3.

CLEANER  PROCESS  TECHNOLOGY  

Definition  
The   Commission   understands   that   cleaner   technology   can   be   defined  
environmentally   and   economically   best   practicable   technology.  
technology   may   be   defined   in   terms   of   minimum   environmental   im
towards  which  the  industry  is  striving.  
 
“Cleaner   production   is   the   continuous   application   an   integrated,   prev
environmental   strategy   towards   processes,   products   and   services   in   or
increase   overall   efficiency   and   reduce   damage   and   risks   for   humans   an
environment  
 
The   primary   task   of   all   cleaner   technologies   is   to   reduce   the   amount   po
emissions;   and   where   possible   change   the   nature   of   pollution   emissio
reduce   the   pressure   and   costs   of   end-­‐of-­‐pipe   treatment.   The   expected  
primarily  include:  
! Lower   water   consumption   –   better   preservation   of   rapidly   dimin
water  resources.  
! Lower  total  dissolved  solids  (TDS)  content  (including  salinity)  –  low
of  affecting  the  usability  of  the  receiving  water  bodies  for  irrigatio
livestock  watering.  
! Avoidance  of  use  in  processing  and/or  presence  in  leather  of  subs
from   the   Restricted   Substances   Lists   (RSL)   promulgated   by  natio
regional   legislation,   leading   (multinational)   brands   and/or   ecolab
to   their   proven   negative   impact   on   human   health   and
systems.                                
! Proportionally  higher  volume  of  solid  wastes  suitable  for  processin
saleable  by-­‐products.  
! Lower   levels   of   BOD,   COD   and   Nitrogen;   their   respective   conte
conformity  with  local  and  widely  prevailing  legislative  norms.  
! Low  level  of  chromium  in  (C)ETP  sludge  –  the  scope  for  land  appl
and/or  composting.  

B  Sc  Chemical  Engineering  (Leather)   21     L

 ! Lower  hazardous  and/or  unpleasant  air  emissions.  
! Appropriate   occupational   health   and   safety   (OSH)   standards   –   better  
work  conditions,  fewer  accidents.  
 
Principles  of  cleaner  technology  
The  principles  of  cleaner  technology  can  be  summarized  as:    
(a)  Prevention  is  better  than  reuse    
(b)  Reuse  is  better  than  recycling    
(c)  Recycling  is  better  than  disposal.  
 
CLEANER  TECHNOLOGICAL  OPTIONS  IN  LEATHER  PROCESSINGS  
A  variety  of  cleaner  technology  options  are  given  below.  

 
 
 
 
 

B  Sc  Chemical  Engineering  (Leather)   22     Leather  Technology  I  

4. GENERATION  OF  SOLID  WASTE  AND  ITS  UTILIZATION  
4.1        Solid  waste  generation  
The  major  solid  wastes  generated  during  the  leather  processes  are    
! Dusted  salt  
! Raw  hide  /  skin  trimmings  
! Green  fleshing  
! Limed  fleshing  
! Pelt  trimmings  
! Wet  blue  trimmings  
! Vegetable  tan  trimmings  
! Shavings  
! Buffings    
Sludge  /  solid  waste  from  effluent  treatment  plants  
! limed  sludge  
! Chrome  /  chemical  Containing  sludge  From  ETPs  and  CETPs  
! Sludge  from  the  Biological  treatment  
! Salt  from  solar  pans  And  evaporators    
 
Curing  Salt:    
During   the   handling   of   raw   skins,   adhered   dusted   salt,   which   is   contaminated  
with   blood,   hair,   dirt   and   certain   type   of   bacteria   is   removed   from   the   skins   and  
obtained  as  solid  waste.  This  salt  is  partly  reused  in  the  curing  process  and  the  
remaining  is  indiscriminately  dumped  in  the  undeveloped  land  near  the  tannery.  
   
Raw  Trimmings:    
Raw  trimmings  are  cuttings  from  the  edges  of  raw  skins.  The  skins  are  trimmed  
specially  at  the  legs,  belly,  neck,  and  tail  parts  in  order  to  give  a  smooth  shape  to  
the  skins.  
   
Fleshing:    
This   is   the   flesh   removed   from   the   limed   skins   and   is   generated   during   the  
fleshing  operation  which  is  carried  out  after  liming  and  un-­‐hairing  processes.  

