Small Scale Industries and its Pollution Potential

1
Small Scale Industries and its Pollution Potential

• Nivit Kumar Yadav
• Centre for Science and Environment

2
Small Scale Industries

• Hand Tools
• Locks
• Scientific Instruments
• Diesel Engines and Parts
• Textile Industries
• Pharmaceuticals
• Edible oil and vanaspati
• Soaps and Detergents
• Paper and Board mills
• Safety matches
• Stainless Steel Utensils
• Wax Candles
• Fire Works
• Domestic Utensils - Aluminium

3
Small Scale Industries

• Definition
• An industrial undertaking in which the
  investment in fixed assets in plant and machinery
  whether held on ownership terms on lease or on
  hire purchase does not exceed Rs 10 million.

4
Spread across the country
5
Why SSIs?

• Strong Case The sector employs 17 million people
  and is the second largest employer of India's
  workforce after agriculture.
• Value addition to economy SSIs accounts for 95
  of all industrial units in the country and 40 of
  total output.
• Decentralised industrial development

6
Energy Inefficient

• High energy consumption The total energy
  consumed in the SSIs is in the order of about
  8000 MW.
• Less efficient in process Old technology
  (foundry industry in Howrah is four decade old),
  lack of finance, lack of technical knowledge

7
Energy Inefficient

• Glass Industry Cluster at Firozabad

8
Energy Intensive High potential for
saving

• High potential for saving SSIs offer an annual
  energy saving potential of about 1000 MW which is
  equivalent to Rs. 28000 Million.
• Opportunity
• 5 - 10 energy saving is possible simply by
  better housekeeping measures.
• 10-15 is possible with small investments like
  low cost retrofits, use of energy efficient
  devices and controls etc.
• Quantum of saving is much higher if high cost
  measures like major retrofit, process
  modifications etc. are considered.

9
Water pollution from SSIs in India
10
River Pollution

• River Bhadar, Gujarat1,200 sari dyeing and
  printing units in Jetpur When public protests
  proved ineffective, the people of downstream town
  Dhoraji filed a PIL After 14 years, the Gujarat
  High court ordered closure of Jetpur units till
  effluent treatment plants were installed. But
  still little has happened.
• Rivers Bhavani and Noyyal, Tamil Nadu
• 800-odd dyeing and bleaching units in
  Tirupur Water stored in the Orathapalayam dam on
  the Noyyal downstream of Tirupur was expected to
  irrigate 5 per cent of the land in the Noyyal
  basin but it is now so poor that the farmers have
  filed a public interest litigation (PIL) against
  pollution from Tirupur
• River Yamuna, Delhi
• 350 million litres of wastewater is
  released everyday in River Yamuna by small scale
  industries in Delhi. However according to
  Pollution Control members, 40 million litres per
  day is treated.

11

• Case study
• Sponge Iron Industry

12
Sponge Iron Industry

• Major success story in the Indian industrial
  sector
• Till 1990s, only 3 plants
• By 2000-01, there were 22 plants with capacity of
  6.97 million tonnes
• Today, there are 206 sponge iron plants with
  production capacity of 19 million tonnes
• Industry Great!!!
• Environmentalist Dangerous for environment

13
Sponge Iron Industry
Sponge Iron Industry Map of India
14
Sponge Iron Industry

• Technology Where the problem lies!
• Coal based or Gas based
• Coal based process is highly polluting whereas
  gas based is cleaner process
• About 80 percent of coal based sponge iron
  manufactured in the world comes form India and
  about 60 of this production comes from small
  scale industry.

