REPORT ON POLLUTION MITIGATION MEASURES FOR

PROPOSED ICE BLOCK MANUFACTFRING PLANT

Prepared for

D M K Enterprises limited

Our Ref: ISL/CB/ES/IEER/046/2017

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Prepared by

Industrial Solutions Lanka (Pvt) Ltd.

123/8, Singhe Mawatha, Dambulla Road, Kurunegala

T: 037 7395390 F : 037 222 3368 E-mail : info@isl.lk URL : www.isl.lk

FEASIBILITY REPORT ON THE PROPOSED COW AND BULL HIDES BASED LEATHER
TANNING INDUSTRY.

1. Introduction

Leather tanning has a long history spanning from several centuries back. It used to be a wide spread
domestic industry with the knowledge and technology being passed down from generation to generation.
Unfortunately, with the introduction of the open economy decline of the traditional industries took place.
As a result, nowadays public tend to go for imported artificial products which are cheap and available in
abundance rather than natural local products which are more user friendly having no adverse health
effects. Thus, the leather tanning industry which was once a thriving industry is now at the verge of
extinction.

Hides of bulls and cows are amassed in the slaughter houses in abundance which are considered to be a
waste. Therefore, the proposed leather tanning plant not only enables to uplift a traditional industry but
also to minimize a would be solid waste issue.

The purpose of this report is to recommend suitable measures to mitigate any environmental issues that
would arise due to the production process. Once the suggested measures for the generated solid waste and
wastewater are implemented which the proprietors are willing to do, the approval for the functioning of
the industry would be granted by the CEA.

1.1 Background Information

Name of the company D M K Enterprises limited

Type of Industry Cow and Bull hides based leather tanning industry
(For Trade License, Please refer annexure 1)
Postal Address Mannaram Road, Udayaweli, Seemaweli, Puttalam

Contact person Mr. Dawud Mohomad Abdul Kiyas

Contact No 072 2276540 / 072 5759186

Employee requirement Manages – 01

Skilled workers – 08
Non skilled workers – 13
Driver – 01
Security - 02
Construction started October 2017
Manufacturing started June 2017
Location of the project: It is planned to be put up in Mannaram Road, Udayaweli, Seemaweli,

Puttalam

Factory layout plan: Please refer annexure 2

Survey plan: Please refer annexure 3

The extent of the project site: 2 acres

Present ownership of the project site: Dawud Mohomad Abdul Kiyas (Proprietor)

Present use of land: No any use of the land. The access road is available.

Proposed timing and schedule including phase development: Land development activities are in
progress. It is expected to start the manufacturing process after the implementation of the waste water
treatment plant.

Anticipated water demand: 60 m3 per day

Water sources: Of the four tube wells present three to be used for the production purposes. 30 m3 of
water can be acquired every 12 hrs from each tube well.

1.2 Existing land

Northern boundary Eastern boundary Southern boundary Western boundary

M. Abdul Kalam M D Abdul Kiyas Road (PS) Tank Reservation

1.3 Existing land and buildings

Construction; No permanent buildings are available at the site. Factory layout plan is attached in
annexure 3.

Main access road: Udayaveli village road

 2. PROCESS DESCRIPTION
2.1 Process Description including Contribution of Each Stage for Generation of Waste.

Curing of skin is often carried out by applying salt which possess dehydrating and bacteriostatic
properties. Thereby, microbial attack on the skin is restrained while reducing the moisture content.
40% of TDS and 55% of chlorides (Cl) in the effluent arise from this process. But it will not be an issue
in this case as it is intended to process hides which are already cured.

Pre-tanning:

 Soaking is carried out in rotating drums where water

rehydrates the skin to open up the contracted fiber
structure which enables the removal of folds from hides.
In addition, impurities like salts, partially soluble
components and denatured protein are also removed.

 Liming is the general method used in removing hair where

10-20% of lime and 2-5% sodium sulphide are applied.
Carbide lime is introduced into the soaking drum after
allowing skins to be soaked for several hours. A Ph value Figure 1:Soaking Drum
of around 9.5 is maintained.

