Code No: TMS069 Price: 1000 Category: Environment: Pollution

Summary  : The scope of studies presented is to cover the current status of the technologies in the world and in the country. It evaluates the economic aspects of the various technologies along with their feasibilities which lead to preferred options and identifying various technologies being used and suggests the suitable technologies.

Year of Publication : 1993

Table Of Contents : 

• Executive Summary
• Quick review of international
• technologies
• Introduction
• Indian Scenario
• Cement Industries
• Integrated Iron & Steel Mills
• Thermal Power Systems
• Aluminium smelters
• Zinc smelters
• Copper smelters
• Foundries
• World Scenario
• Tech. From Russia
• Tech. From Japan
• tech. From German Cos.
• tech. From Europe
• Tech. From Australia
• Tech from Holland
• Tech. From Norway
• Switzerland
• Status of Air Pollution Control Technologies in India
• Status of Air Monitoring Equipments in India
• Equipments selection/options
• Technologies of source control/clean Technologies
• By-Products/Reuse
• Economic/Common Aspects of Air Pollution Control Tech
• General preconditions/Main Issues/Suggestions/Recommendations/Action Plan
• Special work of some urban experts
• References.

SCOPE OF STUDY

1. The conducted Techno-market Survey concerns to the following industries in the World and in India :

a. Cement Industry
b. Integrated Iron and Steel Plants
c. Thermal Power Systems
d. Foundries
e. Aluminum Smelters
f. Zinc Smelters
g. Copper Smelters

2. To assess current status of the technologies for the referred industries in the World and in India.

3. To assess the latest technologies and available technological options

4. To evaluate the economic aspects of the various technologies along with their
feasibilities which leads to the preferred options.

5. Impact of the preferred options and their linkages to the broad area of technologies
and their spin offs.

6. Identification of agencies / groups / individuals involved in the field of industrial air
pollution control.

7. To work out a suggestive action plan for implementation of suitable / feasible
technologies / measures for air pollution abatement.

OBJECTIVES

1. To list out the various technologies being used in India in different industries under study.

2. To list out the various technologies being used world wide concerning the industries under study.

3. To highlight different features of various technologies / equipments under use alongwith their advantages / disadvantages and constraints, if any.

4. To asess the techno – economic /techno-commercial aspects of various technologies / equipments as well as technological options to arrive at certain conclusions for choosing same for suitable implementation in India.

5. To promote new developed / developing technologies in the area of air pollution control.

6. To minimize the hazardous emissions disperse into the environment.

7. To suggest suitable and appropriate amendments in the use of raw material / cleaner processes and latest technological implementations.

8. To identify various Indian experts in the field of system design, operations and management.                                 Back

METHODOLOGY

Following methodology has been applied for collecting the information and evaluation of technological options :

(1) Identified the various Indian industries / agencies to be approached through
various Indian Government publications / reports giving address details etc. and approached through communications / personally by sending representatives.

(2) Identified the various foreign industries / agencies through their different Embassies /
High Commissions / Trade offices in India or through various foreign journals / publications in the air pollution field, approached the identified agencies through different communications means and received their details of latest technologies.

(3) Collected the various details of Indian Industrial processes their emissions and
operating conditions, studied same for selecting suitable technologies / equipments for their implementation / installations in the appropriate industries.

(4) Analysed the available Indian / foreign technologies / equipments in view of their
techno-economic / techno-commercial feasibility for getting solutions for implementations / installation in Indian Industries for abatement and most effective control of air pollution.

(5) To enlist the potential agencies / manufactures who could further study the feasibility /
implementation of various technologies / take up manufacturing air pollution control systems and equipments.              Back

CONTENTS OF REPORT

The conducted Techno-market survey report comprises of thirteen chapters as named below:

CHAPTER IINTRODUCTION-contains air pollution and its hazardous effects to
living beings / plantation / material.

CHAPTER IITechnologies prevailing in India – Indian scenario in general, air
pollution law, emission standards and status of air pollution control.

Sub chapters of CHAPTER II mainly comprise of brief of different
process technologies, air pollution and air pollution control technologies and all the relevant available features in cement industry, integrated iron and steel plants, Thermal power stations, aluminum, zinc and copper smelters and foundries.

CJAPTER IIIIndustrial air pollution control technologies world scenario-contains general overall picture of air pollution, acid rain, approaches to control acid rain, overview of control technologies and clean air act.

Sub chapter of chapter III touch on the air pollution control technologies as being implemented in different countries like Russia, Japan, Germany, Europe, Poland, USA, Norway, Austria, Holland and Switzerland respectively

CHAPTER IVStatus of air pollution control technologies / technological options in India.

