Bulk Industrial Waste Utilization - PowerPoint Presentation

Slide1

Bulk Industrial Waste Utilization

By

Dr.

Navin

Chandra

Chairman, State Expert Appraisal Committee II (SEAC)

EIA (Mining), M.P. Pollution Control Board,

Retired Director, CSIR-AMPRI (Bhopal) &

Ex Vice-Chancellor, SSSUTMS,

Sehore

Slide2

Waste - Definition

European Union Under the

Waste Framework Directive

, the

European Union

defines waste

as

"an object the holder discards, intends to discard or is required to

discard”.

Basel

Convention

,

'Wastes

' are substance or objects, which are disposed

off

or are intended to be disposed

off

or are required to be disposed of by the provisions of national law"

Waste is a material which is no more useful or Required after completion of a process.

United

Nations Statistics Division,

Glossary of Environment

Statistics

"Wastes

are materials that are not prime products (that is products produced for the market) for which the initial user has no further use

in terms of his/her own purposes

of production, transformation or consumption, and of which he/she wants to dispose.

*Wastes

may be generated during the extraction of raw materials,

the

processing of raw materials into

intermediate and

final

products

, the

consumption

of final products, and other human

activities.

*Residuals

recycled or reused at the place of generation are

excluded."

Slide3

Categories of Wastes

Based on Generation : Industrial Wastes, Municipal waste, Medical wastes, Agricultural Wastes, Construction activity wastes etc.

Based on Physical Condition : Solid Wastes, Liquid Effluents, Gas (e.g., Chlorine in

Chlor

-alkali industry), steam etc.

Based on nature of Waste: Bio-Organic Wastes, Inorganic Wastes, Hazardous Wastes (combustibles like solvents, explosives, corrosives, heavy metal bearing

wastes, Radio-active wastes) etc.

Slide4

Utilization of waste

The generator of waste wants to discard a waste does not necessarily mean that the material is useless. Possibilities are that its utilization may not be in his core area of business or scale of operation etc. etc.

The possibility of utilization of a ‘waste’ depends on following characteristics:

Chemical composition of the waste

Mineralogical content

Presence of any valuable trace material

Presence of any Bio-resource

Hazardous nature (if any) – radio activity, combustibility, pH, high reactivity

Impurities and their likely effect on proposed product

Volume of waste and availability/transportation etc.

Availability of suitable technology for its utilization

Economic considerations/profitability

Slide5

A Random List of Inorganic Wastes

Fly Ash

Red mud

Spent Catalysts – Metal oxides, Manganese

oxide

Marble

dust and other inorganic powder wastes

Metal Extraction/Processing/Etching Wastes

Jerosite

cake/Gypsum

Mineral tailings/

Kimberlite

/Mine over burden

Construction Industry Wastes

Electronic Wastes

Slide6

Fly Ash – Waste of Thermal Power Plants

Current Indian Generation > 120 million tons/year

Current utilization ~ 67%

Unutilized is disposed off in fly-ash ponds as slurry

Physical categorization :

Ceno

-spheres, Coarse fly ash and fine fly ash, high/low carbon fly ashes.

Calcium rich/poor fly ashes

Processed and classified fly ashes

Slide7

Fly-Ash and Ceno

-sphere

Slide8

Chemical Composition of Fly Ash

Component

Bituminous

Subbituminous

Lignite

62.12 (38-63) SiO

2

20-60

40-60

15-45

21.3 (27-44) Al

2

O

3

5-35

20-30

10-25

5.55 (3.3 – 6.4) Fe

2

O

310-40 4-104-150.53 (0.2 – 8) CaO1-12 5-3015-401.58 (0.01 – 0,5 ) MgO0-5 1-63-10(0.4 – 1.8) TiO2SO2 = 0.4-1.8SO2 = 0-2SO2 = 0-100.12 (0.07 – 0.43) Na2O0-4 0-20-64.24 (0.04 – 0.9) K2O0-3 0-40-43.30 LOI0-15 0-30-5

Chemical

composition

range for

fly ash produced from different coal

types

Slide9

Mineralogical and Physical Properties of Fly - ash

The main phases encountered are

glass phase,

together with

quartz

,

mullite

and the iron oxides

hematite

,

magnetite

.

