Welcome & Greetings

ECOMARK

Indian Institute of Science Banglore

28 March 2006
 2006

Leather & Leather Products

1975
Leather & Leather Products business

) Established In 1975

¾ Largest Tannery In India

Genesis ¾ Among The Top three Goat tanneries in the World

) Leader in leather exports from India since 1982

) Pioneers
i in
i leather industry
i in
i India
i and in
i the region
i
¾ Exploring new markets
¾ New Product development
Profile ¾ Setting quality standards
) Value proposition for sustainable customer relationship
) Recognized for R&D capabilities
) Responsible corporate citizen
Export Performance- Number one Position in
Overall Exports India.

Export Performance- Number one Position in

Finished Leather India.

Export Performance- Number one Position in

Footwear Components India.

Export Performance- Number two Position in

Leather Garments India.

ISO 14001 Certificate

for Environment First in India.
Management System
 Leather– Global Business of TATA Group
• One of the few global businesses of the group with 85% of
turnover from international markets
– Global Markets – Exporting products to over 35
countries across the globe
– Global Sourcingg – RM from Middle East,, Far East,,
Bangladesh, Africa, CIS etc.
– Global Supply
pp y Chain – India ((Dewas,, Chennai,, Kolkata,,
Kanpur), China, Bangladesh, Italy.
– World-class Technology – Chemicals / Waste recycling /
Advanced Machines.
– Global Alliances – Graziella & Missardi of Italy; Lloyd /
Ara of Germany; Getever & Lianyon of China.
 Leather GBU’s Partners with Global Brands
Finished Leather L th Garments
Leather G t F t
Footwear

• Peter Kaiser • Gabor

• Mango
• Aerosole • Marks & Spencer
• Zara
• Ara
A • Florsheim
Fl h i
• Pierre Cardin
• Naturalizer • Ara / Lloyd
• Gabor • Escada
• Ambiorix
• Betty Barclay
• Grenson
• Hush Puppies
How Environment friendly is our leather ?
R&D capabilities Environmental Care

Liquid Waste Management

• ETP to meet all the norms through physiochemical and
microbiological treatment

Environment • “Reverse Osmosis” to optimize the recycling of liquid waste

Excellence
Awards Solid Waste Management
• The world’s first plant to use bio methanation technology for solid
waste treatment based on in-house
in house patented technolog -
UNDP/TIL/MNES sponsored project
• Developed process for specialty leathers like Zero Chrome (Minerals
free)
ISO 14000 •Most Environmental Friendly way of disposal/recycling of Waste
Certification from
RWTUV,Germany Ecolabelling –
First Leather company in India recommended for Eco Labelling
TOWARDS SUSTAINABLE LEATHER INDUSTRY

Two Lacs Trees Planted all Around the Complex

Energy
e gy Saving
Sav g
- Large Solar array (~700 nos.) for heating Boiler feed water.
Capacit 50M3 per day
- Capacity da to 80oC.
C
- Specific Power consumption reduction in leather processing
- Biogas from leather waste.
Ground and Roof Water Harvesting
 Pollutants Generated:

SOLID WASTE : SHAVING DUST FROM WET BLUE AND TRIMMINGS

LIQUID WASTE : EXHAUST LIQUORS FROM DRUMS OF DYE HOUSE

AIR POLLUTION : VAPOURS FROM SPRAY BOOTHS

How Environment friendly is our leather ?
Environment Care

Pole View of Effluent Treatment Plant

POLLUTION TREATMENT MEASURES TAKEN:

Water Recycling
- Reverse Osmosis Plant on Treated Effluent Recycling.
- RO plant capacity ~ 200 M3 per day.
- Ground and Roof water harvesting.
LEATHER SOLID WASTE CONTAINING CHROMIUM
 Hazardous Waste Recycling :

- Recycling
i Capacity
C i off 700
00 tons per annum off Chromium
C i
containing leather waste.
- Bio-gas
Bio gas from Chromium
Chromi m containing leather waste
aste project
50% sponsored by MNES/UNDP
- Methane gas production 250M3 per day
- Chromium Recovery and recycling, 12 tons per annum as
Chromium Sulphate.
- Two Patents on “Hazardous Waste Recycling”
 Industry Leadership & Accolades
ECO MARK for
2005 FINISHED LEATHER
ECOMARK TERI Corporate Environment
2005
Winner of the CLE’s
Award – Across Industries
Best Exporter MP State Award for Best practices in
2005 Award In Leather
from Environment protection
1984 to 2004 ISO 9001 Certification for Chennai Supply
2004
Chain operations

