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Z tannery prepra nig ltd

ENVIRONMENTAL AUDIT REPORT

FOR

Z – TANNERY
Plot 42/43 CHALLAWA INDUSTRIAL ESTATE, KANO

Prepared by
Prepra Nig.Ltd
31/32 BELLO ROAD, KANO
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Email: prepra@live.com

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AUDIT PREPARERS

ALIYU BABA NABEGU, PhD, MWMS, mni


Lead Consultant, Prepra Nig. Ltd

SULAIMAN MUHAMMAD B. Eng


Civil Engineer, Prepra Nig. Ltd

ABASS ZEIN
Chairman/CEO Z Tannery

ABDULMUNNIR KHAN
General Manager, Z Tannery

HARUNA UMAR SANI


Laboratory Technologist, Prepra Nig. Ltd

ABDULKARIM ALIYU NABEGU


Technical Department, Prepra Nig.ltd

AMINU ALIYU NABEGU


Technical Department, Prepra Nig.ltd
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LIST OF FIGURES

Figure 1 : Location of Sharada Industrial Estate within Kano metropolis

Figure 2: Layout of Z Tannery

Figure 3: Road links to Z Tannery

Figure 4: Organogram of Z Tannery


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LIST OF PLATES

Plate1: Z Tannery from Google earth


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LIST OF TABLES

Table 1: Profile of Z Tannery Limited

Table 2: Plant and equipment stock of Z Tannery

Table 3: Comparison of Z Tannery’s effluent analysis with NESREA standards

Table 4: Noise level in some sections of Z Tannery

Table 5: Air quality in the Z Tannery


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TABLE OF CONTENT

Title Page i
List of Prepares ii
List of figures and Plate iii
List of Tables iv
Table of contents v – ix
Acknowledgement x
Exclusive Summery xi

CHAPTER ONE: 1.0 INTRODUCTION 1


1.1 Background 1-2
1.2 Objectives of the Environment Audit 3
1.3 Terms of Reference of the EA 3-4
1.4 The Audit Criteria 4-5
1.5 Scope of the Audit 5
1.6 Approach and Methods 5
1.6.1 Pre - Audit phase 5-7
1.6.2 On site - Phase 7
1.6.2.1 Undertaking review of relevant documents 7- 8
1.6.2.2 Conducting Staff Interview to obtain Information on Actual 8
Practices
1.6.2.3 Conducting on Site Inspection with relevant Audit Checklist 8
1.6.2.4 Collecting Sample for Analysis 9
1.6.2.4.1 Procedure for Collection of Water Samples 9
1.6.2.4.2 Evaluation of repairable 9
1.6.2.4.3 Evaluation of Noxious gases 10
1.6.2.4.4 Evaluation of Noise level 10
1.6.2.4.5 Evaluation of the quality of waste water 10 -11
1.6.2.4.6 Conducting Material balance 11 -12
1.6.3 Post Audit Activities 12
1.6.3.1 Actions in post Audit phase 12 - 13
1.6.3.2 Evaluation of Findings 13
1.6.3.4. Implementation of the Action plan 14
1.6.4 Audit period 14
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CHAPTER TWO: 2.0 OVERVIEW OF LARRABEE ENTERPRISES LTD 15


2.1 Company Profile 15
2.2 Plant and Machinery of Z Tannery 16
2.3 Location of Z Tannery 17-19
2.4 Description of surrounding Environment 19-21
2.5 The Process Technology 21
2.5.1 Raw Material for the Tanning industry 21-22
2.5.2 The tanning Process 23
2.5.2.1 Currying 23
2.3.2.2 Beam House operations 23-24
2.3.2.3 Soaking 24
2.3.2.4 Liming 24-25
2.3.2.5 De-liming and Bating 25
2.3.2.6 Pickling 26
2.3.2.7 Retanning 26

CHAPTER THREE: 3.0 ENVIRONMENTAL MANAGEMENT PLAN 27


3.1Environmental Policy of Z Tannery 27-28
3.2 Implementation of the EMP 28-29
3.3 Compliance with Environmental laws and regulations in Z Tannery 29-30

CHAPTER FOUR: 4.0 AUDIT FINDINGS 31


4.1 Observation and Evaluation of General housekeeping 31
4.1.1Waste generation from Z Tannery 31
4.1.2 Impact evaluation of existing housekeeping practice 32
4.1.2.1. Waste Water Management 32-33
4.1.1.2 Solid Water Management 34
4.1.2.3 Compatibility 34
4.1.2.4 Cloakroom/Conveniences 34 - 35
4.1.2.5 Safety signs 35
4.1.2.6 Muster point 35
4.1.2.7 Fire Extinguisher 35
4.1.2..8 Noise level 35 - 36
4.1.2. 9 12 Air Quality 36
4.1.3 Socio- Economic Impact 37- 38
4.1.4 Compliance with extant regulations 38
4.1.4.1Compliance with Environmental Regulations 38-39
4.1.4.2 Compliance to other regulations 39

CHAPTER FIVE: 5.0 RECOMENDATIONS 40


5.1 General Recommendations 40
5.2 Specific Recommendations 41
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5.2.1 Elimination of Waste 41


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5.2.2 Reuse of waste on site 41


5.2.3 Recycling of Waste 41
5.2.4 Disposal after compaction, drying or other treatment 42
5.2.5 R Retention /Redirect 42
5.2.6 Separation/concentration 43
5.2.7 Determination of specific water consumption 43
5.2.8 Produce products from waste generated 43
5.2.9 Reducing Noise level and Gaseous pollutants 44
5.2.10 Compliance to all extant regulations 44
5.2.11 General adherence to good Management 44

CHAPTER SIX: 6.0 FOLLOW UP PLAN 45


6.1 Completion and Submission of EAR 45
6.1.1 Submission of EA report 45
6.1.2 Monthly effluent monitoring and sending results to NESREA and 45
Kano state Ministry of Environment
6.1.3 Implementation Follow up on the management of the company’s 43
EMP
6.1.4 Provision of adequate safety equipment 45

6.1.5 Provision of firefighting equipment in strategic locations of the 45


factory identified
6.1.7 Awareness training for staff 45

6.1.7 Quarterly inspection 45

6.1.8 Establishment of quality assurance unit to ensure timely repairs 45


to leaking oil/water pipes

CHAPTER SEVEN: 7.0 CONCLUSION 46


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ACKNOWLEDGEMENT

Prepra Nigeria acknowledges the cooperation and support of the management

and staff of Z Tannery limited. In particular, the support and disposition of the

General Manager, Mr. Khan has been invaluable to the success of this report.