15
Sponge Iron Industry Coal based process
16
Sponge Iron Industry

• Input-Output
• For a tonne of sponge iron, input is
• 1.6-1.75 tonnes of iron ore
• 1.2-1.5 tonnes of coal
• 0.035-0.05 tonnes of dolomite
• 1.5-2.0 tonnes of water
• Output
• 1.8-2.0 tonnes of carbon dioxide
• 0.25 tonnes of dust
• 0.29 tonnes of coal char
• 0.02 tonnes of sulphur, water vapour

17
Sponge Iron Industry Cluster of Industry and
Air Pollution

• The air is laden with smoke,
• The movements of trucks is high,
• The plants are located adjacent to or right in
  the middle of a village or villages,
• The houses in these villages roofs and walls -
  are covered with dust, the leaves and forests in
  the vicinity are black and not green in colour,
• Layers of soot accumulate on the skin, the eyes
  experience a burning sensation if long hours are
• spent in the area,
• Dumps of char and iron ore scrap lie along the
  roadside

18
Sponge Iron Industry Air Emission-Why?

• Most of the sponge iron units either did not
  install ESPs, mandatory to control hazardous
  emissions or do not run it to save money.
• 1-2 tonnes of dust, if they are equipped with
  required pollution control equipment, otherwise
  dust emissions can be as high as 10 tonnes per
  day.

19
Sponge Iron Industry Environmental Issues
20
Sponge Iron Industry Environmental Issues
21
Sponge Iron Industry Environmental Issues

• Suspended particulate matter contains cadmium,
  nickel, hexavalent chromium (most dangerous
  through air and water), arsenic, manganese, and
  copper which are considered fatal even in small
  doses.
• Height of stackThese carcinogenic wastes are
  emitted from the stacks or the chimneys in the
  plant. Lower the height of the stack, the more
  the probability of the emissions settling in and
  around areas closer to the factory.

22
Sponge Iron Industry Environmental Issues

• Water Pollution
• Many a time the solid waste (flyash, char, iron
  scrap) is dug into the ground, polluting ground
  water. The direct disposal of industrial
  effluents and coal washeries into rivers and
  streams is a common phenomenon.
• The other method that is used for disposal is
  building of waste water ponds in the factory
  campus. This stored toxic water then seeps
• into the ground contaminating
• the ground water.
• Even a large company like
• Jindal Steel and Power Ltd dumps
• fly ash in the nearby school ground,
• riversides and in forest areas
• and roadsides.

23
Sponge Iron Industry Health Impact

• Damage to the nervous system especially among
  children due to exposure to lead and mercury
• Danger of kidney ingestion due to mercury
• Skin irritation and various other skin diseases
• Impact on womens health and reproductive system

24
Sponge Iron Industry Environmental Issues

• On health of livestock - It is not just human
  health that is affected by the pollution
  domestic animals, especially livestock such as
  cattle are also affected.
• The crop residue and grasses that the cattle feed
  on, the air that they breathe and the water they
  drink adversely affects their health.
• Their milk and meat is contaminated with toxins,
  which in turn affects the human beings who
  consume them.
• The death of these cattle is very painful
  because of the pollution from the sponge iron
  industries. Other domestic animals like dogs have
  also been affected by the pollution, say the
  villagers of Kormunda in Sundergarh, Orissa.

25
Sponge Iron Industry Environmental Issues

• Agriculture and crop production - Villages on the
  periphery of SIIs have their agricultural lands
  rendered almost unproductive with the increasing
  accumulation of dust and air emissions on the
  soil.
• The quality of the produce has also been
  affected.
• While cooking the rice we can see the amount of
  dust in the grain as it collects in the vessel,
  say women in villages of Raigarh. The crops and
  fruits are damaged and yields reduced.

26
Sponge Iron Industry Role of Politicians

• It is the state governments who are today really
  providing a facilitative and pressure free
  environment for the sponge iron industries,
  offering them every subsidy and incentive
  available.
• The newly formed states of Chhattisgarh and
  Jharkhand have evolved their industrial, water
  and power policies at the dictates of
  industrialists.
• Jharkhand - The maximum number of SIIs mushroomed
  in Saraikela, which was the constituency of the
  former chief minister Arjun Singh Munda.
• In the Giridih district of the state, SIIs are
  owned by local politicians.

27

• Case study
• Textiles Mill in Pali and Tiruppur

28
Textile mill Process

• The Textile industries are very complex in nature
  as far as varieties of products, process and raw
  materials are concerned.
• Brief process
• From raw cotton, yarn is produced.
• Weaving and knitting process to produce the
  cloth.
• Bleaching and dyeing operation. Bleaching is a
  chemical process that removes unwanted colored
  matter from cloth. During the dyeing operation
  color is added to increase product value.
• Printing and finishing operation.

