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: dr.s.rajamani@gmail.com

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