By Dr Navin Chandra Chairman State Expert Appraisal Committee II SEAC EIA Mining MP Pollution Control Board Retired Director CSIRAMPRI Bhopal amp Ex ViceChancellor SSSUTMS ID: 805622
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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
Slide2Waste - 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."
Slide3Categories 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.
Slide4Utilization 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
Slide5A 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
Slide6Fly 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
Slide7Fly-Ash and Ceno
-sphere
Slide8Chemical 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
Slide9Mineralogical 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
Slide10Properties 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.
Slide11Applications 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
Slide12Current 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
Slide13New 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
Slide14Novel 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
Slide15Geo-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
Slide16Photograph of Know-How Transfer to M/s JSPL Raigarh on 11
th
May 2013 for Making Cement Free Green Concrete
Slide17Fly Ash based Frit/Glaze
Slide18New 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
Slide19Industrial 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
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)
Slide21X-ray and
-ray shielding materials from Red Mud
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)
Slide2323
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
Slide24WOOD SUBSTITUTE
Partition
Tiles
Furniture
Doors
Panels
Construction industries (Versatile materials)
POTENTIAL APPLICATIONS:
Slide25Spent 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
Slide26Parameters 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%
Slide27Applications 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
Slide29Achievements
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
Slide30Thank You