2003 Rajiv Gandhi Award for Environment Protection –

B t off All
Best All, only
l leather
l th company in
i India
I di

2002 ISO 14001 certification – 1st in India

2000 Rajiv Gandhi

G National Quality
Q Award
– Best of All, only leather company in India
ISO 9000 certification for Leather Garments and Footwear
1998
- 1st in India
1995 ISO 9000 certification - 1st tannery in India
 How Environment friendly is our leather ?

• Eco friendly leather :

In house eco friendly leather manufacturing process has been

developed which is chrome free.

• Bio-Methanation plant :

Implemented in house developed patented technology for gainful

utilization
ili i off solid
lid waste. At
A present the
h gas generation
i isi around
d
250 m3/day.

• Eco labeling of finished leather:

Eco labeling of our finished leather has been Awarded by
Bureau of Indian Standards (BIS).
Implemented to make our leather free from banned items
like PCP, formaldehyde, Azo dyes to meet the eco criteria.
 How Environment friendly is our leather ?

ETP Treatment by new process:

A new process has been developed at pilot level for reducing

chemical , manpower & energy cost as well as sludge reduction.

Substitution by cheaper chemicals:

Expensive & hazardous chemicals have been replaced with cheaper
& environment friendly chemicals.
Chemicals from Waste Recycling

Up gradation of technology:

Adopted Reverse Osmosis technology for further improving the

effluent treated water. Daily 200 M3 water as good as drinking water
is supplied to boiler house.
house
MANUFACTURING PROCESS:

WET BLUE (WB)

SKINS

SHAVING
SOLID WASTE
OF WET BLUE

DYE HOUSE LIQUID WASTE

MECHANICAL
OPERATIONS

FINISHING AIR POLLUTION

SPRAY BOOTH

W/H
DESPATCH
 ENVIRONMENT FRIENDLY TOTAL SOLUTION
FOR
LEATHER SO
SOLID WASTE
S CONTAINING
CO G CHROMIUM
C O U

MODE: GAINFUL UTILIZATION THROUGH

BIOTECHNOLOGY/BIOMETHANATION
ENVIRONMENT FRIENDLY TOTAL SOLUTION FOR LEATHER SOLID WASTE
CONTAINING CHROMIUM

L E A T H E R B U S IN E S S
P e rfu m e
W A S T E G E N E R A T IO N
B o a rd
Sheet
L I Q U ID W A S T E S O L ID W A S T E
F ib e r

E f f lu e n t S h a v in g B u f f in g D ru m T r im m in g s Used
Dust Dust S lu d g e P ro d u c t

ETP
L a n d F ill
P ig m e n t
B io -
R e v e rs e O n Land M e t h a n t io n C h r o m iu m
O s m o s is P la n t R e c o v e ry L e a th e r
C h e m ic a ls
B io lo g ic a l
P ig m e n t
H o rm o n e
A m in o
A c id s
E n zym es
F e r t i l iz e r
S a la b le Power
E le
l c t r o p la
l t in
i g B io G a s G e n e r a t io n

Non-Environment Friendly Innovative Route Recycle Present

LEATHER SOLID WASTE BIOMETHANATION
BULK IMPLEMENTATION.

DEMONSTRATION PLANT FOR LEATHER SOLID

WASTE BIOMETHANATION

AT TATA INTERNATIONAL LTD

DEWAS
BASED ON IN-HOUSE R&D PATENTED TECHNOLOGY

WITH SUPPORT FROM

UNDP / MNES (G.O.I.)
&
MONITORED BY CLRI.
CONCEPT:

A novel innovative scheme for utilizing these

wastes in-house as an economically self
sustaining environmental care project
project.