Prepra Nigeria ltd wishes to stress that in line with its policy, all information

obtained in the course of this Audi exercise as well as those contained in this

report will be accorded the strictest confidentiality.


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EXECUTIVE SUMMARY

This environmental audit (EA) was carried based on the guidelines and
regulation of the National Environmental Standards and Regulations
Enforcement Agency (NESREA) in particular Section 8 (k) of the Act that
empowers the Agency to make Regulations, one of which is the Regulations S. I
No 29, that requires existing industries to undertake environmental audit and
submit reports of such every three (3) years.
Desirous of complying with extant environmental laws and regulations Z Tannery
limited appointed MESSR PREPRA NIGERIA LTD – a NESREA accredited consultant
to conduct the audit.
In order to evaluate the impact of the activities of Z Tannery, an assessment of
the location in terms of compatibility and of the processes and housekeeping of
the factory was undertaken. This initial contact ensured management consent
and selection of audit team from the company.
Standard questionnaire was administered to the management and key staff to
obtain information that was used in the facility inspection as well as examination
of records and documents of the company.
The main activity in Z Tannery limited is tanning of hides and skins which involves
considerable use of water, either to cleanse them or in the form of process
liquors during the various unit processes. Generally, a tannery can contribute to
problems of health hazard by (i) causing depleting of oxygen in water where it is
discharged, thereby removing the dissolved oxygen required by fish and other
aquatic organisms for respiration, (ii) leading to high concentration of salts and
possible formation of metal sulphides which are very harmful to both human
beings and animal (iii) causing bacteriological pollution by pathogenic
organism.

This Audit exercise indicated that the operation of Z Tannery will result in short
and long term adverse impact to the environment as well as nuisance to the
community especially from waste water which is by far the most dominant
waste product. Thus various strategies for treating the wastewater have been
proffered as well as to minimize the generation instead of treatment. Further
measures in which the wastewater can be reused directly subject to the
guidelines of NESREA have also been suggested. In addition, suggestions were
made in the report that will ensure that resources are used appropriately and
efficiently.
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1.0 CHAPTER ONE: INTRODUCTION

1.1 BACKGROUND

One of the efforts that have been made towards environmental protection in the

world is the 1992 United Nations Conference on Environment and Development

(UNCED) referred to as the Earth Summit and whose outcome is the Agenda 21,

emphasized the need for Governments to evaluate human activities that

endanger the health of the environment in their countries. Consequently, at

national levels Environmental Audit report (EAR) has become an important

instrument that is employed for the systematic evaluation of how organizations,

institutions and equipment used in manufacturing and allied activities safeguard

the environment and human health.

The National Environmental Standards and Regulations Enforcement Agency

(NESREA) is responsible for ensuring that all businesses and organizations in

Nigeria comply with environmental laws that protect the environment and

public health through the extant national sectorial environmental regulations

that require existing industries to undertake environmental audit and submit

reports every three (3) years. In addition several other regulations in the NESREA

act are in place to reinforce the laws including the following:

 The NESREA Act, Section 7 (a) that vests in the Agency the responsibility to
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enforce compliance with laws, guidelines, policies and standards on


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 Section 7 (j), that empowers the Agency to enforce environmental control

measures through registration, licensing and permitting systems.

 Section 7 (k) of the NESREA Act empowers NESREA to conduct

environmental audit and establish data bank on regulatory and

enforcement mechanisms of environmental standards other than in the oil

and gas sector

 Section 8 (k) of the NESREA establishment empowers the Agency to make

Regulations, one of which is the Regulations S. I No 29, that requires

existing industries to undertake environmental audit and submit reports of

such every three (3) years.

In essence therefore, Environmental Audit Report (EAR) of facilities is designed to

protect the environment with specific objectives of:

 Assessing performance against a set of targets related to specific issues

 Evaluating compliance with environmental legislation and corporate

policies

 Measuring performance against the requirements of an environmental

management system standard

 Exploring the potential economic, social and environmental benefits that

an improved performance can achieve.


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1.2 OBJECTIVES OF THE ENVIRONMENTAL AUDIT REPOR (EAR)

The objectives of this EAR include: -

 Generation of adequate environmental information of Z Tannery for the

potential environmental risks that are likely to be caused by its operations

to the immediate environs

 Achieving resources optimization and improved process performance

 Encouraging Z Tannery to self- regulate their environmental practices and

to increase its responsibilities to its stakeholders and society in general.

 Ensuring compliance, not only with laws, regulations and standards, but

also with company policies and the requirements of the NESREA endorsed

Environmental Management Plan of Z Tannery

 Enabling environmental problems and risks to be anticipated and

responses planned.

 Minimizing human exposure to risks from environmental health and safety

problems associated with the operations of Z Tannery.

1.3 TERMS OF REFERENCE OF THE EAR

For the purpose of the mandatory Compliance Audit due every three (3) years,

this audit assesses compliance of Z Tannery with terms of reference derived

from:
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 National Environmental standards and Regulations enforcement Agency


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provided in sections 21 of the S.I.9 regulations of 1991 on National

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Environmental protection (pollution abatement in Industries and facilities

generating wastes), EA Act No 86 of 1992 and 7 (a) and 7 (k) of the

NESREA Act No 25 of 2007 and those that will come into force from time to

time

 Corporate or management policy of Z Tannery

 NESREA Approved Environmental management plan of Z Tannery

1.4 THE AUDIT CRITERIA

The Audit criteria considered in this study included but not limited to:

 Industry codes of practice

 Specified organizational requirements, specifically compliance with the

company environmental policy

 Environment protection Act

 Environment protection regulations

 Conditions of licenses, workers approvals and exemptions

 Other applicable Federal/State / Local government - environment

legislations

 Standards, rules, orders, etc made under an act and having the force of

law
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 International agreement such as, convention, protocol, and treaties


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which have been ratified by the government.

