feasibility report for tannery...

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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Feasibility Report

For

Tannery Udyog

Capacity (300 Hides)

PROJECT: M/s Tesmia Tannery Udyog

Village: Mussa Sher Nagar

Janshat Road

Muzaffarnagar-, Uttar Pradesh


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Executive Summary

Tanning leather involves a process which permanently alters the protein structure of skin.

Making "rawhide" (untanned but worked hide) does not require the use of tannin. Rawhide is

made by removing the flesh and fat and then the hair by use of an aqueous solution (this process

is often called "liming" when using lime and water or "bucking" when using wood ash (lye) and

water), then scraping over a beam with a somewhat dull knife, then drying. The two

aforementioned solutions for removing the hair also act to clean the fiber network of the skin and

allow penetration and action of the tanning agent, so that all the steps in preparation of rawhide

except drying are often preludes to the more complex process of tanning and production of

leather Livestock Mortality and Biosecurity.

Basic Information

Sl.

No.

Item Details

1 Name of the project/s M/s Tesmia Tannery Udyog

2 Proposed capacity 300 HIDES

3 New/ Expansion/ Modernization -

4 Location and Address M/s Tesmia Tennery Udyog

Musa Sher Nagar

Muzaffarnagar

Uttar Pradesh

Plot/ Survey/ Khasra No.

Village

District

State

5 Nearest railway station/ airport along with

distance in kms.

Muzaffarnagar Rail Way Station 8 KM

6 Nearest Town, City, District Headquarters

along with distance in kms.

Muzaffarnagar

http://en.wikipedia.org/wiki/Rawhide_%28textile%29

http://en.wikipedia.org/wiki/Meat

http://en.wikipedia.org/wiki/Fat

http://en.wikipedia.org/wiki/Fur

http://en.wikipedia.org/wiki/Liming_%28leather_processing%29

http://en.wikipedia.org/wiki/Lye


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7 Villages Panchayats, Zilla Parisad,

Municipal Corporation, Local body

Tehsil:Sadar, Muzaffarnagar

8 Name of the owner Mr. Hazi Mannoom

9 Nearby Drain Nala 2m from back side boundary

wall

10 Nearby Highway Janshat Road

11 Source of water Ground water

12 Power 90 H.P from UPPCB

Power backup: 50 KVA D.G. Set

13 Total No. of Employee 18 person

Location and site Details of project :

Mussa Shernagar is a Village in Muzaffarnagar Mandal in Muzaffarnagar District in Uttar

Pradesh State in India .Mussa Shernagar is 8 km distance from its Mandal Main Town

Muzaffarnagar . Mussa Shernagar is 8.3 km distance from its District Main City Muzaffarnagar

and 423 km distance from its State Main City Lucknow.

Near By Villages of this Village with distance are Kheriwiran(1.7 k.m.) ,Bhikki(1.9 k.m.) ,

Shernagar(2.4 k.m.) ,Bahadarpur(3 k.m.) ,Sikhreda(3.2 k.m.) ,. Near By towns are

Muzaffarnagar(8 k.m.) ,Jansath(12.7 k.m.) ,Khatauli(15.6 k.m.) ,Morna(17.1 k.m.).


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Leather Manufacturing Process:

Process Unit

PRE TANNING

OPERATION

Sorting

Trimming

Curing and storing

BEAMHOUSE Soaking

Unhairing & liming

Fleshing


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Deliming and bating

Pickling

Splitting

TANYARD OPERATION Tanning

POST TANNING

OPERATION

Sammying

Splitting

Shaving and Trimming

Re-chroming

Neutralization

Dying

Fatliquoring

Drying

Applying a surface coat

Pre-tanning operations

a) Raw hides/skins

Usually, the hides/skins consist 65% of the water and 30-35% proteins and fat. Because of the

high amount of moisture in the hides/skin, there will be bacterial degradation. In order to prevent

this bacterial activity, the moisture content should be brought down to less than 30%. This

dehydration is usually done by applying common salt (i.e., Sodium Chloride) to the hides/ skins

to the tune of 30-45% by weight.

b) Sorting

Hides and skins are sorted into several grades by size, weight, or quality.


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c) Trimming

Trimming is generally carried out during the sorting process. Some of the edges (legs, tails and

heads, etc.) of the raw hides and skins can be cut off. Usually this is done in the abattoir, but it

can also be carried out in tanneries (if required).

d) Curing and storing

Curing is a process that prevents the decomposition of hides and skins from the time they

are flayed in the abattoir until the processes in the beam house begin. Whenever a raw material

cannot be processed immediately ("green"), it must be cured.