 Deliming as the name implies is used to remove lime used in the preceding stage. Skin which is
free of hair at this stage is made into contact with ammonium sulphate and sodium bisulphite for
the removal of lime.

 Fleshing is carried out by using the drum scudder where fleshy particles attached with the skin
are removed.

Figure 2:Drum scudder (Fleshing machine)

  Splitting is the process where further reduction of the skin thickness is achieved where the
separation of top and bottom layers take place A gelatinous layer of flesh referred as split leather
is removed at this point. Grain leather is recovered and sent for further processing.

Figure 3:Splitting machine

 Pickling reduces the Ph of the skin from 8 to 2.8-5.0. Skins are kept overnight in a solution of
crushed salt and sulphuric acid. This process is used to counterbalance the alkalinity raised by
lime.

Tanning:
This process incorporates permanent stability to skin. Chrome tanning process is carried out with the help
of chrome powder together with sodium formate. The chemicals are introduced into a rotary drum filled
with water which are stirred well prior to the introduction of skins. At the end of this process tanned skins
bluish in colour are obtained.

Figure 4:Tanning Drum

Please refer annexure 5 for the PFD.

Environmental Impacts
As per the site visit made to S.A. Perera a leather tanning plant in Mattakkuliya with whom D.M.K.
enterprises are to function in collaboration, several environmental issues that may arise in the proposed
leather tannery was identified. They fall under the following categories,
 Wastewater from three streams of varying characteristics
 Solid waste disposal
 Generation of noise

Wastewater-
Pre-tanning and tanning operations contribute about 57% of the water consumption in leather processing
and about 35% is due to washings. Typically, a plant processing 3000 kg of hides per day generates
around 60,000 liters of wastewater. The generation of wastewater from each stage is as follows,
 Soaking – 25,000-30,000 l
 Fleshing – 2,000-3,000 l
 Tanning – 25,000-30,000 l
Wastewater from soaking comprises of impurities like salts, partially soluble components and sulphides
while that from fleshing contains organic components. Chromium is discharged with the effluent from
tanning. 50% of COD and 40% of BOD that contributes to 60–70% of the total pollution load in leather
processing is generated at the phase of liming.
Thus, due to the diverse nature of the effluents formed a complex wastewater treatment methodology is
required to treat the wastewater generated.

Solid waste-
According to literature, per one thousand kg of raw skin/hide 150 kg of leather is yielded and remaining
850 kg contributes to solid wastes out of which 450 kg is collagen waste and 400 kg is fleshing waste.
Solid waste is in the form of raw hide/skin trimmings, chrome shavings, buffing dust, chrome trimmings,
leather strips and cuttings, lime and chrome sludge.

Generally, solid waste is generated 80% from beam house operation, 19% from tanning operation and 1%
from finishing operation. Fleshing process which is one of the beam house operations, amasses the
highest amount of solid waste followed by the splitting process.
Noise-
Though not in significant amounts, there is still a tendency of generation of considerable amount of noise
due to the functioning of machines, specially from the fleshing machine.

Odour-
Since leather tanning is associated with perishable substances presence of an inherent odour is
unavoidable. Yet it is not expected to be a major issue as long as it will not reach an intolerable level.

Measures for Pollution Mitigation and Disposal of Generated Waste.

Wastewater
Wastewater from tanning comes under three streams one contaminated with sulphides, another having
chromium ions while the rest having normal organic pollutants. Therefore, the effluent has to be collected
separately and unique treatment methods have to be adopted for the treatment of each stream.

The treated effluent can be used for irrigation purposes once its parameters are met with the standard
limits after following the recommended treatment procedure. The area marked in the figure is to be used
for cultivation of coconut and watering is to be done using the treated water.

Please refer attached proposal of proposed wastewater treatment plant for more details

Figure 5:Satellite view of the land indicating the area

allocated for the discharge of treated effluent
Solid waste
Fleshy particles generated during the fleshing phase have to be disposed of in such a way that good
hygiene practices are ensured. Thus, a sanitary land filling is recommended. Split leather generated will
not create any issues as it can be used in the production of dog food.

