat treatment in the presence of ammonium chloride and powdered aluminium), chromating, zinc or aluminium spraying or hot dip aluminizing;

Paint coating by brush, spray or electrostatic or airless processes, dipping, curtain coating, flow coating, rumbling, hot spraying or electropainting; Chemical colouring by blackening, blueing or chromating; Plastic coatings, applied by spray, dipping, fluidized bed, powder spraying; Pre-finished metals as painted, anodized, aluminized, galvanized or plastic-coated strip or sheet metal that has been coated.

SOURCES OF POLLUTION
Produce liquid waste containing 1. Metallic ions(nickel, chromium, zinc, lead, silver, copper, tin, cadmium, mercury etc). 2. Salts of cyanides, hydrogen sulphide, ammonia and chloramines. Two general sources of waste 1. Batch solutions, 2. Rinse waters including both non overflowing reclaimable rinses & continuous overflow rinses.

The major type of wastes originating from the stripping, cleaning, and plating of metal parts are: 1. Proprietary solutions 2. Cyanide concentrates 3. Cyanide rinse water 4. Concentrated acid and pickling wastes 5. Strong acid rinse waters 6. Chromates orginate 7. Concentrated alkalis 8. Other waste requiring treatment 9. Waste water not requiring treatment

CHARACTERISTICS OF WASTES
Most stripping baths are acidic in nature(sulfuric, nitric and hydrochloric acid). Some are alkaline baths(sodium sulfide, cyanide, and hydroxide). Concentration of chemicals present in stripping solution less than 10%. Cleaning carried out by organic solvent, pickling, or alkaline cleaning compounds.

Organic cleaners petroleum or coal-tar solvents coupled with an emulsifier. Alkaline cleaners sodium hydroxide, orthophosphate, complex phosphates, silicates, carbonates, some organic emulsifiers, and synthetic wetting agents. Concentration of metal ions in the effluent limited to 1ppm for a single metal ion Cyanides and hexavalent chromium in drinking water must be less than 0.01 & 0.05 mg/l respectively

TREATEMENT METHODS

3 Objectives Removal of Cyanides Removal of Chromium Removal of all other Metals, Oils and Greases

TREATEMENT OF CYANIDES
Chlorination (Gas) 2. Hypochlorites 3. ClO2 4. O3 (Ozonation) 5. Conversion to less Toxic Cyanide complexes 6. Electrolytic Oxidation 7. Acidification 8. Lime Sulfur method 9. Ion Exchange 10. Heating to Dryness
1.

TREATMENT OF CYANDE BY ALKALINE CHLORINATION


Addition of Chlorine gas to the waste of high pH Prior to Chlorination Ca(OH)2 or NaOH is added to bring the waste to a pH of about 11. To prevent Cyanide salt of Na or Ca from precipitating violent agitation is done 2NaCN + 5Cl2 + 12 NaOH N2 + 2Na2CO3 + 10NaCl + 6H2O

Continuous chlorination of cyanide wastes


Caustic
chlorine Chlorinator feed tank

Mixing tank

Cyanide waste

baffles Secondary chlorination may be necessary Sludge removal Retention tank

Batch chlorination of cyanide wastes


Causti c storag e

chlorine

chlorinator

Caustic feeder

Chlorine solution line Concentrated cyanide solutions agitato r pump

Sludge
disposal

Mixing and retention

Treated waste to sewer

Sodium hypochlorate, Ca(ClO)2 , H2SO3 are also used for oxidation. Cyanide containing waste is precipitated as ferrocyanate by the addition of ferrous sulfate and lime. The disposal of ferrocyanate sludge is a problem.

TREATMENT OF CHROMIUM BY REDUCTION AND PRECIPITATION


The Hexavalent Chromium in the waste is reduced to trivalent stage with reducing agents such as FeSO4, SO2 or NaHSO3 A residual pH of 3 or lower is maintained to ensure complete reaction After the reduction is complete an alkali (lime slurry) is added to neutralize the acid and precipitate the trivalent Chromium

Equations are

H2Cr2O7 + 6FeSO4 + 6H2SO4 Cr2(SO4)3 + Fe(SO4)3 + 7H2O Cr2(SO4)3 + 3Ca(OH)2 2Cr(OH)3 + 3CaSO4 Fe(SO4)3 + 3Ca(OH)2 2Fe(OH)3 + 3CaSO4

Reduction & Precipitation of Chromium

Reduction & Precipitation of Chromium

TREATEMENT OF OTHER METAL, OIL & GREASE BEARING WASTE


By neutralization and precipitation usually involves recombining the waste with previously oxidized Cyanide and reduced Chromium waste for subsequent and final treatment 5-10% of lime slurry is added to neutralize and precipitate the metals The floc produced is large and heavy Waste is settled since the velocity of flow is reduced Sludge is removed by lagooning

Acid Neutralization

Ion exchange, evaporation are used for recovery or disposal. The plating solutions containing nickel, copper, chromium etc. are concentrated and recycled. The water recovered during evaporation is used again in process(rinsing operation). Ion-exchange cationic and anionic resin beds are used (selected according to the nature of chemicals to be recovered) when salt concentration is low.

For recovery of chemicals from plating resins 3 beds consisting of carbon, cationic resins and anoinic resins are employed. Beds can be regenerated and concentrated solutions recovered /reused in plating baths.eg:-nickel, silver, gold and platinum recovered from spent-bath/rinse solutions. Stationary and moving beds are used for recovery of solutions. For metals that do not have high value of evaporation recycling becomes uneconomical, but necessary.

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