CHAPTER VStatus of air pollution monitoring in India.

CHAPTER VIAir pollution control equipments selection / options.

CHAPTER VIITechnology of source control / clean technologies.

CHAPTER IX-BYPRODUCT / REUSE through air pollution control technologies.

CHAPTER XI-General preconditions / main issues / suggestions / recommendation / action plan.

CHAPTER XIIImportant / impressive work of some of Indian experts.

CHAPTER XIIIReferences-contains names of experts, agencies, institutions, books journal referred to prepare the report.

IMPORTANT FEATURES / POINTS FOR CONSIDERATIONS
FOR DIFFERENRT INDUSTRIES :

CEMENT INDUSTRY:Indian cement industries a pioneer in accepting and implementing the newly developed technologies. Cement is one of the largest pollution generating industry, having pollution generated at every stage. Most of the modern cement plants in India are installed with ESPs, bag filters, multicyclones, pocket filters etc. old plants are also retrofitted. Re-utilization of by-pass kiln dust in cement industry is showing importance.

INTEGRATED IRON AND STEEL PLANTS: Technologies as adopted for the treatment of air pollutants are conventional ones used globally. Success of any one method at a particular plant does not mean its universality and the methods for treatment are to be tailored in view of the local industrial environmental suitability.

THERMAL POWER SYSTEMS: Thermal power stations are one of the major sources of air pollution, which is in the form of fly ash, dust , Sox and NOx emissions from the stack and coal dust from the coal handling, conveying and crushing systems. The quality of coal used in India for the power generation is poor having high ash content and low volatile matter, which requires larger quantity of coal to be burnt. Indian coal is also low in sulphur having high ash content and low volatile matter, which requires larger quantity of coal to be burnt. Indian coal is also low in sulphur having extremely low sulphur / ash ratio leading to a very high resistively and needing excess air for operation. Re-use of fly ash in the manufacturing of bricks, partial replacement of cement in concrete and fly ash, ferro cement beams and roofing sheets have potential uses in the construction projects.

ALUMINIUM SMELTERS: Aluminum holds a great promise in the industrial development of India in view of its importance for use in the various strategic sectors. India has very large bauxite deposits of the order of about 2650 million tons. The production technology adopted in India involved two main stages which are:

Production of alumina from bauxite by Bayer’s process.
Extraction of aluminum metal from alumina in electrolytic cells by hall-heroult process.

The environmental impacts associated with the mining industry are mainly ecological balance are to be taken. Emitted dust is controlled through spraying water using wet scrubbers etc.

The air pollution caused mainly by the fluorides in the aluminium smelter industry and it comes out of the aluminium reduction cell. The excessive intake of fluorides can cause fluorosis in human beings and affect animal life. The latest technique accepted for the control of fluorides is by using Dry Scrubbing system for the smelter gases, controlling pollution and also recycling the fluorides thereby affecting economy in the consumption of cryolite and Aluminium fluoride.

ZINC SMELTERS: Processes like blasting, crushing and grinding of ore generate a fine dust, which it allowed to disperse may cause air pollution. Gases like SO2, NOx, CO2, or HC etc. are not generated. Dust emitting sources are identified and appropriate facilities are installed to prevent dust entering the local environment. At smelting units, dust containing sulphide and oxides of metals, acid mist, SO2 and metal fumes are main air pollutants. Gas cleaning and dedusting facilities and sulphuric acid plants have been incorporated to take care of these emissions.

COPPER SMELTERS: All the copper smelters working in India are being managed by M/S Hindustan Copper Ltd., a Govt. of India enterprise. HCL is engaged in mining of the copper ore, its beneficiation smelting and refining to produce electrolytic cathode copper, wire bars and cathodes. Besides this the by-products produced are Sulphuric acid, Phosphatic fertilizers, Nickel Sulphate, Selenium, Silver and Gold. HCL has formulated schemes for arresting gaseous sulphur dioxide emissions by implementations of new acid plants to use the emitted SO2.

FOUNDRIES: Foundries are relatively small factories which are frequently used where pig iron and the scrap metal has to be melted down and cast into moulds with very intricate shapes. Their air pollution problems, dust and fumes from the material handling and smelting are similar to steel mills but on a much reduced scale.

In moulding and core making shops, the pollutants emitted are – Dust, Carbon monoxide, Sulphur dioxide, Hydrogen sulfide, Ammonia, Furfural alcohol, Touene, Benzene, methanol, Xylene, Phenol, Formaldehyde, Cyanide, Iso-cyanates, Dimethl – ethl amine, Acrolein and Triethlamine. The generated pollutants have to be caputured and conveyed through duct to the suitable cleaning system which comprises of (1) dry dust removal equipments (2) wet dust removal equipments and (3) chemicals.