Salt packs will be employed. in this process the first hide is placed on a bed of salt,it is then

covered with salt and the next hide placed on top. A medium grade rock salt will be used.

Hides and skins will be stored on pallets in ventilated or areas, depending on the method of

curing chosen. From storage the hides are taken to the beam house.

BEAM HOUSE OPERATION

Soaking

The main purpose of this process is to remove the salt used during curing, re-hydrating the

material and to get rid of unwanted materials such as dung, blood, soil, etc. The duration of

soaking may range from several hours to a few days. Depending on the type

of raw materials used, soaking additives such as surfactants, enzyme preparations and

bactericides can be used.

The process of soaking can be classified into three stages

Dirt Soaking – In dirt soaking, 300-400 % of water is used to remove the unwanted

materials

Main Soaking – The purpose of main soaking is to re-hydrate the material. In this

operation, water, non-anionic wetting agent (0.2 % concentrated Soda ash (0.2%

concentrated) and preservatives (0.0 5% concentration) are used.

Final soaking – Only water is used for the washing purpose in this operation

Major part of salt associated with preservation of skin/ hides is removed during the


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soaking operation.

Liming

The purpose of this operation is to facilitate the removal of hair, flesh, fat (partially),

inter-fibrillary protein and to open-up the fibrous structure for osmotic swelling. The

process of liming can be broadly classified into two parts i.e., dehairing and re-liming

Dehairing – Lime (8-10 %) along with Sodium Sulphide (3 %) is applied to the skin

to remove hair

Re-liming – To open up fibrous structure, lime, soda ash, caustic soda, etc., are

applied. The pH of the skin being processed will rise to 12- 12.5.

Fleshing

The excess fleshing will be removed manually or by using fleshing machines. The quantity of

wet fleshings is in the range of 10-15% of the weight of raw hides/skins

De–liming

This is a process to adjust the pH in between 8-8.5 in order to enhance the enzymatic

activity, which converts some of the proteins into soluble forms. pH correction i.e., from

12-12.5 to 8-8.5 are done by using ammonium chloride in case of soft leather and

ammonium sulphate in case of hard leather.

Pickling

Pickling is a process of correcting the pH suitable to the tanning operation and to prevent

swelling of the leather i.e. dehydration of the leather. In this process, water (80%), salts

(8-10%), formic acid (0.28- 0.3%), sulphuric acid (0.75 – 2% based on thickness) are

applied.

PH CORRECTION: pH in between 2.5 and 7.3 is maintained in case of chrome tanning.

PREVENTION OF SWELLING: the salts to the tune of 8-10% are used in this process,

to prevent the swelling. Thus the dehydration takes place.

Tanning operations

.

a) Chrome tanning

Basic chromium sulphate [Cr2(SO4)3] (7-10 %) containing 25% Cr2O3 and sodium

sulphate (25- 30%) will be used. Part of the pickle bath will be used for chrome

tanning operation. The pH is increased to 3.8-4.0 at the end of chrome tanning process

which is called basification. The semi-finished leather after chrome tanning is called wet blue.

Post-tanning operations


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Post-tanning operations comprise of re-chroming of semi-finished wet blue leather,

neutralization, dyeing, fat liquoring and finishing. In case if post-tanning of vegetable

tanned semi-finished leather, the operations involved are semi-chrome tanning,

neutralization, dyeing, fat liquoring and finishing. However the operations vary

depending upon the final product.

Sammying: It is a mechanized process followed to remove excess moisture in the wet

blue.

Splitting: After sammying, the material is split into required thickness using splitting

machine

Shaving and Trimming: The semi-finished leather is leveled using the shaving

machine.

Re-chroming: Depending on the quality of wet blue, re-chroming is carried out to

improve the chromium content in the leather.

Semi-chroming: Incase of vegetable tanned semi-finished leather, chrome tanning is

given depending on the final leather quality.

Neutralization: pH is adjusted to 4.5-6.5

Dyeing: The leather is coloured using dyes such as anionic dyes, acid dyes, direct,

metal complex compounds and basic dyes.

Fat-liquoring: Natural/synthetic oils are applied for fat liquoring, thereby imparting

softness to the leather

Finishing: Phenolics, melamine, acrylics, polymers, naphthalene, etc., are used for

finishing to impart fullness to the leather.