B  Sc  Chemical  Engineering  (Leather)   23     Leather  Technology  I  

  
Splitting  of  Wet  Blue:    
This   operation   is   carried   out   in   hides   tanneries   processing   hides.   After   chrome  
tanning,   the   hide’s   thickness   ranges   from   6-­‐8   mm.   Therefore,   to   get   proper  
thickness  the  wet  blue  of  the  hide  is  sliced  into  two  layers.  Upper  layer,  which  is  
having   grain,   is   used   for   preparation   of   finished   leather.   Whereas,   the   lower  
layer   is   treated   as   a   by-­‐product.   However,   it   is   further   processed   and   is   used   for  
manufacturing   low   grade   shoe   upper   leather   and   as   such   is   not   considered   as  
solid  waste.  
 
Chrome  Wet  Shaving:    
After  chrome  tanning,  skins  or  split  hides  are  shaved  to  proper  thickness  by  the  
shaving  machine.  This  operation  produces  chrome  containing  solid  waste  usually  
called  shaving.  
   
Buffing  Dust,  Trimming  and  Dry  Shaving:    
Buffing,   adjustment   of   the   thickness   of   leather   and   trimming   operations   are  
responsible   for   the   generation   of   buffing   dust,   cuttings   (trimmings)   and  
shavings,   respectively.   Tanneries   mostly   have   a   good   buffing   dust   collection  
system  that  does  not  allow  the  dust  to  spread  out  around  the  working  area.  The  
dust  is  collected  via  the  suction  machine  in  cloth  bags.  
 
4.2        Environmental  impacts  of  solid  wastes  
When   solid   waste   is   disposed   off   on   land   in   open   dumps   or   in   improperly  
designed  landfills  (e.g.  in  low  lying  areas),  it  causes  the  following  impact  on  the  
environment  .  
! Ground  Water  Contamination  by  the  Leachate  Generated  by  the  
Waste  Dump  
! Surface  Water  Contamination  by  the  Run-­‐off  from  the  Waste  Dump  
! Bad  Odour,  Pests,  Rodents  and  Wind-­‐Blown  Litter  in  and  Around  the  
Waste  Dump  

B  Sc  Chemical  Engineering  (Leather)   24     Leather  Technology  I  

 ! Generation  of  Inflammable  Gas  (e.g.  Methane)  Within  the  Waste  
Dump  
! Fires  Within  the  Waste  Dump  
! Erosion  and  Stability  Problems  Relating  to  Slopes  of  the  Waste  Dump  
! Epidemics  Through  Stray  Animals  
! Acidity  to  Surrounding  Soil  And    
! Release  of  Green  House  Gas    
 
4.2        Utilization  of  solid  wastes  
Disposal  options  of  dusted  salt  
! Can  be  reused  for  curing  along  with  fresh  salt.  But  pre  treatment  is  
required.  
! Reuse  for  pickling  operation  
 
Green  Fleshing  
! Recovery  of  grease  and  meat  meal  
! Pet  Chews  
! Gelatin  production  
 
Disposal  of  limed  fleshing    
! After  cleaning,  processed  for  Gelatin  
! Substitute  for  fish  meal  
! Methane  production  –  Composting  
 
Chrome  Tan  and  Vegetable  Tan  Shavings  
! Leather  Board  Manufacture  
! Thermal  Treatment  for  Recovery  of  Chromium  and  
! Bio  –  Energy  Generation  
! Enzymatic  Treatment  
! Conversion  in  to  fertilizer    
   

B  Sc  Chemical  Engineering  (Leather)   25     Leather  Technology  I  

5. Water  Usage  and  its  management  
Usage  of  water  in  leather  processing  
Leather   production   is   a   water   intensive   industry;   Water   is   the   main   mediumof  
transport   for   the   chemicals.   Many   of   the   leather   processingsteps   depend   on   the  
large   use   of   water.   Thisexplains,   in   part,   the   development   of   the   industry   alongthe  
river  basins.  The  leather  industry  employs  about  30–40  litre  of  water  per  kg  of  hide  
processed.     The   pre-­‐tanning   operations   consume   nearly   15–22   lof   water   per   kg   of  
hide   processed,   while   the   tanningoperation   consumes   1–2   l   of   water   and   post-­‐
tanning  2–4  l  per  kg  of  hide  processed.  Washings  contribute  11.5–13  l  of  the  water  
used  for  processing.  
 
The  details  ofwater  consumption  for  each  step  are  presented  in  Table  
 

 
 
Therefore   measurement   and   control   ofconsumption   are   important   and   essential  
points   of   water   management.     In   many   countries   water   has   become   a   scarce  
commodity   and   the   costs   for   theconsumption   and   discharge   of   water   increase  
regularly.   Water   has   to   be   managedproperly   and   several   options   are   available   to  
minimise  the  overall  consumption  ofwater.  
 