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 Conditions contained in facility permits

 Codes of professional practice / international code of conduct

 Good environmental management

1.5 SCOPE OF THE ENVIRONMENTAL AUDIT REPORT

The scope of this Audit exercise covers the following:

 Evaluation of Z Tannery’s existing Environmental management system

 The existing environmental policy and objectives

 Housekeeping and records

 Existing strategies for environmental improvement

 Z tannery’s compliance status with statutory laws and regulations

1.6 APPROACH AND METHODS OF THE EAR

This environmental audit was undertaken in three phases:

 Pre – audit

 On – site audit

 Post – audit

1.6.1 PRE – AUDIT PHASE

This is the preparation phase of the Audit exercise. It entails:

 Getting management approval and commitment for PREPRA NIG LTD to

embark on the audit exercise


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 Setting overall goals, objectives, and priorities of the audit exercise


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 Assembling a team to ensure objectivity and professional competence

 Putting out pre-audit questionnaire to management and key staff of Z

Tannery (see appendix1)

 Reviewing background and operational information with the

management of Z Tannery.

 Undertaking initial site visit at the Z Tannery facility

 Reviewing audit plan and arranging logistics.

i) Management commitment

A letter from the management of Z Tannery to Prepra Nigeria to conduct the

audit was duly signed by the CEO. This signaled the commencement of the

audit.

ii) Team selection

The audit team was carefully selected and includes employees of Z Tunney and

Prepra Nigeria. The team leader is the NESREA accredited consultant while the

other team members have skills and knowledge relevant to the audit process.

Each member of the team was assigned his/her role and responsibilities and pre-

audit training was done to ensure that all the team members are adequately

prepared for the task.

In addition to other relevant information requested for in the questionnaire used


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(Appendix1), the following information was also collected by the team


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 Identifying types of pollutants and waste type, generation, storage,

transportation, treatment as well as the general practice of disposal

 Identifying requirements, regulations and limitations as applicable in the

form of Permits and Licenses

 Federal and State database relevant to Z Tannery , such as, any nearby

hazardous waste sites; Industrial landfill; Solid waste sites, Drinking water

sources etc.

1.6.2 On site audit phase

The objective of the on-site audit exercise is to determine whether audit criteria

are being complied with through the use of well-defined and systematic check

lists drawn to:

 Identify areas to be inspected

 Outline procedures

 Outline schedules

 Identify records and documents to be reviewed during audit

 Review health and safety requirement

 Review how confidential data will be handled

1.6.2.1 Undertaking a review of relevant documents such as:

 Corporate or/and management policy

 NESREA endorsed Environmental Management Plan (EMP)


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 Management system documentation


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 Operational procedures and records

 Records (inventory, utility bills, monitoring, transportation, training)

 Environmental monitoring/quality records

 Correspondence on environmental committee/team meeting minutes

 Previous environmental audit report (if available)

1.6.2.2 Conducting staff interview to obtain information on actual practices;

awareness level; expectations and possible suggestions through:

 Identifying key facility personnel

 Scheduling ahead of time, meeting in work areas

 Confirming interview time

1.6.2.3 Conducting detailed on - site inspections with the relevant audit

checklist

This exercise was conducted to investigate the presence of sensitive sites within

or in the neighborhood of the Z Tannery that are capable of impacting on the

data collected such as, the nature of the past and present usage of the factory;

nature and operations in adjourning properties - type and use past and present;

above ground storage tanks ; Air sources mobile and stationary; Presence of

Asbestos; Boilers usage; Contaminated sites; Drinking water quality cross

connections; Discharges to groundwater; Neighboring wetlands and waterways

protection; PCB containing transformers and/or other PCB regulated equipment;


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Sewage and septic system discharges etc.


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1.6.2.4 Collecting samples for Analysis

1.6.2.4.1 Procedure for collection of water samples

Samples of wastewater representing the existing conditions in Z Tannery were

collected from effluent pit every day, over a period of seven days in suitable

polythene containers with screw cap and stored in a refrigerator where

immediate analysis was not possible.

Samples (250ml) meant for the estimations of biochemical oxygen demand

(BOD) sulphide were collected separately in two glass bottles stoppers. The

dissolved oxygen and sulphide were fixed on the spot by the addition of winker

reagent (MnSO4 followed by alkine-iodide-azide) and zinc acetate respectively.

Since the components of the liquor undergo significant and unavoidable

changes on storage, composite samples could not be used.

1.6.2.4.2 Evaluation of Repairable particles

Air samples from factory floor, utility area, generator/boiler/workshop area and

main yard of the Z factory were collected as ambient with the aid of GILLIAN

BDX II abatement multi air flow sampler. Air was drawn into the cassette of the

sampler which already had a pre-weighted filter. After a period of 2hrs, the pre-

weighted filter was removed and re-weighed. The particulate level was then

calculated by dividing the difference in weight by the flow rate and time spent
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sampling.
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1.6.2.4.3 Evaluation of Noxious Gases

Relevant pollution indicator gases were sampled with the aid of CASELLA MX 21

automatic air sampler which through sensors captures the level of

concentration of noxious gases present in the air. The measure is displayed on a

digital screen which is then recorded.

1.6.2.4.4 Evaluation of Noise level

Noise level measurement was taken in the three identified areas of Z factory

with the aid of REALISTIC SOUND LEVEL METER TYPE 2.

1.6.2.4.5 Evaluation of the quality of waste water

The wastewater was evaluated based on the criteria and NESREA guidelines, on

waste water in tanning industries, consequently, the following parameters were

determined as follows:

a) Measurement of Temperature, pH and Conductivity

The temperature and pH of the samples were determined on the spot; the

measurements of pH were conducted using the pH Meter (Philips PW 9418). The

electrical conductivity was measured with the Griffin conductivity bridge.

b) Determination of total solids, suspended, dissolved solids and total ash

The methods for the determination of solid used is that of Hanson (Hanson,1973).
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The term’ Total ash’ is a measure of the total mineral content and was
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determined by the method prescribed by the society of leather technologists

and chemists(Soc. Leath,Tech.Chem.,1965).