The concept was to treat the solid wastes to

separate the chrome and the organics. The
organics would go for Biomethanation and
chrome would be recycled for leather making.
Patents/Publication by TIL,
TIL R&D:

Two Patents granted by Govt. of India in August 2003

1. Indian patent no. 188788 (612/BOM/98) Dated 22nd
S t b 98
September
“A process for the production of methane containing
fuel gas and nitrogenous fertilizer by Biomethanation
of pelt/chromed leather solid wastes.”
2 Indian patent no.
2. no 188789 (613/BOM/98) Dated 22nd
September 98
“A p
process for the recovery
y of Basic Chromium
Sulphate (BCS) from chromed leather solid wastes.”
 High Rate Biomethanation Plant Based on
Solid Waste From Leather Industry

Place of Installation : Dewas, Madhya Pradesh

Date of Commissioning : September, 2002

Status of Functioning : Continuously Running

Implementing Agency : Tata International Limited

UNDP & MNES (Govt of India)
Technology : Tata International Limited

Technology Institution Central Leather Research Institute,

for Monitoring : Chennai

Plant Installation Agency : Mailhem Engineers Pvt. Ltd

Progress Report On Biomethanation Plant
Chronology of events for Bulk implementation:

1994-96: Bench scale data established.

Late ‘96: Ministry of Non Conventional Energy Sources
(MNES) (Govt. of India) Brainstorming session on
leather industry Solid waste treatment process.
‘97: MOU signed by TATA, Central Leather Research
Institute ((CLRI),
), Chennai/MNES/UNDP.
‘98: Patent application.
DPR preparation
’99-00 Tender document preparation by CLRI, All
India tender invitation, screening & awarding
off tender.
t d
Chronology
gy of events for Bulk implementation:
p

March ‘01: Final agreement signing between TIL, MNES &

Mailhem for implementation of the UNDP
sponsored project.
project
Plant installed.
Aug. ‘02 Commissioning.
Mar ‘03 O&M Completed.
Apr ’03 –
Mar ‘06 Run by TIL
 PROCESS FLOW DIAGRAM:

The process flow for Hazardous solid waste treatment

from leather is as given below

W e t b lu e
s h a v i n g d u s t, C h e m ic a l F i l tr a ti o n S o lid re sid u e C o n v e r te d F o r C h ro m e
tr i m m i n g s tr e a tm e n t to B C S ta n n i n g
S p l i t w a s te s

B i o -g a s to
t B o ile r
F i l tr a te
fe d to
B i o m e th a n a ti o n T o e x i s ti n g E T P
p la n t

E n v i r o n e m e n t fr i e n d l y
fe r ti -i r r i g a ti o n m a te r i a l
fo r h o r ti c u l tu r e
 Recycled Chrome Sulphate (10%) in Tons/Year
175

150

125

100

75

50

25

0
'0 2 -0 3 '0 3 -0 4 '0 4 -0 5 '0 5 -0 6
 Solid Waste Recycling : Biogas M3/Year

100000 Yearly

90000
80000
70000
60000
50000
40000
30000
20000
10000
0
'02-03 '03-04 '04-05 '05-06
Benefits Of Biomethanation Plant
 Revenue Generation from Haz. Leather
Solid Waste treatment
by
TIL B M Pl
TIL-B.M. Plantt on full
f ll scale
l operation
ti
A. Products:
1
1. Bi
Bio-gas generation:
ti @ 280 m3
3 60
60-65%
65% M
Methane/day
th /d
2. Chrome Recovery : @ 500 Lits. (10 % BCS liquor)/day
i.e., 50 Kg commercial Powder /day
B. Revenue generation/Yr.
1. From gas: @ of Rs. 18.5 / M3 as Rs. 750/,
equivalent to 19 Kg Industrial LPG and
280 * 18.5 *300 = Rs. 15.5 lakh.
2. From Chrome Liquor @ of Rs. 30 /kg. of powder
50*30*300 = Rs
Rs. 44.5
5 lakh
lakh.

Total revenue generation = Rs. 20 lakh / year approx.