Figure 6:Refuse from fleshing Figure 7:Split leather

Figure 8:Sanitary land filling

A typical problem arising in any land filling is the formation of a leachate having very high BOD and
COD values. Therefore, it is expected to transfer the leachate to the wastewater treatment plant to be
treated prior to discharge. In order to monitor the quality of the ground water, two pipe lines before and
after the pit will have to be installed. This will ensure that ground water resources near the land filling are
not contaminated due to the leachate.

Also, it is recommended to insert pipe lines for the recovery of gas generated within. This will eliminate
any possibility of occurrence of an explosion due to the buildup of pressure. This has an added advantage
as the gas collected can be used as a fuel once the necessary conditions are met.

Noise

It is recommended to build the factory in the center of the land so that any generation of noise will not
create nuisance to the neighborhood. Please refer Annexure 4 for clarification.

Conclusion

The capacity of tube wells is more than enough to cater for the estimated water demand of the factory and
three phase current is to be taken from the national grid. Since well-planned and feasible waste disposal
methods are to be implemented, little or no adverse impacts on the environment will take place.
Therefore, as a whole it can be concluded that the proposed factory can be initiated without further ado.
 Annexure 1

Trade Certificate
 Annexure 2

Factory Layout Plan

 Annexure 3

Survey Plan
 Annexure 4

Proposed location of the factory

PFD Annexure 5
Proposal for the WWTP of D.M.K. Enterprise Attachment 1

INTRODUCTION

D.M.K. Enterprises is a proposed leather tannery that is to established in near future with the
collaboration of S.A. Perera, a well-established tannery. Typically, a plant processing 3000 kg of
hides per day generates around 60,000 liters of wastewater. Pre-tanning and tanning operations
contribute about 57% of the water consumption in leather processing and about 35% is due to
washings.

Wastewater from soaking comprises of impurities like salts, partially soluble components and
sulphides while that from fleshing contains organic components. Chromium is discharged with
the effluent from tanning. 50% of COD and 40% of BOD that contributes to 60–70% of the total
pollution load in leather processing is generated at the phase of liming. Thus, due to the diverse
nature of the effluents formed a complex wastewater treatment methodology is required to treat
the wastewater generated.

The purpose of this report is to propose a feasible wastewater treatment mechanism which upon
implementation would yield treated water meeting the discharge standards stipulated by CEA.

BACKGROUND DETAILS

Name of the Proprietor D M K Enterprises limited

Type of Industry Cow and Bull hides based leather tanning industry
Postal Address Mannaram Road, Udayaweli, Seemaweli, Puttalam
Contact Person Mr. Dawud Mohomad Abdul Kiyas
Contact No 072 2276540 / 072 5759186
Name of the Local Authority Puttalam Pradeshiya Sabha
P&ID Please Refer Annexure 01
Plant Layout Please Refer Annexure 02
TYPICAL COMPOSITION OF TANNERY EFFLUENT

DISCHARGE LIMITS

The environmental norms published by the CEA of Sri Lanka prescribe the following values for
effluent discharged to irrigation purposes.

Tolerance Limits for the Discharge of Industrial Waste into Irrigation Purposes

Parameter Unit Tolerance Limit

pH at 25 oC - 5.5 – 9.0

Total dissolved solids O2 mg/l 2100

Chemical Oxygen Demand COD O2 mg/l 400

Biological Oxygen Demand mg/l 250

BOD5

Oil & grease (mg/l) mg/l 10

ANTICIPATED COMPOSITION OF TREATED EFFLUENT

The following table contains the composition of the effluent that is expected to be obtained after
undergoing the treatment method described herewith.