Treatment   ofthe   large   volumes   of   effluents   and   their   subsequent   dischargeinto  
sewers,   rivers   etc.   are   only   a   short-­‐term   solution,which   adds   to   compounded  
problems  of  investmentand  recurring  expenditure.    

B  Sc  Chemical  Engineering  (Leather)   26     Leather  Technology  I  

  
Water  conservation  
Water   conservation   has   important   secondary   benefits,   in   addition   to   reducing  
demand  on  the  water  supply.    The  benefits  of  water  conservations  are    
! Smaller  sized  plants  (especially  treatment  plants)  
! Reduced  consumption  of  chemicals  
! Lower  operating  costs  and  energy  costs  
 
Technologicaloptions  to  reduce  the  usage  of  water  and  to  increase  itsreuse  are  to  be  
considered  for  evolving  long-­‐term  solutionsfor  the  leather  industry.  
 
A  decrease  in  water  consumption  is  mainly  achieved  as  follows:    
! Reduction  
! Recycling  
! Reuse  
 
Reducing:  
! The   first   step   is   reduction   of   water   consumption,   with   strict   measurement  
and  control  of  consumption.    
! Short  float  processing,  batch-­‐wise  washing  instead  of  rinsing  and  combining  
processes  can  reduce  water  consumption  by  30%  and  more.  ·∙    
 
Recycling:    
! Recycling  typically  means  a  second  utilisation  for  the  same  purpose.  
! Certain  specific  processes  are  suitable  for  recycling  of  floats,  although  inmost  
cases   installations   for   treatment   are   necessary.   Examples   are;soaking,   liming,  
unhairing,  pickling  and  chrome  tanning  liquors,  which  canreduce  the  overall  
water  consumption  by  20-­‐40%.  
! Soaking,  liming,  unhairing,  pickling  and  chrome  tanning  liquors  are  examples  
of   floats   suitable   for   recycling,   although   in   most   cases   pretreatment  
equipment  has  to  be  installed.  Overall  water  consumption  can  be  reduced  by  
30  -­‐  50%.  ·∙    

B  Sc  Chemical  Engineering  (Leather)   27     Leather  Technology  I  

  
Reusing:  
! Reuse  may  meanutilization  for  different  purposes  and  recovery  incorporates  
an  isolation  step.  
! Biologically   treated   effluent   offers   the   opportunity   of   replacing   a  
certainamount  of  the  process  floats,  such  as  the  beam  house  process  floats,  
withtreated  water.    
! Membrane   systems   provide   the   possibility   of   reusing   treated  
effluents,provided   that   most   of   the   residual   organic   matter   is   removed   and  
disposalof  the  concentrate  is  achievable.  
! Up  to  60%  of  the  beamhouse  and  tanning  process  floats  can  be  replaced  by  
treated  effluent.  
 
   

B  Sc  Chemical  Engineering  (Leather)   28     Leather  Technology  I  

Questions  
7. What  are  the  environmental  impacts  of  leather  industry  wastes  on  surface  
waters?  
8.  Which  are  unit  operations/processes  generated  high  saline  wastewater?  
Write  any  two  operations  and  explain  why?        
9. What  is  the  approximate  range  of  following  parameters  in  composite  
wastewater?  
a. BOD  
b. COD  
c. pH  
d. TDS  
10. What  are  the  steps  involved  in  treatment  of  tannery  effluents?  
11. What  is  the  purpose  of  primary  treatment?  
12. What  is  coagulation?  Write  any  two  names  of  coagulating  agents?  
13. Define  “cleaner  process  Technology”?  
14. What  is  the  cleaner  production?  
15. What  is  the  principle  of  cleaner  process  technology?  
16. Write  the  cleaner  process  options  for  liming  operation?  
17. Write  the  cleaner  process  options  for  deliming  and  pickling  operation?  
18. What  are  the  possible  cleaner  technology  options  for  beam  house  and  
tanning  operations?                 (5  Marks)  
19. What  are  the  solid  waste  generated  during  leather  processes?    
20. Write  a  utilization  methods  for  green  fleshings  and  limed  fleshings.  
21. What  are  the  environmental  impacts  of  tannery  solid  wastes.     (5  Marks)  
22. Write  the  name  possible  utilization  methods  for  following  solid  wastes    
a. Dusted  salt  
b. Green  Fleshing  
c. Limed  fleshing    
d. Chrome  Tan  and  Vegetable  Tan  Shavings       (5  Marks)  
23. What  are  the  benefits  of  water  conservation  in  leather  processing?  
24. Describe  the  possible  approaches/methods  to  minimize  the  water  usage  in  
leather  processing                 (5  marks)    

B  Sc  Chemical  Engineering  (Leather)   29     Leather  Technology  I