Documente Academic
Documente Profesional
Documente Cultură
Semester: 5th
Faculty: Mr. Vikram Singh Nanda
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
INTRODUCTION:
The pressure of increasing population, growth of industries, urbanization,
energy intensive life style, loss of forest cover, lack of environmental
awareness, lack of implementation of environmental rules and regulations and
environment improvement plans, untreated effluent discharge from industries
and municipalities, use of non-biodegradable pesticides/fungicides/
herbicides/insecticides, use of chemical fertilizers instead of organic manures,
etc are causing water pollution. The pollutants from industrial discharge and
sewage besides finding their way to surface water reservoirs and rivers are also
percolating into ground to pollute ground water sources.
The polluted water may have undesirable colour, odour, taste, turbidity, organic
matter contents, harmful chemical contents, toxic and heavy metals, pesticides,
oily matters, industrial waste products, radioactivity, high Total Dissolved
Solids (TDS), acids, alkalies, domestic sewage content, virus, bacteria,
protozoa, rotifers, worms, etc. The organic content may be biodegradable or
non-biodegradable. Pollution of surface waters (rivers, lakes, ponds), ground
waters, sea water are all harmful for human and animal health. Pollution of the
drinking water and that of food chain is by far the most worry-some aspect.
In order to avoid ill effects of water pollution on the human and animal health
and agriculture, standards/rules/guidelines have been devised for discharge of
effluents from industries and municipalities, quality of drinking water, irrigation
water, criteria for aquatic life in fresh water by various authorities including
central pollution control board (India), World Health Organization (WHO),
World Bank, Indian Standard Institution, Indian Council of Medical Research,
etc.
Alarming level of lead (Pb) and arsenic (As) has been found in the sediments as
well as waters of Damodar, Safi, Ganga, Adjai rivers in Jharkhand, and West
Bengal. High level of contamination by heavy metals, chemicals, organic
matter, nitrates, coliforms, human and animal excreta, pesticides, etc is found in
various rivers in India including Ganga, Yamuna, Gomti, Ramganga, Hindon,
Chambal, Godavari, Krishna, Sabarmati, Subernrekha, Cauvery, etc specially
near big cities and industries.
Many areas have arsenic and fluoride in underground waters. Arsenic in many
districts of West Bengal and UP is very high. Fluoride content in underground
water of many districts in Tamil Nadu, Orissa, Andhra Pradesh, Gujarat,
Rajasthan and UP is high while it is also high in some places in Jammu &
Kashmir, Punjab, Haryana, Delhi, Bihar, Madhya Pradesh, and Maharashtra.
The source of fluoride is generally underground rocks.
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
The effects of water pollution: Some forms of water pollution simply alter the
physical state of the water, such as its temperature, pH, or turbidity
[cloudiness], but others involve the addition of potentially harmful substances.
They include poisonous drinking water, poisonous food animals (due to these
organisms having bio-accumulated toxins from the environment over their life
spans), unbalanced river and lake ecosystems that can no longer support full
biological diversity, deforestation from acid rain, and many other effects.
Thermal pollution is the unnatural heating of water which changes the ambient
temperature. Heated water is produced during industrial processes, specifically
thermal power production, and the released water is cooled in local waterways.
In warmer waters the decomposition of organic waste occurs faster, depleting
the Dissolved oxygen in water; this affects the aquatics organisms ability to
Metabolize and may compromise sensitive species.
Acid rain (or more correctly termed acid deposition) can fall on the Earth as
rain, snow or sleet [mixture of rain and snow], as well as dry, sulfate-containing
particles that settle out in the air. It is a world-wide problem because of the
widespread use of coal for heating and electricity and the continued use of fossil
fuels for transportation. Normal rainfall has a pH between 5.2 and 5.6 where
acid rain is more acidic than normal rainfall. Acid rain produces forests with
sickly, stunted trees and lakes that are so acid that they cannot support fish. It
also releases heavy metals (for example, cadmium and mercury) into the food
chain.
Ocean Acidity: The Ocean acts as a CO2 sink, absorbing much of the CO2
produced by the burning of fossil fuels. CO2 reacting with water forms
carbonic acid through the chemical reaction: CO2 + H2O H2CO3.
An increase in carbonic acid levels is causing the pH of the oceans to fall. This
has major implications for marine life. The pH is a logarithmic scale, so even a
small pH change represents a large change in H+. Thus a pH of 5 is 100 x more
acidic than a pH of 7.