C

ristobalite, anhydrite,

free lime, periclase, calcite, sylvite

, portlandite, rutile and anatase. The Ca-bearing minerals anorthite, gehlenite,

akermanite

and various calcium silicates and calcium aluminates identical to those found in

Portland cement can be identified in Ca-rich fly ashes.Bulk density : 0.9 to 1.3 g/cm3 ; Specific gravity : 1.6 to 2.6Water holding capacity : 40-60%; pH = 6.0 to 8.5 Surface area: 500 – 5000 m2/kg ; Cohesion - Negligible

Slide10

Properties of Ceno

-spheres

Thermal stability * Resistance to acids * High strength

Presence of internal cavities and porosity

.

Physical, Chemical and Mineralogical Properties

Density : 0.19 to 0.4 g/cm3

Diameter : ~ 100 to 180 microns

Wall thickness :

(

3.1 to 7.6 microns)

50–65

wt

%

SiO2, 20–36

wt % Al2O3, and 2–10

wt % Fe2O3 The glass-crystalline shell of cenos-pheres is a multiphase system

consisting of the glass phase (50–90 wt %) and the crystalline phases of mullite, quartz, cristobalite, calcite, potassium feldspar, hematite, and magnetite.

Slide11

Applications of Ceno

-spheres

In light weight ceramic/refractory components

Metal coated particles for electrical use

Fast flowing materials in concretes

Filler in light weight Rubber/Polymer/metal composites

Adsorbents for recovery of rare earths

Adsorbents for disposal of toxic and radioactive wastes

Slide12

Current Utilization of Fly ash

Added Component in Cement

Fillers for under ground mines

Fine aggregate in construction/road making

Brick/Block making

Dykes/Embankments

Abrasives

Fillers in composites

Ceramic Uses – Tiles, Frit/Glaze

Slide13

New Fly ash utilizations – (i) Geo-polymer

Cement Free Concrete from

FlyAsh

(Geo-polymers)

Road making, Prefabricated building components,

foamed panels for partitions/insulation Structures,

Gradient Stabilizers,

Reclaimation

of lands

90% Fly Ash + 10% Chemicals (High fly ash utilization)

Cement Replacement : 1 ton Cement ~ 1 Ton CO2

No adverse effect of chloride ions

Water Curing Not required

Coastal areas – Sea sand and sea water may be used

20 MPa to 40 MPa. Target = 100 Mpa

Slide14

Novel Patented* Concept of CSIR-AMPRI, Bhopal for Advanced

Ligno

-

Silico

-Aluminous (LSA) Materials (* India (2301 DEL 2012) and USA (13 / 949585) .

Conventional

Tetrahedral silicon complexes

Novel

Penta

coordinated silicon complexes

CH

2

O

CH

2

O

Si

OCH

2

OCH

2

14

CH

2

O

CH

2

O

Si

OCH

2

OCH

2

OCH

2

CH

2

O

M

+

-----n

-OH moieties of organic precursors

Conventional Geopolymeric Material

Advanced LSA Material

Advanced LSA Material enables improved Engineering Properties

e.g. workability, compressive strength etc.

Know-How transferred to M/s JSPL, Raigarh and

demonstration

completed successfully.

Versus

Slide15

Geo-polymer based structure and Road

Compressive Strength

30-45

Mpa

(60Mpa)

Flexural Strength

3- 4.5

Mpa

(5MpA)

Density

2200-2400 Kg/ m

3

2500 Kg/m

3

The developed binder (90% fly ash) replaces the conventional cement

Slide16

Photograph of Know-How Transfer to M/s JSPL Raigarh on 11

th

May 2013 for Making Cement Free Green Concrete

Slide17

Fly Ash based Frit/Glaze

Slide18

New Fly ash Utilization : Composites and in agriculture

Wood Substitute - Furniture

Partition panels/Doors

Lower weight sandwich panels/doors

Soil modifier in Agriculture

Improves water retention

Reported to provide micronutrients

Improves crop yield

Slide19

Industrial Waste Utilization

– Red Mud

Red Mud Generation – 5.5 Million Tons per year

High Temperature solid state reaction along with additives

generates phases for radiation shielding from X-rays and

Gamma Rays

(BRNS program, testing at BARC and certified by AERB}.