29
Dyeing Operation

• Dyeing operation A number of dyes chemicals and
  auxiliary chemicals are used to impart desired
  quality in the fabrics.
• Wastewater Highly alkaline in nature and
  contains high concentration COD and TDS.
• It can cause environmental problems unless it is
  properly treated before disposal.

30
Air Pollution

• Air Pollution Processing of fibres prior to and
  during spinning and weaving generates dust, lint
  etc. which degrades working environment in the
  industry.
• Health Problem Dust may cause respiratory
  diseases in workers. A chronic lung disease is
  commonly observed among workers exposed to
  cotton, flax and hemp dust

31
Water intensive

• Water requirement by textile sector
• Small and medium unit consumes - Average 175
  liters of water for dying one kg of cloth
• Large unit 120 lit/ kg of cloth

32
Textile Sector Water intensive

• Water requirement for different purposes

33
Wastewater Generation
34
Textile Mill in Pali

• Pali is an important district of Rajasthan,
  having a population of 18,19, 201 people. It
• It is situated on the banks of river Bandi.
• Problematic Point There are around 989 dyeing
  and printing units, most of which discharge their
  untreated textile effluents, directly into river
  Bandi.

35
Textile Mill in Pali

• According to the Rajasthan State Pollution
  Control Board (RSPCB), these units discharge
  approximately 34 million litres per day (mld)
  today.
• Since 1983, three common effluent treatment
  plants (CETPs) with a capacity to treat 22.5 mld
  of industrial effluent have been installed at the
  cost of Rs 8.13 crore.
•  

36
Textile Mill in Pali

• Where is the Problem? - Currently less than 45
  per cent of the generated effluents are treated
  before disposal into the river.

37
Textile Mill in Pali

• Industries are not connected to the treatment
  plants
• Weak regulatory framework Currently, there is no
  system to connect the unregulated industries to
  the common effluent treatment plant.
• According to RSPCB, 193 textile mills are not
  functional as on date and 151 industrial units
  are not connected to CETPs. These industries
  discharge the waste to the drains and to the
  river.

38
Textile Mill in Pali

• Poor Efficiency Even if all the waste is
  conveyed to the treatment plant, the efficiency
  of treatment is very poor.
• Only CETP I working Analysis of the data
  provided by CETP officials shows that the BOD,
  COD and TSS values of the CETP II and CETP III
  are much higher than the norms set by the RSPCB.

39
Textile Mill in Pali

• High BOD BOD values were in the range of 80-110
  mg/l in CETP II and 40-110 mg/l in CETP III as
  against the norm of 30mg/l.
• High COD COD values were in the range of 420-480
  mg/l in CETP II and 270-450 mg/l in CETP III as
  against the norm of 250mg/l.

40
Textile Mill in Tiruppur

• Tiruppur A textile hub
• In 1981 Only 26 bleaching and dyeing units in
  Tiruppur.
• In 1991 - increased to 324
• In 2001 number increased to 702
• Most of the units are located on the sides of
  Noyyal river - Convenient to discharge the
  effluent.

41
Textile mill in Tiruppur

• Water consumption by the processing units has
  also increased over time from 4.4 (mld) in 1980
  to 40.8 mld in 1990 and to 86 mld in 2000

42
Textile mill in Tiruppur

• High TDS (3000 to 11000 mg/lit) in - Open wells
  and bore wells in and around Tiruppur and the
  downstream stretch of Noyyal river
• High level of chloride (gt 2000 mg/l in certain
  areas up to 5000 mg/l) due to industrial
  pollution (Standard is 1000 mg/l)

43
Textile mill in Tiruppur

• High concentration of heavy metals in ground
  water - including zinc, chromium, copper, and
  cadmium.
• Available ground water is not suitable for
  domestic, industrial or irrigation use.
• Noyyal river Down stream of river highly
  polluted and not fit for aquatic organisms

44
Textile mill in Tiruppur Drinking water problem

• Due to surface ground water pollution -
  Municipality is bringing 32 mld of water from the
  neighbouring (Bhavani) basin for drinking water
  supply.
• More than 90 per cent water brought through
  tankers from peripheral villages located 25 - 30
  km away from Tiruppur.
• Tiruppur textiles Spend Rs. 89.10 crore on
  water purchasing.