Effect of Ocean Acidification: Because the oceans are naturally alkaline
[having a pH greater than 7 i.e Basic], acidification will not produce acid
waters. Shells will not dissolve but organisms will find it more difficult to gain
the CO32- ions needed to make shells. Shell making organisms are able to use
CO32- but cannot use HCO3-. Acidification lowers the amount of CO32available.
Chemical Pollutants: Organic chemicals are carbon based chemicals like
detergents, pesticides, tree and brush debris, and food wastes. Inorganic
Branch: Metallurgy
Code: 338512 (38)
chemicals are not carbon based, like phosphorous and nitrogen based chemicals
and can include acids, salts, and heavy metals. Most organic water pollutants
are synthetic, carbon based, chemicals created for human activities. These
include pesticides, solvents, industrial chemicals, and plastics. Some organic
compounds enter water sources directly or through seepage from landfills,
through agrichemical runoff, or by leaching into groundwater. Inorganic
chemical pollutants include mercury, lead, road salt, and acid drainage. Most
are toxic to aquatic organisms and their presence may make water unsuitable for
drinking and other uses. Inorganic chemicals enter water sources from industrial
plants, mines, irrigation runoff, oil drilling, and municipal storm drainage.
Inorganic Plant Nutrients: Fertilizer runoff from agricultural and residential
land contributes inorganic plant nutrients, particularly nitrogen and phosphorus,
to water bodies. This nutrient enrichment accelerates the natural process of
eutrophication, and causes algal blooms and prolific aquatic weed growth.
High nitrate levels caused by inorganic fertilizers are also toxic in drinking
water, particularly for infants, small children, and pregnant women.
Eutrophication: It is the Biological process. Eutrophication is a term
describing the enrichment of water with nutrients especially nitrates and
phosphates. It often results in excessive growth of weed and algae. In other
words, eutrophication is Excessive nutrients in a lake or other body of water,
usually caused by runoff of nutrients (animal waste, fertilizers, sewage) from
the land, which causes a dense growth of plant life; excessive plant and algal
growth depletes the supply of oxygen, leading to the death of animal life inside
water.
Microorganisms decompose the organic matter in the polluted water and their
activity increases the Consumption of dissolved oxygen [DO] in water. This
reduces the amount of dissolved oxygen available to other aquatic organisms /
animals in water and may subsequently cause their death.
BOD: Biochemical or Biological oxygen demand is a measure of the polluting
capacity of effluent [waste water] where decomposition of organic matter
results in oxygen depletion. Organic matter decays as bacterial activity
increases. BOD is measured as the weight (mg) of oxygen used by one litre of
sample effluent stored in darkness at 20oC for five days [also called BOD5].
When the BOD is high and dissolved oxygen becomes depleted, decomposition
becomes anaerobic [Living or active in the absence of free oxygen]. Anaerobic
microorganisms produce compounds with unpleasant odours, leading to a
further deterioration in water quality.
Branch: Metallurgy
Code: 338512 (38)
Sewage Pollution
Raw or partially treated sewage is a common water pollutant. Sewage pollution
results from the disposal of household and industrial wastes into rivers, lakes,
and seas. Sewage includes all waste water that has been used by a household or
industry. It does not include storm water from road and property runoff, which
is usually diverted directly into waterways. In some cities, sewerage and storm
water systems may be partly combined, and sewage may overflow into storm
water during high rainfall. Most communities apply some treatment to raw
sewage prior to discharge from point sources, but even treated sewage can be
high in nutrients.
Sewage is a source of pathogens (disease-causing agents). During floods,
human waste may mix with drinking water and increase the risk of water-borne
diseases such as cholera.
Processing of Sewage Water: Sewage usually undergoes several levels of
treatment (purification):
Pre-treatment removes any large objects, such as tree limbs, leaves,
condoms, & tampons, with screens.
Primary treatment uses mechanical processes, such as screening and
settling, to remove suspended sand and silt. This forms the primary
sludge.
Secondary treatment uses microorganisms to decompose the suspended
organic material in the waste water aeration tank. The bacteria-laden
solids settle out as sewage sludge.
Disinfection (usually by chlorination but ozone and UV light can also be
used) kills any bacteria and other pathogens before the waste water is
discharged.
Tertiary treatment using biological, chemical, and physical processes is
required to remove nitrogen, phosphorus, heavy metals, and synthetic
organic compounds.