Red Mud – Fly Ash Combination

Pavement Blocks developed and tested for several years;

Bricks/Prefab under development

Red Mud-Fly ash – Polymer Composite door panels developed

Slide20

Red Mud Utilization

Chemical composition of red mud

Weight percentage

Density (gm/cm

3

)

Haemitite (Fe

2

O

3

)

35-40%

5.255

Rutile (TiO

2

)

20-24%

4.25

Alumina (Al

2

O3)19-25%3.69Silica (SiO2)6-8%

2.30

Alkali

8-10%

2.27

S.No

.

Properties

Conventional materials

AMPRI Developed * materials

1.

Composition

Simple physical mixture of Haemitite and cement.

Chemically formulated multi phase and multi elemental material using barium compound

2.

Shielding phases

Haemitite, Calcium aluminum silicate (Cement)

Barium iron

titanate

, Iron

titanate

silicate etc.

3.

Density (gm/cm

3

)

3.20 – 3.50

3.7 – 4.2

4.

Shielding thickness (cm)

7.0

3.06 (Shielding thickness reduced by 60%)

5.

Mechanical properties

Meets ASTM-C-637-98a(2003)

Meets ASTM-C-637-98a(2003)

Slide21

X-ray and

-ray shielding materials from Red Mud

 

Slide22

Pavement Blocks from Red mud-fly ash

Properties

Paver Blocks of

CSIR-AMPRI*

Conventional Paver blocks

Compressive

strength (kg/cm

2

)

280-310

250-270

Percentage

Water absorption

7-10

9-12

Block density

kg/m

3

2100-2500

1900-2200 Abrasion Resistance, (mm) 2-3 4-5 Pavers Blocks thickness (mm) 48-50 48-50 Physico-mechanical properties (BSI British Standards-BS EN-1338 & IS 2185)

Slide23

23

Room temperature processing

High strength to weight ratio

Termite & corrosion resistant

Self extinguishing

Versatile applications

Maintenance free green composite

Cost effective

Utilisation

of industrial wastes

Reduces Deforestation

Reduction in environmental pollution

SALIENT FEATURES of polymer

based composites

Process

Products

Environmental

Benefits

Slide24

WOOD SUBSTITUTE

Partition

Tiles

Furniture

Doors

Panels

Construction industries (Versatile materials)

POTENTIAL APPLICATIONS:

Slide25

Spent Catalyst Wastes

(a) manganese oxide & (b) Nickel based catalysts

(a) Manganese Oxide Based Catalysts

# Manganese is a multivalent

cation

with

MnO

,

MnO2, Mn2O3 and M3O4 oxides

#

Leachability

in acid depends on

Mn

oxidation state,

Acid concentration and temperature of leaching# Carbothermal treatment to enhance leachability

Reduction with coal leads to high solid waste volm.# Liquid reducer (LDO) improves leachability with minimized solid waste generation

Slide26

Parameters for leaching of

carbothermal

treatment & leaching of manganese resources

Carbothermal

Treatment

LDO in the mix : 20%

Temperature : > 160 C; exothermic

Time : 45 -60 Min.

Leaching

Sulphuric Acid

Concn

. : 20%

Leaching Temperature : ~ 85 C

Leaching Time : 120 Min.

Recovery of available Manganese values : >85%

Slide27

Applications of leached manganese values

MnSO4 as micronutrient in agriculture

Chemical and

electrochem

. MnO2 for battery

Additive in electrolytic bath for zinc metal extraction

Pigment in ceramic glazes

In smoked glasses

Preparation of

MnOOH

/

Mn

(OH)2/Manganese

Oxide for (Re)use

as

catalyst .

Slide28

(b) Nickel based catalysts

These catalysts are generally supported on porous ceramic substrates

After crushing, nickel is dissolved in

HCl

/H2SO4

P

igments for ceramic glazes/smoke glasses by preparing nickel chromate/nickel

titanate

or oxides

SEM of Nickel chromate SEM of Nickel

titanate

Slide29

Achievements

Other Prominent wards

*

ICSU/UNESCO

Distinguished Scientist

Award (one of the three awardees world wide (1984)

NRDC

Award

for Development of Ion Selective Electrodes for

pollution

Monitoring (1985)

DAAD Fellowship 2001 by DAAD (Germany)

Ramachar

Award by Electrochemical Society of India

Slide30

Thank You