 Benefits Of Biomethanation Plant

• Environmental Friendly Disposal of Hazardous waste.

waste
•Resource recovery of Chrome as Basic Chromium Sulphate
for Tanningg Process.
• Converting hazardous, non-degradable waste to
non-hazardous recyclable waste gainfully.
•Energy recovery from renewable non-conventional
sources by Biomethanation
•Solving
S l i off Hazardous
H d waste
t disposal
di l problem
bl saves
soil/ground water pollution
Environmental Care Clean Technology Self Sustainable Plant
•Environmental
while solving Solid Waste Disposal Problem.
A WAY FORWARD
Energy Conservation : Reduction/Generation

- Increased production of Bio-gas (Biomethanation Plant)

- Used CO2 for Neutralisation of Hydrolysed Shaving Dust

- Bio-methanation Plant without Chemicals in Progress

- Hot Water Generation (Value addition to RO Water) trial successfully

Conducted

- Bio-purification of Biogas (~ 15% CO2) Pilot Plant Studies Completed

- Increased Chromium Recycling

 Recycling of Process Water
Recycling of Re-Chrome Liquor
Approaches
pp :
- Equilibrium Approach : Recharging in Re-chroming Float

- Value Addition Approach : Use in BM Plant

Shaving Dust Chrome Cake Ratio

Present Process 500 gm 72.4 gm 100 %

Proposed Process 500 gm 106.5 gm 145 %

Present Process 2 tons 288 kg 100 %

Proposed Process 2 tons 416 kg 145 %

 Bio-purification of Biogas – Pilot Plant (1 Tons)
100
90
80
70
60
CO2
P e rc e n t

50
CH4
40
30
20
10
0
0 10 20 3 0 D ays 4 0 50 60
 Waste Management : Energy Conservation
Bio-Gas Production
P
Process R
Remarks
k 140
Control Gelatin Digester Control
Nutrients Approach High Efficiency 120

Shaving Dust Digester No Chemical

100
(Complete Bio-Chemical Treatment
Treatment)
80
Treated Drum Sludge Reverse
Digester (Preliminary Degradation 60
Data)
40
Description Gas/Day Ratio
, lit
20
1 Control 2200 -
2 Expt 1 : Nutrients Route 2800 1:1.3 0
3 Expt 3 : Shaving Dust 1000 1:0.5 C o ntro l N e utrie nts S having D us t D rum S lud g e
(Bi /N t i t Route)
(Bio/Nutrients R t ) Pilot Plant Digester(~ 2 ton
4 Expt 4 : Treated Drum 2500 1:1.2 capacity) for increased efficiency
Sludge are running for ~ 6 months
 Energy Saving Continuous Digester

Installed on = 1/10/2004 Gas = 900-1200 liters/day

Volume = 2.78 Cu Met Feed = Treated Drum Sludge
Length = 2.37 Met Feed Rate = 20-40 liters/day
Radius = 0.4 Met Sludge = Shaving Dust
Charging = Continuous
Gas/Feed = 33
IN Gas Volume/Feed = 92

Gas

Feed

Out
Sludge

Gas
Flushing
Line
 Gas
Three Stage Digester (D)
Gas

Installed = 1st Sept 2004 Out

Volume = 1.06 Cubic Meter

Height = 2.37 Met
Radius = 0.377 Met

Gas
G = 500-700
500 700 lit
liters/day
/d
Feed = Normal
Feed Rate = 20-40 liters/day Feed
Sludge
g = Shaving g Dust/Cow Dung-Once
g
Charging = Contineous

Gas/Feed = 20
Volume/Feed = 35
Sludge IN
GAINFUL UTILISATION OF SLUDGE / WASTE

- No Technology was Available for Recycling of Hazardous

B ffi Dust
Buffing D t / Drum
D Sludge
Sl d / Trimming.
Ti i

Solution:

- Developed In
In-house
house Process for Degradation

- Generation of Power is Progress

Leather Waste Sludge Treatment Plant Digesters
Black Sludge
SLF
Chemicals Solid

10000 M3
2 M3
250
Sludge Solid
Dye House Vessel
Bed/Tank

Loading
Transsportation
ETP Fitering/
P
Pressing
i Device
D i Liquid Sludge Bio Gas
Other Waste,

ETP
Liquid Tank
Line SLF

Vessel, pump, steam, Electricity, wiring, piping, filter press, Digesters, pump, wiring,
Nertzch filter, loading device, tanks, platform piping, Electricity

Receiving Tank
Dye Hot
House, Water
Boiler
k

Gas Balloon
Balloon
Purified Gas

Scrubber
Biological
Electric
Factory
Power

150 M3 200 M3
CHP Gensets

Power Station Bio-purification

 Water Recycling : M3 per year

14000
12000
Good
10000

8000
6000
4000

2000
0
'02-03 '03-04 '04-05 '05-06
 Control

White Crust Pieces Dyed with Bacterial Colour