Detecting Water Pollution
The extent of water pollution can be determined in many ways:
The nutrient loading can be assessed by measuring the BOD (the
Biochemical (or Biological) Oxygen Demand).
Electronic probes and chemical tests can identify the absolute levels of
various inorganic pollutants (nitrates, phosphates, and heavy metals).
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Step 1
Step 2
Clean
For Example:
Degrease, Soak, &
Electroclean
Step 2R
Rinse
Step 3
Step 3R
Rinse
Step 4
Step 4R
Pre-Plate
(If required)
Rinse
Step 5
Final Plate
Step 5R
Rinse
Step 6
Post Treatments
(As Specified)
Step 6R
Rinse
Step 7
For Example:
Hydrochloric, Sulfuric,
or Fluoboric Acids.
(Some cases Peroxide
Descale or Brite Dip
For Example: Copper,
Sulfamate Nickel, or
Nickel
If more than one is
specified Repeat Steps
4 & 4R as needed.
For Example:
Cadmium, Chromium,
Copper, Gold, Lead,
Nickel. Silver, Solder, &
Tin
For Example:
Chromates, Lacquers,
& Seals
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Changes in Process:
Replace cadmium with high quality corrosion resistant zinc plating. If
Possible, Use cyanide-free systems for zinc plating. In those cases where
cadmium plating is necessary, use bright chloride, high alkaline baths or
other alternatives.
Use trivalent chrome instead of hexavalent chrome: acceptance of the
change in finish needs to be promoted.
Give preference to water-based surface cleaning agents, instead of
organic cleaning agents, some of which are considered toxic.
Regenerate [improve or re-design] acids and other process ingredients,
whenever feasible.
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Replace the cyanide in plating solutions with less toxic compounds like
zinc chloride and pyro-phosphate copper.
Lower Emissions at the Source
Cover containers of cleaning solvents and used shop towels. This will
reduce emissions of toxic air pollutants and VOC as well as the amount
of solvent lost to evaporation. This reduces the amount of new solvent
purchased.
Securely cover all containers to reduce the chance of spills when
transferring materials.
Use funnels or pumps to avoid spills when dispensing materials.
Install ventilation hoods over plating baths to help protect workers from
evaporative plating solutions.
Change Cleaning Procedures
Mandate a clean as you go policy to reduce the amount of solvent
needed for removing heavy buildup.
Mechanically clean parts with a wire brush or sandblasting equipment to
reduce solvent use.
Use old solvent as a pre-wash or wipe for cleaning equipment or parts.
Switch to a water-based cleaning system like ultrasonic cleaners, manual
parts washers, automatic spray equipment, steam cleaners, or baths with
agitation.
Clean parts with hot water and detergent at high pressures in a
pressurized washer.
Recycle Materials
Use an on-site distillation unit to clean dirty cleaning liquid. This makes
the solvent available for reuse in the production process. An on-site
distillation reduces the costs of both solvent disposal and fresh solvent
purchase.
Use old solvent for cleaning very dirty parts.
Reuse plating bath solution and rinse water.
Reduce bath dumps by continuously filtering bath solutions.
Change Production Processes
Review and streamline production processes to reduce overall cleaning
solvent and degreaser use. For example, evaluate your solvent quality,
consolidate parts washing processes, and service units only when
necessary. These steps can greatly reduce solvent waste.
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Several key environmental issues associated with metal finishing are listed
below:
Use of hazardous chemicals
Solid and hazardous wastes
Air pollution
Water use
Wastewater
Use of Hazardous Chemicals
Metal finishing operations routinely use various hazardous chemicals, including
solvents for cleaning the metal parts, acids and bases for etching them, and
solutions of metal salts for plating the finish onto the desired form (substrate).
Most coating processes require the metal surface to be thoroughly cleaned
before-hand, because surface contaminants greatly diminish the quality of the
finished product. Both cleaning and plating processes generally occur in a
baththat is, a tank in which parts are dipped into a solution of chemicals.
Preparing the surface of the metal for treatment involves the removal of greases,
soils and oxides. Cleaning agents used for this purpose include detergents,
solvents, acidic solutions and caustics. Finished metal parts are often further
coated with some combination of paint, lacquer or ceramic coating. These
coatings can themselves contain toxic solvents and heavy metals.
Chemicals used may include the following:
Acids (sulphuric, hydrochloric, nitric, phosphoric)
Toxic metals (cadmium, nickel, zinc, chromium, lead, copper) and
compounds which contain these metals
Solvents (1,1,1-trichloroethane, methylene chloride, tetrachloroethylene,
methyl ethyl ketone [MEK], toluene, xylene)
Cyanide compounds.