Other characteristics were estimated on the aliquots of the samples (100ml)

obtained after removing the suspended solids by filtration. Estimation or chloride

and total nitrogen were carried out using the argentimetric and ‘kjeldahl’

methods respectively. The amount of BOD was determined using the dilution

method. Estimation of metals was carried out by using perkin-Elmer Model 306

Atomic Absorption Spectrophotometer and EEL Model A Flame Photometer.

1.6.2.4.6 Conducting a material balance

The mass balance approach was used in this study whereby, each process was

clearly demarcated in terms of inputs and outputs. This was achieved on the

simple principle that the total mass of material going into the process should

equal the total mass going out i.e. Input – losses = outputs

In Z Tannery, for example, the inputs considered were : raw materials – skins and

various chemicals, packaging e.g pallets, plastic drums and containers,

polythene and cardboards), consumable (e.g. Gloves, aprons and ear

defenders) and utilities or services servicing each process (e.g water. energy,

steam, cooling water and compressed air). The losses from the inputs were also

determined as waste materials such as packaging, liquids such as effluent or


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lubricants, air emissions and waste generated by the utilities or services.


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The outputs are the final product(s). The mass of inputs to the process in Z

Tannery should balance the mass of outputs as products, emissions and wastes,

plus any change in stocks.

The following steps were followed to assess the input – output of Z Tannery.

 Assembling unit process input and output information

 Deriving a preliminary material balance for unit processes

 Evaluating the material balance

 Refining the material balance

1.6.3 Post audit activities

The objectives of the post Audit exercise is to produce an environmental audit

report with audit findings and recommendations and to contribute toward

formulation of an action plan for continuous improvement of operations of Z

Tannery.

1.6.3.1 Actions in post audit phase

 Collation of information and follow up on outstanding issues

 Evaluation of findings including outcome of material balance and impact

evaluation of Z Tannery process on the environment and human health.

 Preparation of the draft audit report in the approved presentation format

 Circulating draft audit report to management and audit team for


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 Incorporating or resolving all comments

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Preparation of an action plan with consultation with the management of Z

Tannery to incorporate the following:

 A list of recommended actions in terms of increasing cost effectiveness in

addressing the facility’s critical environmental issues.

 Interim and long term targets/objectives and a time-table for achieving

them for environmental improvement in the operation of Z Tannery

 An indication of investments and other resources (human and

information) that would be required at Z Tannery without compromising

commercial confidential information

 Produce report for use of Z Tannery and NESREA

 Facilitate the implementation of action plan at the management level of

Z-Tannery

1.6.3.2 Evaluation of findings

The information gathered and data collected together with the overall findings

of this Audit report will be reviewed in line with the extant regulations with the

management of Z tannery. The key rules in discussing the findings are: -

 The exact nature of the problems identified.

 Communicating the extent of the problems and existing level of

compliance.

 Providing good management practices suitable to Z Tannery.


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1.6.3.3 Implementation of the action plan

Responsibilities needed to be undertaken according to unit and timeline for

completion within the environmental action plan framework.

1.6.4 AUDIT PERIOD

The audit was conducted between, 25th October to 15th November 2014
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2.0 CHAPTER TWO: OVERVIEW OF Z TANNERY

2.1 COMPANY PROFILE

Table 1: Profile of Z Tannery Limited

The Company Z TANNERY LIMITED

RC. NO. 700365

Date of Incorporation 25th July, 2007

Registered office Plot 42/43 CHALLAWA INDUSTRIAL ESTATE,

Nature of Activity TANNING

Installed Capacity 10,000 SKINS/DAY (WET BLUE)

Raw Materials RAW ANIMAL SKINS, CHEMICALS AND


WATER
Consumables DIESEL,PETROL,LUBRICANTS, GREASE etc

Manpower: Skilled 34

Semi-skilled 120

Unskilled 150
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2.2 PLANT AND MACHINERY OF Z-TANNERY

Table 2 Plant and Equipment stock in Z Tannery

S/N DESCRIPTION QTY


1 Paddle with electric Motors 16
2 Tanning Drum 3
3 Re-tanning Drum 2
4 Fleshing Machine x1200mm 1
5 Fleshing Machine x1500mm 3
6 Fleshing Machine x1000mm 1
7 Setting out Machine 1
8 Sample Drum 2
9 Vacuum Dryer 1
10 Shaving Machine 1
11 Water Condition Machine 3
12 Staking Machine 1
14 Quick Toggling Machine 4
15 Hanger Conveyor 1
16 Brushing Machine 1
17 Brushing Machine x 1.2m 1
20 Polishing Machine 1
21 Buffing Machine 1
22 Buffing Machine x 800mm 4
23 Milling Drum 1
24 Roller Staking Machine 1
25 Conveyor Staking Machine 3
26 Measuring Machine (Alletti) 2
27 Measuring machine (Moris) 1
28 Measuring machine(Normal) 1
29 Air compressor 1
30 Generator 350kvA 1
31 Generator 250kvA 1
33 Boiler 8 Ton 1
34 Transformer 1
35 Dust Collector 1
36 Tanning Drum 1
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2.3 LOCATION OF Z TANNERY FACTORY

Z Tannery Limited’s factory is located in Challawa Industrial estate, Kano, the

most important and largest center of manufacturing activity in Northern Nigeria.

The location of the Industrial estate within Kano metropolis is shown in Figure 1.

Figure 1 Location of Sharada Industrial Estate within Kano metropolis

The factory is sited between latitude 110.53` 146 and longitude 0080.29`481.Based

on the coordinates, the exact position of the factory is shown in Plate 1 as

extracted from Google earth. The site of the land in which the factory is located

consists of a land covered by C of O No. LKN/1ND/97/006 and covers 0.4950

hectares. A 40 year leasehold interest commencing 9th December1997 subsists.