SOAKING

LIMING / UNHAIRINGSOAKING

FLESHING


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Fig: Process Flow Diagram Of Tannery

Environmental Issues


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The Tannery industry has a significant positive impact on environmental quality. The processing

of low economic value organic matter from the livestock production, meat processing, food

processing, and food service industries by the Tannery industry reduces the amount of wastes

deposited in landfills and discharged to municipal wastewater treatment facilities

Type of pollution

1. Water pollution

2. Air pollution

3. Solid waste

WATER POLLUTION

Volume of Waste Water from Manufacturing Process and By Products:

Capacity According to : 1 ton of hide, generated waste water = 28 KL/ton of hide

So, for 300 hides total weight of hide = 300x15 = 4500 kg= 4.5 ton

Total waste water generation = 28 x 4.5 = 126 KLD

Extra Load = 4,000 Ltrs

So we Offer Plant Capacity : = 130 KLD

Plant Operation Time : = 20 Hr.

Flow Rate : = 6.5 M3/Hr

Total Discharge per day: 130 KLD

The effluent will be segregated in two streams namely--- the soaking and pickling discharge and

the combined effluent generated from all the other processes. The volume of soaking and


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pickling estimated to be 40,000 liter/day at peak level. The remaining 90,000 liters/day will

come from liming, deliming, tanning liquor and utility waste water.

Conservation of water:

1. The second installment of water used for soaking will be reused for first soaking to reduce the

salt content in the final effluent.

2. Pickling water after suitable adjustment of pH will also be tried to use for soaking and

recovery of salt.

Characteristics of Effluent

Parameters Untreated Treated

pH 5 to 7

6.5 – 7.5

TSS 300 to 500 ppm <100 ppm

Chlorides(as cl) 1000 to 2000 ppm < 200 ppm

BOD5 400 to 2000 ppm < 30 ppm

COD 1000 to 4000 ppm < 250 ppm

Metal (Chromium) 250 to 450 ppm < 2 ppm

Treatment proposal:

A separate line from the rest of the effluent segregates the soak and pickle liquor. This stream of

waste can be treated by three methods

(i) Solar evaporation pond(With or without heating element)

(ii) Reverse Osmosis System

(iii) Electro Dialysis Method


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We propose to treat this stream in solar evaporation ponds. Evaporation ponds of sufficient

surface area are provided to allow for considerable buffer on rainy days. Heating elements

are provided to increase the evaporation rate. Solid waste left after evaporation are

proposed to be collected in bags and disposed off or either reused for pickling after adding

preservatives incorporating necessary modification.

The combined effluent stream after passing through the CHROME RECOVERY PLANT will

be held in an equalization tank to equalize the effluent. The effluent is then pumped to the

flash mixer. The flow is controlled by a flow regulating valve. The flow is observed by

the flow meter. In the flash mixer, Ferric Alum and lime dosing is done. Effluent flows by

gravity to the flocculator where polyelectrolyte’s may be used to hasten the settling

process. Most of the suspended solid settle down in the primary clarifier will flow by

gravity to the first stage aeration tank of the double stage extended aeration activated

sludge process. An MLSS of 3000-4000 ppm. will be maintained with the help of return

sludge from the secondary clarifier in the two aeration tanks. A bacterial culture will be

developed in the aeration tanks by nutrient dosing of Di-Aluminum Phosphate (DAP) and

urea dosing and using cow dung or septic tank effluent. Aeration will be provided by

surface aerators (fixed type). The over flow from the secondary clarifier is fully treated

and is released from a Clearwater collection tank by pumping for land irrigation . The

sludge from the two clarifiers will be pumped to the sludge drying beds. The dried sludge

from the sludge drying beds will be disposed off either as manure or making bricks.

PRINCIPLE AND PROCESSES OF CHROMIUM RECOVERY PLANT

The Chromium Recovery Method is based on the principle that the chromium present in the

effluent in its trivalent form and thus is generally insoluble at a pH of 8 to 12. It reacts with an

alkali such as Ca O, Mg O, etc, and precipitates as chromium hydroxide [Cr (OH)3 ]. The

precipitate, after separation by filtration yields chrome sludge that when treated with sulfuric

acid, forms soluble chromium sulfate, which can be reused after alkalification, as it is turned

again into basic chromium sulfate.

OPERATIONS AND SUB-PROCESSES FOR CHROMIUM RECOVERY

The operations and sub-processes involved in the Process of Chromium Recovery are self-

explanatory as shown in Fig. 1


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Fig : chromium Recover plant Flow Diagram

Technical Data/Specification of Civil Work- Civil Work

Sr

No

Item MOC Size Qty Cost (Rs.)