45
Textile mill in Tiruppur
46

• Case study
• Small Scale Mining

47
Small Scale Mining

• Definition Mine area, production, level of
  mechanization, number of people employed or
  capital investment.
• Pakistan and United States Small scale mines are
  defined in terms of employment which is mines
  with less than 50 workers in Pakistan and less
  than 20 in United States.
• Capital investment is another criterion for
  small-scale mining, varying from specified limits
  such as 2.5 million in Argentina, R8 million in
  South Africa, 1 million in Thailand, 30,000 in
  Zimbabwe

48
Small Scale Mining

• India specific definition Small-scale mines are
  those where investment may not exceed Rs.6
  million and if beneficiation/processing plants
  are installed the investment may not exceed Rs.10
  million.
• National Institute of Small Mines (NISM) has
  adopted a different parameter for SSM, which is
  all mines producing upto 0.1 million tonne per
  annum for small.

49
Small Scale Mining

• Common practice in all countries It is estimated
  that it contributes as much as 1520 per cent of
  the global value of non-fuel mineral production.
• Indian mining industry also operates a number of
  small mines spread throughout the country.

50
Small Scale MiningNo Data

• No Data SSM does not fall under the purview of
  the IBM, so there is no official data on number
  of SSM in India.
• The minor minerals fall under the jurisdiction of
  respective state government, which has a poor
  track record in maintaining statistics.

51
Small Scale Mining

• Other than fuel minerals which is reserved for
  public sector, small-scale mines dominate Indian
  mining industry

52
Small Scale MiningAdvantages

• High employment potential (Worldwide, it is
  estimated that about 13 million people are
  directly engaged in small-scale mining.)
• According to a report, the total employment
  generated by SSM in the country is about 0.5
  million.
• Provides a source of employment in all seasons
• Extract mineral present in small quantity and in
  remote areas

53
Small Scale Mining Disadvantages

• Unrecognised sector The sector contributes a
  significant 10 per cent to the total mineral
  value produced in the country.
• The sector is recognised by low salary, poor
  working condition, no consideration of health and
  safety, out-dated technology, higher cost of
  production, poor quality.

54
Small Scale Mining Poor environmental
performance

• Profit making No initiative for mineral
  conservation, environmental protection
• Destroy vegetation and ecology (small-scale
  mining of limestone in the Mussoorie Hills
  resulted in widespread degradation of the
  Himalayan environment)
• No monitoring no initiative to meet environmental
  standard
• No safety (According to the ILO, the annual
  fatality rate in the small-scale mines in the
  country ranges around 15-50 per year)

55
Small Scale Mining

• Women Worst sufferers
• Of the 13 million or so miners engaged in the
  world, approximately 30 per cent are women.
• Approximately 6-7 per cent (20,400) of miners in
  India are women.
• Poor working condition for women
• Lower salary then men
• No benefit such as paid holidays or maternity
  leave
• No access to safety equipment
• Exploitation by mine owner
• Due to constant exposure to dust, noise and poor
  water quality, they also suffer from occupational
  hazards such as respiratory problems, silicosis,
  tuberculosis, arthritis, poor vision and deafness
  

56
Small Scale Mining

• Should there be ban on small scale mining?
• Logical as unchecked operations of small-scale
  mining has destroyed environment and it is often
  hard to monitor, manage and prevent pollution
  from these small mines.
• Devise mechanism It is an important source of
  income for millions of people and efforts should
  be made to integrate them into main stream and
  devise mechanism for controlling them better.
• Need proper monitoring by government agencies,
  IBM, State Pollution Control Board, activist and
  NGOs.