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Plate 1: Z Tannery from Google Earth

All structures on the premises shown in Figure 2 have been approved by Kano

urban planning development authority (KNUPDA). Access into the premises is

via a double leaf vehicular metal gate. The un – built portion of the premises
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remains in its natural topsoil save the immediate premises of the administrative

block which is paved with interlocking stone and landscaped with carpet grass.

Figure 2: Layout of Z Tannery

2.4 DESCRIPTION OF SURROUNDING ENVIRONMENT

The factory site is very firm, relatively level and well drained. Z tannery is very

close to Fata Tanning Co ltd, Ayafa Tannery, Fan Milk and United Gases. Access

to the factory is very easy because as seen in figure 3, the factory is located

about 450 meters off- the main Challawa Industrial estate road via the Industrial

link road. The factory is sited within an area demarcated for medium to

heavy wet industrial operation. There are three main warehouses that

make up 90% of the factory buildings. The main offices are situated near
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the entrance and are separate from the factory buildings. The whole

premises is concreted and fenced with a metal gate for entry.

Figure 3: Road links to ZTannery

The factory administration is based on conventional management of line

reporting as shown in figure 4. The main units are headed by managers

that report to the General Manager for day to day guidance. The

Managing Director is the chief executive and is responsible for policy

direction.
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M.D

G.M

Factory Manager Accounts Personnel Export Sales


Manager s

Stores
Workshop Beam Wages
house

Figure 4: Organogram of Z Tannery

2. 5 THE PROCESS TECHNOLOGY

Tanning is the process of treating animal’s skins to produce leather, which is

more durable and less susceptible to decomposition. A tannery is the term for a

place where the skins of animals are processed. It can be performed with either

vegetable or mineral methods.

2. 5.1 Raw materials for the Tanning industry

 Animal skins
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a) Wet – salted Goat skins


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b) Wet – salted Sheep skins

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 Chemicals

a) Sodium chloride

b) Sodium sulphide

c) Chrome

d) Sulfuric Acid

e) Ammonium sulphate

f) Caustic soda

g) Soda Ash

h) Ammonium liquor

i) Dyes

j) Bactericides

k) Fungicides

l) Formic Acid

m) Enzymes

n) Syntans

o) Synthetic oils

p) Vegetable oils

q) Lacquers

r) Pigments

s) Binders (acrylic and non-acrylic)


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2.5.2 The tanning process

The first stage of the leather production begins with the collection and sorting of

raw skins – normally supplied by designated agents to the companies

warehouse. Plate 2 shows sorted raw sheep skins in the company’s warehouse

Tanning involves four stages as indicated below:

2.5.2.1Curing

Preparing the skins begins by curing them with salt. Thus the skins form the

abattoirs are wet-salted before being transported to the company. Curing is

employed to prevent putrefaction of the protein substance [collagen] from

bacterial growth during the time lag that might occur from procuring the skins to

when it is processed. Curing removes excess water from the skins using a

difference in osmotic pressure. The moisture content of skin is greatly reduced. In

wet- salting, skins are heavily salted, then pressed into packs for about 30 days.

In brine-curing, the skins are agitated in a salt water bath for about 16 hours.

Generally, curing substantially reduces the chance of spoilage by bacteria.

Curing can also be done by preserving the skins at a very low temperature. In

Nigeria the only form of curing is wet-salting.

2.5.2.2 Beam-house operations

The steps in the production of leather between curing and tanning are
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collectively referred to as beam-house operations. They include: soaking liming,


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removal of extraneous tissues (un-hairing, scudding, and fleshing), de-liming,

bating, drenching and picking

2.5.2.3 Soaking

In the process known as soaking, the hides are soaked in clean water to remove

the salt left over from curing and increase the moisture so that the hide or skin

can be further treated.

2.5.2.4 Liming

After soaking, the hides and skins are taken for liming which is a treatment that

involves the addition of sharpening agents like sodium sulfide, cyanides, amines

etc. The objectives of this operation are mainly to:

 Remove the hairs, nails and other keratinous matter.

 Remove some of the inter-fibrillary soluble proteins like mucins.

 Swell and split up the fibers to the desired extent.

 Remove the natural grease and fats to some extent

 Bring the collagen in the hide to a proper condition for satisfactory

tannage.

The weakening of the hair on the breakdown of the disulfide link of the amino

acid is called cystine, which is the characteristic of the ketarin class of protein

that gives strength to hair and wools (ketarin makes up 90% of the dry weight
34

hair). The hydrogen atoms supplied by the sharpening agent weaken the
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cystine. To some extent, sharpening also contributes to un-hairing as it tends to

break down the hair protein.

2.5.2.5 De-liming and Bating

The pH of the collagen is brought down to a lower level so that enzymes may

act on it in a process called de-liming. Depending on the end use of the leather,

skins may be treated with enzymes to soften them, a process called bating.

2.5.2.6 Pickling

Once bating is completed, the hides and skins are treated with a mixture of

common table salt and sulfuric acid, in a case a mineral tanning is to be done.

This is done to bring down pH of collagen to a very low level so as to facilitate

the penetration of mineral tanning agent into the substance. This process is

called picking. The common salt penetrates the skins twice as fast as the acid

and checks the ill effect of sudden drop of pH. The pH is very acidic when the

chromium is introduced to ensure that the chromium complexes are small

enough to fit between the fibers and residues of the collagen. Once the desired

level of penetration of chrome into substance is achieved, the pH of the mineral

is raised again to facilitate the process. This step is known as Basification. In the

raw state chrome tanned skins are blue in appearance and are therefore

referred to as Wet Blue. Chemicals used in tanning include chrome, salts, sulfuric

acid, ammonium sulphate and bactericides.


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2.5.2.7 Retanning

The wet blue is selected and shaved to specified thickness often determined by

the final product to be used and subsequently moved back to the drum for re-

tanning. Re-tanning is the process of using oils and vegetable extract to convert

the skin into leather.