Parameter Unit Value

Biological Oxygen Demand O2 mg/l 250

BOD3

Chemical Oxygen Demand COD O2 mg/l 400

chromium, total (as cr3+) mg/lit 1

sulphides mg/lit 2

PROPOSED TREATMENT PROCESS

Wastewater from tanning comes under three streams, one contaminated with sulphides, another
having chromium ions while the rest having normal organic pollutants. Therefore, the effluent
has to be collected separately at the generation point of each pollutant and directed to the
relevant treatment process.
Wastewater stream having chromium ions
Effluent arising from tanning comprises of chromium ions. So as to recover the chromium
present that stream is made to undergo a chromium recovery procedure. If post tanning and
finishing processes are to be commenced, wastewater generating from those stages also has to be
directed to that treatment system.

Pump sump 1

Incoming effluent streams containing chromium ions are directed to the pump sump where
homogenizing takes place. Since tanning is carried out batch wise a shock load of 5000 l arises
every 2 hrs or so. Thus, this unit enables the steadying of the flow rate as well.

Mixing & Batch reactor units

pH level of the effluent is brought around 2-3 by adding sulphuric acid. Sodium metabisulphite is
introduced afterwards which acts as a reducing agent to convert Cr(VI) to Cr(III) ions under
alkaline conditions. Then again, the pH level is brought up with the aid of Mg(OH) 3. Chemical
dosing is strictly monitored by automated pH and ORP control systems. Soon after the effluent
reaches the required pH and ORP levels it is provided with the retention time required for the
precipitation of chromium hydroxide.

Wastewater stream having sulphide ions

Pump sump 2

Effluent streams deriving from liming and deliming stages are contaminated with sulphide ions.
These streams are directed to the pump sump to be homogenized.

Mixing & Clarifier units

Treating of water contaminated with sulphide involves the removal of sulphdes via addition of
iron salts. In this case ferric chloride is to be added where the precipitation occurs in the form of
ferric sulphide. Sufficient time is provided for the settling of the precipitate.

Wastewater stream free of chromium and sulphide ions

Since wastewater generating from pickling and soaking phases are not contaminated with the
ions mentioned above, the best practice is to collect those streams separately.
Pump sump 3
Those streams are directed into a pump sump as in the previous cases.

Treatment following the combination of three streams

Eq tank

The prime purpose of an Eq tank is to overcome the fluctuations of flow so as to obtain a

consistent flow in both quality and quantity. Supernatant from the first two streams and the
effluent from the last stream are pumped into the Eq tank. The three streams arriving at different
rates are homogenized and passed into other units at a steady state.

Rapid mixing tank

Effluent from Eq tank is pumped into the rapid mixing tank having a capacity of 2000 l where
coagulant is fed by using a dosing pump. Mixing will be done by using a mechanical agitator
with a speed of 50 RPM. Formation of clogs takes place at this phase.

Slow mixing tank

Flocculent is added to the slow mixing tank of 2000 l capacity using a dosing pump. Mixing is to
be done using a mechanical agitator with a speed of 25 RPM. Clogs formed in the previous stage
are combined together at this phase to form polymer chains referred to as flocs.

Clarifier

Flocs formed are separated from the partially treated water at this phase by incurring a
momentum change which is the technique behind the clarifier mechanism.

Aeration tank

After a retention time of two hours water from the batch reactor is decanted and transferred into
the aeration tank where an activated sludge process takes place. Required aeration demand is met
by continuous aeration via an air blower.
Clarifier

This clarifier is used to separate the mixed liquor suspended solids (activated sludge) which are
formed in aeration tank. Overflow from the clarifier is directed to the treated water tank.

DISPOSAL OF TREATED EFFLUENT

Liquid Waste

Treated water arising from the final stage is to be used for irrigation purposes. 6 acres land
belonging to the proprietor of the tannery is to be watered with the treated effluent. Since it
comprises of sandy loam soil which is having a fairly good absorption capacity, it will be able to
hold the daily water discharge.

Solid Waste

The only heavy metal generated in this process is chromium and it occurs during the tanning
phase. But the total chromium content present in the sludge amassed during the treatment of
wastewater is completely recovered to be reused in the process of tanning. Therefore, no threat
will be imposed on the environment due to heavy metals.

Sludge accumulated from other streams which are free from chromium can be sent to the
relevant local authority to be disposed of as municipal solid waste.
P&ID Annexure 1