These chemicals may be toxic to humans and animals, cause cancer in both
humans and animals, easily catch fire, and/or persist in the environment for a
long time, entering the food supply.
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Air Pollution Vapour degreasing operations and hot plating baths generate
used solvents that emit volatile organic compounds (VOCs). VOCs can cause
serious health problems for workers, and they also contribute to air pollution in
the lower and upper reaches of the atmosphere. Poor handling practices can
result in the loss of as much as 30 percent of solvents and degreasing agents.
This can be a significant cost, as these chemicals would otherwise be reused.
VOCs are also emitted during paint application, curing and drying. In general,
some sort of pollution control investment will be necessary to fully control air
emissions from metal finishing facilities. Cleaner production can help to reduce
air pollution by preventing solvents from escaping into the air (i.e., volatilizing)
and improving the efficiency of pollution control systems. These methods are
described in detail below.
Selected Mitigation Strategies:
Cover the degreasing unit during idle or down times to prevent solvent
from volatilizing.
Exhausts should be treated to reduce VOCs and heavy metals before
venting to the atmosphere. Carbon filters can both reduce VOC levels and
allow employees to recover solvent using steam stripping and distillation.
Use mist collection and scrubbing systems to control vapours and mists
from process baths.
Use non-caustic paint removers such as alkaline or non-phenolic strippers
to reduce phenol emissions.
Wastewater Problems
Metal finishing, especially electroplating, generates large quantities of
wastewater, primarily from rinsing between process steps. Because of the
hazards to the community associated with the chemicals involved in metal
finishing operations, wastewater should always be treated before disposal into
ground or surface waters. Improperly treated wastewater can contaminate
drinking water and irrigation supplies, with long-term consequences for the
health of the local population, including employees.
Branch: Metallurgy
Code: 338512 (38)
Water Use
Metal finishing requires water in almost every stage of the process. Many metal
finishing businesses have yet to grab major opportunities to reduce their water
use. Often, limited water resources in an area must satisfy the needs for public
drinking water, sanitation, irrigation, river transport and industrial needs.
Inefficient use of these resources for metal finishing can leave insufficient or
highly polluted waters in lakes, rivers and wetlands, degrading their ability to
perform crucial economic and ecological functions.
Branch: Metallurgy
Code: 338512 (38)
There are various cost-effective ways for metal finishing enterprises to reduce
their water use that could provide substantial savings.
Selected Mitigation Strategies:
Ensure the proper design of rinse tanks in order to improve rinsing
efficiency, reduce water use, and reduce drag-out. Tanks should be the smallest
size necessary for all parts/products that will be used in them, in order to reduce
water usage. Using a static rinse tank before a running rinse tank will reduce
drag-out in the running rinse tank, using less water for the same degree of
cleanliness.
Carefully placing water inlets and outlets on opposite ends of the tank will
maximize water mixing in the tank, improving the effectiveness of the rinse.
Inlet flow baffles, diffusers, distributors or spray heads can also help control the
injection of freshwater into the rinsing tank and aid in mixing the water. Also,
adding air blowers, mechanical mixing, or pumping/filtration systems can
improve mixing by agitating tank water.
Mechanical agitation is preferable to air agitation, however, since air blowers
can introduce contaminants like oil into the bath.
Consider alternatives to tank rinsing. Tank rinsing may not be the most
water-efficient solution for rinsing certain types of parts. Consider spray rinsing
instead of immersion for flat-surfaced parts. Ultrasonic rinsing works well for
cleaning parts with small crevices or irregular shapes.
Employ a flow control technique. Effective flow control techniques are flow
restrictors AND flow cut-off valves. Flow restrictors ensure that excessive
water is not fed to the process line. Flow cut-off valves are simple mechanisms
that shut off water flow to rinse tanks when the process lines are not in use.
Measure usage at individual production points. Install an inexpensive flow
meter or accumulator on the main water feed line (leading to the process line) or
on individual rinse tanks. Flow meters indirectly conserve water by allowing
careful monitoring of usage and can identify optimum water usage (or excessive
waste), leaks, and system failures.
Change the mechanics of the rinsing process. Rinsing is more
effective when the parts are dipped into the rinsing tank multiple times
than when parts are dipped once and agitated while submerged.
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)
Branch: Metallurgy
Code: 338512 (38)