The re-tanned leather is referred to as crust and it is often colored depending on

the requirement. The crust is now complete leather and can be finished to

various formats by the spray of pigments and lacquers. Chemicals used in re-

tanning includes, dyes, formic and sulfuric acids, fatliqours and Syntans

For finishing the main chemicals are binders of different make ie acrylic and

non-acrylic, pigments and lacquers

The stages can be summarized as follows:-

Preparation for Tanning=>Tanning=>Re-tanning=>Finishing

In addition to skins and chemicals other materials that are required in a tannery

like Z factory include water, lubricants, fuel, diesel, packaging materials and

auxiliary facilities such as power supply etc.


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3.0 CHAPTER THREE: ENVIERONMENTAL MANAGEMENT PLAN

3.1 Environmental Policy of Z Tannery Limited

The realization of the legal requirement to protect the environmental as well as

the consciousness of the company to protect the health of its employees as well

as the community in its vicinity led the company to initiate a company –

community relation in order to come up with an enduring environmental policy.

To ensure the actualization, the company engaged a NESREA accredited

environmental consultant - PREPRA NIGERIA LIMITED to lead the committee and

come up with an environmental policy.

The result of these consultation resulted in the adoption of an environmental

policy by Z Tannery limited.

The main objectives of the environmental policy adopted by Z Tannery are:

i) To maximize resource utilization and reduce waste

ii) Fully comply with all applicable environmental protection regulations

iii) Minimize damage to the environments from its operation

iv) Use the best technology at all times

The environmental policy of the company is implemented through the

environmental monitoring plan of the company that was submitted to

NESREA. The EMP structured the implementation of the company


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environmental plan through the following plans:


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1) Development of a company environmental policy

2) Environmental Management Implementation plan

3) Environmental Monitoring plan

4) Contingency plan

5) Safety plan

6) Risk assessment and Emergency response plan

7) Environmental management plan review

8) Reporting plan

3.2 IMPLEMENTATION OF THE EMP

Z Tannery limited has established an environmental and social monitoring unit

that ensures implementation of the environmental management plan. The unit is

led by a project manager and consists of staff members of Z Tannery limited and

a representation of the community. The unit is responsible for ensuring that the

overall environmental targets are achieved and that the environmental

responsibilities and obligation of the EMP is satisfied. Also the unit coordinates

the day-to-day monitoring of regulatory bodies.

Because liquid effluent forms a great proportion of the waste generated and to

comply fully with the legal requirement to have a primary treatment plant, Z

Tannery established a waste water primary treatment plant with the waste water
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collection pond.
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As a practical demonstration of compliance to environmental regulation and

care to the health and well-being of staff, Z Tannery makes it mandatory for all

staff to wear protective clothing at all times based on the recommendations.

To ensure smooth implementation of the EMP environmental, the following plans

are put in place:

 Environmental Reporting

 Staff training Plan

 Emergency Response Plan

 Emergency Response plan

 Contingency plan

 Safety plan

 Plan Review

 Environmental monitoring plan

3.3 COMPLIANCE WITH ENVIRONMENTAL LAWS AND REGULATIONS IN Z TANNERY

The following among others are laws and regulations that are applicable to Z

Tannery limited

 Laws of the Federation of Nigeria 1990, Labor ACT CAP 198 Relating to

general welfare to staff – Changing rooms, toilet facilities, compensation,


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safety and protective wares, pre-employment medical examination,


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 Business premises registration LAW (CAP, 18) 1992 section 4(1) of Kano

state Government

 Hides and Skins premises license

 Hides and skins buyers license

 The hides and skins (Northern states)Regulations 1958 - Exporters license

 Billboard fees local government edict section 40 (t)chapter 84,vol.01.2 of

laws of Kano state of Nigeria 1991, as harmonized by (JIB) decree 21,

1998section 7 (5)

 Public health act

 Polluter fee

 Section 1 (1) of Regulation S.I.8 of 1991

 Section 3 (1) of Regulation S.I.8

 Section 17 of Regulation S.I.9

 Factories Act CAP 126 LFN 1990


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4.0 CHAPTER FOUR: AUDIT FINDINGS

4.1 OBSERVATIONS AND EVALUATION OF GENERAL HOUSE KEEPING

The following are the results of observations and data collected in respect of the

operations of Z Tannery.

4.1.1 Waste Generation from Z Tannery operation

The following are the wastes that are generated from the manufacturing

process in Z Tannery:

Liquid waste

 Waste water – effluent

 Oil and greases

Solid waste

 Trimmings

 Fleshings

 Dust from buffing

 Plastic and cartons from packaging

 Spent chemical residues

 General sweepings

Gaseous waste
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 Ancillary dust and compounds from boiler and generators


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Noise

 Sound from generators and machinery

In addition to the wastes generated from operation of Z Tannery, other issues

considered for evaluation include level of compliance to regulations, safety and

welfare provision to workers.

4.1.2 IMPACT EVALUATION OF EXISTING HOUSE KEEPING PRACTICE

4.1.2.1 Waste water Management

Wastewater effluent is the dominant waste generated and data collected

indicated about 800,000 litres is generated at full capacity.The existing methods

of waste water disposal presently being followed in Z Tannery is by discharging

waste water after primary treatment through the main drainage outlet that

ultimately gets into Challawa River. This method of disposal has its attendant

problems. Table 1 shows the analysis of wastewater of Z Tannery and its

comparison with NESREA standard for waste water from tanneries, showing

clearly it is not fully in compliance. Although a small volume of waste discharge

into rivers is eventually broken down by micro-organisms especially if nitrogenous

organic substances are present, many of the substances in the wastewater from

Z Tannery are resistant to bacterial action and the breakdown may be very slow.