The constraints for installing effective air pollution control systems by the existing plants in India are :-

To have a cost effective technology for the retrofitting of the existing control technologies.
Problems of mobilizing financial resources for small industries, to bear huge costs of installing control equipments / technologies.
Technology gap exists in the following areas for reducing pollutant emissions in India
.flue gas desulphurisaiton

• DENOx systems
• Dry scrubbing technology for the removal of fluorides from aluminium smelters.
• Specialized technology for cleaning CO rich blast furnace gases and gases from steel convertors in special gas tight multistage variable throat venture.
• Energy management systems for ESP and fabric filters particularly for fly ash application.
• Special gas absorption system for the removal of toxic gases.
• The international companies are engaged in upgrading their technologies keeping in view:providing set emission standards
• educing hazards
• recycling wastes
• reducing hardware requirements
• optimizing energy requirements
• inducting new/cleaner processes

The latest development in the technological up gradation is in the field of removal of fluorides emitted during the primary gas cleaning from aluminium smelters, by means of dry scrubbing.
The indigenization of equipment manufacturing is making rapid progress, reducing the foreign exchange content to minimum. The present installed capacity for the manufacturing of air pollution equipments is more than sufficient in India to meet the industry’s requirement. Some of the units are closed or are underutilized due to:

1. Lack of awareness and low pace of implementation of air pollution control.
2. Lack of fiscal incentives for industries to meet the emission standards.

The technology of source control is interdisciplinary and includes working out of the economic feasibility, planning standards, application of specific hardware, fuels and materials with low emission potential. The control strategy depends on the selection of the best air pollution control measures among the available ones. Following four factors for reducing four factors for reducing emissions from a polluting process are –

1. Eliminating the source
2. Regulating the location of the source
3. Modification of the process/using cleaner technology
4. Reducing or eliminating emissions, using control devices and systems.

                                                                                                                                                                         Back                                                                   

Germany has introduced a number of technologies, by which by products are used. The various technologies as well as their different by-products are given as below :

The reuse of flyash from thermal power plants, re-utilization of by-pass kiln dust in cement industry, utilization of cement kiln dust in wet process cement kilns etc. have been elaborated in the report.

The techno-economic as well as techno-commercial aspects of the industrial air pollution control technologies for different air pollution control equipments/systems in use are discussed in detail giving advantages and disadvantages of individual systems and presenting a “Quick Comparison Guide for several air pollution control systems”. Economics of clean air, estimates of incremental costs of removing pollutants from the existing and new sources, cost of air pollution control and its advantages, comparison of air pollution control equipments and their costs, economical / commercial feasibility for various industries are also given.

The industrial costs of air pollution on account of disease, damage to health, material damage are elaborated, because their indirect costs also have an impact on the overall pollution costs which need to be minimized.

The last chapter points to the preconditions imposed for the erection and operation of the emitting plants, measuring and monitoring their emissions, time availability of gas cleaning systems to maintain the standards. It also contains concepts for the industry incentives as laid down by the Environmental Protection agency (EPA), USA action plan as chalked out by the Ministry of Environment and Forests main issues involved in air pollution and action plan for the control of various industries under study individually as well as a “Suggestive Action Plan” to control industrial pollution.

Suggestive Action Plan may be:

1. Approach to prevention of pollution rather than its control.

2. To integrate environmental considerations into decision making at all levels.

3. To ensure adherence to Public Insurance Bill passed by the Parliament.

4. Environmental courts to be set up to provide for speedy dispensation of compensation to the victims of environmental hazards.

5. Environmental Act, 1986 to be amended to widen its scope for implementation.

6. A realistic time limit should be given to fulfill consent conditions.

7. Power interruptions and voltage fluctuations, even for short durations affects the continuity of the pollution control measures and the efficiency of the systems. Proper consideration must be given to this aspect.

8. Availability of good quality coal should be assured as high ash content coal lowers the efficiency of equipments like ESP’s.

9. The standards based on initial raw water characteristics such as TDS and ambient air quality specifications should as far as possible be flexible and location wise.

10. A phased programme of implementation of standards be adopted for different industries.

11. The penalties for not achieving and adhering to the laid standards should be proportionate to the deviations.

12. Pollution awaress creating programmes may be tailored and given wide publicity.

13. training programmes may be organised quite oftenly.

A quick Review of Technologies from various countries and widely used, alongwith their special features is summarized in the Table in following pages.

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