Feasibility Report for Tannery Udyog Capacity (300 Hides) PROJECT

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Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

Feasibility Report

For

Tannery Udyog

Capacity (300 Hides)

PROJECT: M/s Tesmia Tannery Udyog

Village: Mussa Sher Nagar

Janshat Road

Muzaffarnagar-, Uttar Pradesh

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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. Item Details No. 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 Plot/ Survey/ Khasra No. Village District Musa Sher Nagar State Muzaffarnagar Uttar Pradesh 5 Nearest railway station/ airport along with Muzaffarnagar Rail Way Station 8 KM distance in kms. 6 Nearest Town, City, District Headquarters Muzaffarnagar along with distance in kms.

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 7 Villages Panchayats, Zilla Parisad, Tehsil:Sadar, Muzaffarnagar Municipal Corporation, Local body 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.).

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

Leather Manufacturing Process:

Process Unit

PRE TANNING Sorting OPERATION Trimming Curing and storing

BEAMHOUSE Soaking Unhairing & liming Fleshing 4

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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.

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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 6

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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 7

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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 8 LIMING / UNHAIRINGSOAKING

FLESHING Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

Fig: Process Flow Diagram Of Tannery

Environmental Issues

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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 10

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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 6.5 – 7.5 5 to 7

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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

Screen Deemulsifi Reactor Filtration cation Filtrate to E.T.P

Chromium for Cake – Sec Recycling Treatment

Fig : chromium Recover plant Flow Diagram

Technical Data/Specification of Civil Work- Civil Work

Sr Item MOC Size Qty Cost (Rs.) No

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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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 B/W 7.0 x 7.0 x 0.3 M 2 ponds

12 Pump Foundation

Air Pollution

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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog 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, Animal feed stuff blood 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 Composting with liming and Recovery of fat unhairing chemicals 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 Organic matter with Leather fiber board shavings content according to production Trimmings tanning Compostin

Feasibility report for Tannery Plant M/s Tesmia Tannery Udyog

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.