Consequently remedial measures must be put in place to comply with NESREA


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guidelines.
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Table 3: Comparison of Z Tannery waste water in comparison with NESREA


standard

Parameter NESREA permissible Z Tannery Effluent Remark


limits Analysis

Temperature Less than 40(0C) 32.0 OK


Colour Colourless colorless OK
pH 6-7 8.5 poor
BOD5 at 20(0C) 50 1056 poor
Total suspended solids 25 33 poor
Total dissolved solids 2,000 4978 poor
Chloride (as Cl-) 600 904 poor
Sulphate (as SO42-) 500 276 OK
Sulphide (as S-2) 0.2 2.67 poor
Cyanide (as CN-) 0.1 nil OK
Detergents (linear alkylate 15 34.1 poor
sulphonate as methylene
Oil and grease 10 11.9 poor
Nitrate (as N03-) 20 34 poor
Phosphate (as PO43-) 5 42.3 poor
Arsenic (as AS) 0.1 nil OK
Barium (as BA) 5 0.8 OK
Turbidity 10 14 poor
Iron (as Fe) 20 6.96 OK
Manganese (as Mn) 5 0.45 OK
Phenolic compounds (as phenol) 0.2 0.72 poor
Chlorine (free) 1.0 14.3 poor
Cadmium (Cd) Less than 1 0.1 OK
Chromium Trivalent and hexavalent Less than 1 nil OK
Copper Less than 1 nil OK
Lead Less than 1 nil OK
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4.1.2.2 Solid waste management

A substantial amount of sludge consisting of fleshing and solid residue from the

liming made up of broken hair and other ancillary product such as plastic and

paper from packaging, residue of various chemical and greases are the major

constituents. A further component of the solid is dust from the buffing operation

as well as general sweepings. Data indicated that about 2300kg of these wastes

are generated daily from Z Tannery’s operations. This is presently deposited on

land surface within the factory and is eventually evacuated after the box made

up of block is filled up. It is expected that when the waste slowly percolate

through the soil and gradually undergo oxidation by soil bacteria it would result

in the formation of harmless end products. However, it was observed that this

practice requires large areas of land that the company currently does not have;

it leads to bad smell; may contaminate underground water and can ultimately

lead to poor agricultural productivity of the land. Also the polluted groundwater

eventually flows into a drinking water well or river resulting in the spreading of

waterborne diseases in the long run. Therefore remedial measures are required

immediately

4.1.2.3 Compatabilty

The factory is located in Challawa industrial estate and is thus compatible with

the existing approved land use of section 3.2 of the National policy on
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environment and Kano urban planning development authority requirement.


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4.1.2.4 Cloakroom/Conveniences

There is adequate cloak room, but for the female employees who are about

15% of the total work force, there is need for separate toilets for them.

4.1.2.5 Safety signs

There are no enough safety signs to warn staff and visitors within the factory.

4.1.2.6 Muster point

There is a muster point centrally located by the main gate with clear sign

4.1.2.7 Fire extinguishes

There are sufficient Fire extinguishers within the factory, but clear signs are

required

4.1.2.8 Noise levels

Noise level within identified units of the Z Tannery were measured and

compared with the NESREA permissible limits are shown in Table 3. Most units of

the Z Tannery is within the limit but the area in the vicinity of the generating

room which also houses, the workshop and ETP are well above the limit and

considering the presence of workers all the time in the area constitute a risk to

the long term health of the workers.


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Table 4 Noise level in some sections of Z Tannery

SITES WITHIN Z TANNERY NOISE LEVEL

NEAR THE GENERATOR HOUSE 110dB

AVERAGE WITHIN THE FACTORY 69dB

NEAR THE OFFICES 45dB

NESREA STANDARD FOR INDUSTRY 90dB

4.1.2.9 Air Quality

Air qualities within identified units of Z Tannery were measured as shown in Table

4. Most areas of the Z Tannery has emission of gases within the limit but the

observed variation not only indicated differences in the levels of air quality, but

also potential problem that require attention especially the area in the vicinity of

the generating room and the Boiler.

Table 5: Air quality in Z Tannery

SITES CO N02 S02 H2S CH4

Near the generator/effluent 1.5 2.4 0.71 1.21 0.10

Near the offices 0.1 0.1 0.1 0.1 0.0


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4.1.3 SOCIO-ECONOMIC IMPACT

Kano is known for its traditional leather and is famous in the tanning sub-sector

with international reputation. The bulk of leathers produced in Kano are

exported to Europe and Asia. Also, the artisanal producers convert finished

leather for domestic finished leather goods markets. Kano state has abundant

supply of skilled labor in the Tanning sector. This is obvious as commercial

production for leather and leather products existed for many years in Kano.

Leather and leather products are among the most widely traded and universally

used commodities in the world. Already, the total value of annual trade is

estimated at 1.5 times the value of the meat trade, more than five times that of

coffee and more than eight times that of rice. In Nigeria, according to the

Federal Ministry of Industry, Trade and Investment, leather has overtaken Cocoa

as the second biggest foreign exchange earner for the country. A study by

Chemonics International Inc. prepared for the United States Agency for

International Development (USAID) in 2012 disclosed that Nigeria’s huge leather

industry export worth $43.4 billion is begging for investors. According to the

Report filed by Business Day, the industry is believed to be worth about $4.4

Billion for raw hides and skins, $14 billion in rough-tanned and finished leathers of

all types and $25 billion for footwear with leather uppers. This indicates high

exports potentials from the products. However, according to FAO current


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production in Nigeria is still less than 40% of the potentials that exist in the tanning
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sector. The aforementioned facts informed the decision of the Share-holders of Z

Tannery limited to launch themselves into the leather processing business.

4.1.4 COMPLIACE WITH EXTANT REGULATIONS

4.1.4.1 Environmental Regulations

 Section 7 (k) of the NESREA Act empowers NESREA to conduct

environmental audit and establish data bank on regulatory and

enforcement mechanisms of environmental standards other than in the oil

and gas sector

 Section 8 (k) of the NESREA establishment Act also empowers the Agency

to make Regulations. One of such made is the “National Environmental

(Permitting and Licensing System) Regulations, 2009; S. I No. 29”

 All the extant national sectorial environmental regulations require existing

industries to undertake environmental audit and submit reports every

three (3) years.

 Section 1 (1) of Regulation S.I.8 of 1991

 Section 3 (1) of Regulation S.I.8

 Section 17 of Regulation S.I.9l

Z Tannery is in compliance with the existing regulations as enumerated

above by establishing a functioning effluent treatment plant and


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Management plan (EMP) which has been submitted to NESREA and now

an Environmental Audit.