01 Screen Chamber B/W 1.0 x 1.0 x 1.0 M 1

02 Equalisation Tank RCC 3 .0 x 4.0 x 3.0 M 1

03 Flash Mixer RCC 1.0 x 1.5 x 1.0 M 1

04 Flocculator

RCC 1.0 x 1.5 x 1.0 M 1

05 PST RCC 3.0 x 2.0 x 3.0 M 1

06 Aeration - I

RCC 4.0 x 4.0 x 3.0 M 1

Screen Deemulsifi

cation Reactor Filtration

Cake – Sec

Treatment Chromium for

Recycling

Filtrate

to E.T.P


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07 Aeration - II

RCC 3.0 x 3.0 x 3.0 M 1

08 SST RCC 3.0 x 2.0 x 3.0 M 1

09 Buffer Tank RCC 3.0 x 3.0 x 3.0 M 1

10 S.D.B B/W 1.5 M x 1.5 M x 1.5 M 4

11 Solar Evaporation

ponds

B/W 7.0 x 7.0 x 0.3 M 2

12 Pump Foundation

Air Pollution

Type of Emissions : DG Set Emission, VOCs, Ammonia, dust, H2S


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PROVISION FOR AIR POLLUTION CONTROL:

Stack height for D.G. Set : 4.5 M above from the building

PROVISION FOR ODOUR CONTROL

The latest technology in odour control is a Bio Filter System which we shall be using for

effective control. Bio filter systems are designed as single or multistage units according to the

actual requirement for instance with a preset bio- or chemical scrubber.

Bio filtration is an efficient and economical process to deal with odour compounds and low-level volatile organic compounds (VOCs). The use of bio filtration provides the advantage of no troublesome byproducts or dust being produced. The end products of the process are carbon dioxide (CO2), water vapour (H2O), and inorganic salts. The technology of a bio filter is applied microorganisms in the process to treat odorous air and degrade the compounds.

Materials:

PE, PP, FRP

coated steel, stainless steel

Possible constructions are available:

Areal filters

Round filters

Multistage filters

Coated sea container filters

Compact bio filter units

Mobile bio filter units (also as mobile hook-up container according to DIN 30722)

Filter materials:

compost of bark, compost, wood mix, heather, peat and coconut fibers


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Biofilter for odour control

BIO FILTER

Bio filter systems are designed as single or multistage units according to the actual requirement

for instance with a preset bio- or chemical scrubber.

BIO FILTER CALCULATION

So as per calculation we need Area for Bio Filer 120 Sq. Feet Minimum

Area taken in our Plant = 12’ X 40’

Our Bio Filter Size is = 240 Sq. Feet i.e Two time of required size


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Solid waste Management:

TYPES OF SOLID WASTE

Process unit Type of waste content Further

treatment/disposal /

recycling

Trimming Parts of raw hides Collagen , hair,fat

,connective tissue,

blood

Animal feed stuff

Curing Solid salt NaCl Re -use

Liming and unhairing hair Keratin rich material Re-use as filling

material

Fertilizer / agriculture

/ animal feed stuff

Fleshing fleshing Fat, blood, possibly

with liming and

unhairing chemicals

Composting

Recovery of fat

splitting Lime split Same as fleshing Composting

Recovery of fat

Tanning/ retanning Tanning liquor c---------------- Recovery of chrome

in

Splitting and shaving Tanned split and

shavings

Trimmings

Organic matter with

content according to

tanning

Leather fiber board

production

Compostin


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List of Chemicals :

SUMMARY

This is a comprehensive report to present the effluent treatment and management plan for M/s

TESMIA TANNERY UDYOG. This report gives an overview of the rigorous feasibility

assessment of the proposed scheme, for control of Air / Water pollution prudently opted by the

industry.

The potential of effluent generation is well defined and the scheme design assessment is almost

20% higher than the theoretical capacity. The pollutant availability has also verified. The

information is further used to evaluate the quality and quantity of the effluent that is generated.

The system proposed is most cost effective and adjustable with existing space as well as cost

effective.

The scheme including system description along with technical details has been presented in this

report which will help any further processing and assuring the technical proneness of system.

Finally, the proposed scheme not only preserve the surrounding as ecosystem balance but its cost

effectiveness will promote other industry to upkeep their plant, and think in new dimension.

feasibility report for tannery...

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