4.1.4. 2 Compliance to other regulations

Z Tannery is in partial compliance to most of the regulations, but needs to

be aware of the laws currently in place that require adherence to.


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5.0 CHAPTER SIX: RECOMMENDATIONS

5.1 GENERAL RECOMMENDATIONS

 Z Tannery needs to consider both the short and long term environmental

issues arising from its operations with a strong view to sustainable

development

 Aesthetics and landscape of the frontage of the factory as well as the

areas surrounding the effluent treatment and waste water holding tanks

should be managed. A horticulturist should be engaged to enhance the

beauty of the surrounding by planting flowers and trees that could also

serve as a sink

 There is the need to improve housekeeping especially around the effluent

plant and water holding tanks

 The solid waste collection should be segregated through the provision of

bins of different colors with a view to recovery of such waste based on the

principles of cradle to grave or life cycle approach

 The importance of the Materials safety data sheet for the different raw

materials especially chemicals should be made clear to the store keeper

And other production staff

 Z Tannery must integrate environmental issues in its operation by


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introducing environmental accounting procedures to all its staff


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5.2 SPECIFIC RECOMMENDATIONS

5.2.1 Elimination of waste

 Ensure constant monitoring to repair leaking hose/ pipe, a faulty

valve on a tanning drum, and from disconnected pipe work. Minor

repairs can result in substantial water and effluent elimination.

 Lights/Generators to be switched off during lunchtime (one hour)

and shift breaks. The lighting procedure can be a standard practice

by considering censor to control lighting in the toilets to increase

savings.

 Steps should be taken to ensure that empty cans are fully drained.

This will result in substantial reduction in spent chemical waste

 Leaking oil from the bearings of drums and other equipment should

be monitored as well as the use of excess oil.

5.2.2 Reuse of waste on site

 Collection of waste liquors from the soaking processes could

enable the recovery of, 350,000lites of water for reuse in

subsequent batches.

5.2.3 Recycling of waste

 Recycled polythene can be used as part of product packaging.


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On average, 1527kg of polythene are used each week.


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5.2.4 Disposal after compaction drying, or other treatment

 Currently, Solid following coarse screening of effluent are collected

in open sumps. It is recommended now to transfer wet sludge to

slotted cages where it is left to drain for a week. The dried sludge

should then be transferred to a skip, which is sent to landfill. This will

reduce the chance of land pollution by 80%

 1,300 kg fleshing/week are generated from typical processing of

50,000 skins/ week. In the past, these fleshing were collected in skips

and disposed of to landfills. However, it is recommended that

through compaction, fleshing can be now handled as a solid rather

than a liquid waste eliminating hazard to soil and groundwater.

5.2.5 Retention/redirection

This simply means determining uses for wastewater other than discharge.

Examples of redirection include using “clean” wastewater or using nitrogen-rich

wastewater as a fertilizer for plant grass areas. These approaches require close

attention to regulatory requirements.

5.2.6 Separation/concentration

This should involve separating out solid or other materials from wastewater. Low-

technology options include installing drain screen, setting basins, or systems to


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separate waste products out of wastewater before it is discharge.


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5.2.7 Determination of specific water consumption

Specific water consumption is the volume of waster used per unit of production,

measured in m3 of product. Similarly, specific wastewater discharge is the

volume of wastewater discharge per unit of production, measured in m 3 of

products. Establishing these figures will allow the industry to compare the

performance with benchmarks and that of other companies, regardless of

company size and variations in throughput. As well as measuring how much

water the industry is using, it is also useful to know how this consumption relates

to the industry’s levels of production and therefore pointer to whether Larrabee

is within industry limit or not. Above industry limit means the company is wasting

money in water bill and discharging more than is necessary.

5.2.8 Produce products from the waste generated

Another best strategy that can be adopted in wastewater management is to

look for wealth from waste. For example because of the process by which

sewage collected, the solid content varies from 2-4%. They need to be pre-

processed before use in a digester (biomethanation) for energy production. The

biogas so obtained can be used in engines. Clean sewage based biogas has

400-1500 ppm of hydrogen sulfide. Mixed sewage based biogas has 1-3%

hydrogen sulfide. Such a gas needs treatment before use in engines.


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5.2.9 Reducing Noise level and Gaseous pollutants

Generators should be sound proof and provided with acoustic devices to

reduce high noise level. They should also be overhauled and serviced as at

when due to minimize the levels of SO2

5.2.10 Compliance to all extant regulations

Operations of establishments such as Z Tannery are regulated and guided by

local, state and Federal legislations that are either in force now or will be

enacted from time to time. Z Tannery must ensure that it is in compliance with all

extant laws and regulations at all times. Such compliance is an indicator to

integrity of the company.

5.2.11 General adherence to good management

Z Tannery must put in place good cleanliness of its premises; ensure that all staff

are provided with appropriate uniforms and that they use them at all times;

illuminations in all sections of the factory; Explicit signs in strategic sections of the

factory; training of staff as enshrined in its EMP; Regular submission of effluent

analysis as at when due etc.


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6.0 CHATER SIX; FOLLOW UP ACTION PLAN

6.1 Completion and submission of EAR

6.1.1 Submission of EA report NOVEMBER – DECEMBER, 2014, to

i) NESREA NWZ, Kano

ii) NESREA Headquarters, Abuja

iii) Kano State Ministry of Environment

6.1.2 Monthly effluent monitoring and sending results to NESREA and

Kano state Ministry of Environment

6.1.3 Implementation follow up on the management of the EMP

6.1.4 Provision of adequate safety equipment

6.1.5 Provision of firefighting equipment in strategic locations of the

factory identified

6.1.6 Awareness training for staff

6.1.7 Quarterly inspection

6.1.8 Establishment of quality assurance unit to ensure timely repairs to

leaking oil/water pipes


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7.0 CHAPTER SEVEN: CONCLUSION

This exercise examines the operations of Z Tannery limited – a tanning

plant as well as the compliance status of the plant with respect to

environmental regulations and the contingency plans. Relevant

general and specific regulations in these regards were proffered on the

basis of the data collected during the exercise.


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