Indian Aluminium Company Limited, Alupuram Smelter Eloor.

77 

INDIAN ALUMINIUM COMPANY LIMITED, ALUPURAM SMELTER. 

Name of Industry 

: Indian Aluminium Company Limited., 

Alupuram Smelter. 

Date of inspection : 7-9-05 

Raw materials : 

(a) For pot room and associated facilities. (Plant de energized effective-1-8-03) 

1. Alumina : 75 t/day 

2. Cryolite : 0.07 t/day 

3. Aluminium Fluoride : 1.1 t/day 

4. Electricity : 661830KWh/day 

5. Pitch : 5.4t/day 

6. CP Coke : 15.3 t/day 

(b) For casting plant. 

1. Aluminium ingots :14 t/day. 

2. Aluminium process and extrusion scrap :14.5 t/day 

3. Furnace oil : 3860 litres/day 

4. Alloying ingredients :1 t/day. 

Products: 

(a) From pot room and associated facilities. 

1. Aluminium metal 

(smelter de energized effective –1-8-03) 

2. Carbon electrode paste 

(carbon plant shut down effective1-10-03) 

:1143 t/months 

: 580 t/months 

(b) From casting plant 

1. Aluminium billets :700 t/month 

2. Aluminium ingots(shut down since August 2003) :443 t/month 

3. Aluminium Wire Rods (shut down since August 2003) 

Process: 

Aluminium is produced by electrolysis of alumina .The electrolytic cell consists of a cathode 

which is a steel shell lined with refractory and baked carbon black. The carbon anode is 

suspended over the cathode. DC power is supplied across the cell. Alumina the main raw 

material is charged to pots periodically. Molten aluminium collected on the cathode is tapped 

out in vacuum crucibles and sent to casting plant. Aluminum ingot is fed to the melting 

furnace of the casting plant. Required alloying elements are added and billets are cast as per 

the requirement.

78 

Solid Waste generation: 

1. There are two main hazardous wastes generated from the electrolytic cells. 

a. Gaseous fumes containing fluorides and alumina dust. This is led to wet scrubber 

for removal of fluoride and dust. The removed fluoride is neutralized using lime 

and filtered. This scrubber sludge is land filled. Quantity of the same is 1000t/year 

as per the authorization issued by KSPCB. 

b. Another hazardous waste originates is from cathodes. The carbonaceous lining 

degenerates after an age of 1500 to 2000 days. Upon this the lining is demolished. 

This waste is called spent pot lining. Quantity of waste is 700 t/year and is stored 

in building under cover on concrete pits. 

c. Lead acid batteries retired from mobile equipments. This comes to 50 numbers per 

year. Lead acid batteries are sold to authorized vendors or to the manufacturers. 

d. Waste asbestos used as thermal insulation. Quantity of Asbestos waste is 1 t/year 

which is land filled. 

e. Spent bricks. 

Refractory and fire bricks of failed pots are removed as and when required. 

Quantity of this waste is 150 t/year as per the authorization issued by KSPCB. 

2. Waste generation from casting plant. The following hazardous wastes are generated from 

this plant. 

a. Aluminium Dross. 

b. Oil containing sludge and oil emulsion. 

c. Lubricating oil and System oil. 

Aluminium dross is oxides of aluminium, generated during the time of melting. Quantity 

of the waste is 120 t/year. Generation of oil containing sludge is 1.5 t/year and 

Lubricating /system oil is 2 t/year. 

All the above wastes are disposed by sale to authorized reprocessors. 

3. Water Consumption and Liquid waste: 

The industry now consumes 1140 KL of water per day. According to the consent 

issued by KSPCB the quantity of effluent discharged through outlet No.A is 

20,50,000 litres/day and through outlet no B is 6,50,000 litres /day. This quantity 

is based on water consumption when the unit was working in full swing. Now the 

industry is closed. The outlet A is to Periyar River which discharges effluent 

from bath rooms and other washings .The outlet B is over flow from cooling 

water tank which is discharged into land for percolation. During inspection there 

was some effluent discharge through the outlet A. 

Findings/ Recommendations: 

1. The industry had de energized the smelter and associated facilities effective 1 st 

august 2003. 

2. There is no waste generation from the smelter since the above period. 

3. The carbon electrode paste plant was shut down effective 1 st October 2003. 

4. Hazardous waste from the scrubber generated prior to the above period is seen 

land filled. 

5. Spent pot lining is seen stored carelessly in the industrial building. 

6. Spent bricks are also seen stored carelessly inside the industrial building. 

7. Oil containing sludge /lubricating oil/system oil are seen stored inside the 

plant building. This is disposed by sale to authorized reprocessors.

79 

8. The industrial plant was not working and hence there was no effluent 

generation. 

9. Company has obtained consent under the Water Act (to be renewed), consent 

under the Air Act and authorization under the Hazardous Waste (Management 

and Handling) Rules 1989. 

10. The monitoring well is to be relocated close to the capped pond to ascertain 

the leachate. The present inspection well in oversized and wide open which 

is totally unreliable to test leachate. These wells should be closed. 

11. The company has to renew the consent from KSPCB before restarting 

production. 

12. The sample taken from inspection well indicates fluoride content 2.26 mg/l 

which indicate ground water contamination. Even open wells of nearby 

residents indicates fluoride contamination. Therefore the unit must take 

necessary measure to prevent leachate from the disposal site. 

13. The unit on functioning in full swing , there would be good number of 

employees using canteen . There should be Effluent Treatment Plant for 

treating canteen waste. 

14. This is a unit which should go for zero discharge, since major discharge is 

overflow from cooling tower. 

Consented Parameters and limits 

Consented parameters under Water(Prevention and Control of Pollution)Act 1974. 

SL.No Characteristic Unit Tolerance 

limit 

Outlet A 

1. pH 5.5-9 

2. Suspended Solids mg/l 100 

3. Dissolved solids ,, 2100 

4. Sulphates ,, 1000 

5. Fluoride ,, 2 

6. Oil and Grease ,, 10 

7. Free Ammonia ,, 5 

8. Ammoniacal Nitrogen 50 

9. Zinc ,, 5 

10. Bio Chemical Oxygin Demand 30 

11. Nickel (as Ni) 3 

12. Chromium 2 

13. Copper(as Cu) 3 

14. Lead 0.1 

15. Outlet B 

16. PH -- 5.5-9 


18. Bio Chemical Oxygin Demand 100 

19. Dissolved solids 2100 

20. Oil and Grease 10

80 

INDIAN ALUMINIUM COMPANY- EXTRUSION DIVISION 

Name of industry 

: Indian Aluminium Company- Extrusion 

division 

Date of inspection : 7-9-05 

Raw materials. :Aluminum billet :1200 t/month 

Electricity : 27356 KW h/day. 

Products 

: Aluminum extruded sections :840 t/month. 

Aluminum extruded scrap :360t/month 

Production Process. 

Aluminium extrusion is produced by squeezing a pre heated aluminium billet at a high 

pressure through an orifice of required shape in a steel die. Aluminum and its alloys are soft 

and plastic in temperature between 400 o C to 550 o C.The material can be easily extruded in the 

above temperature range. Aluminium scrap generated in the process is sent to the smelter 

section for reprocessing into billets. 

Solid waste generation.: 

Lead acid battery –5 nos/year. Used battery is stored in shed with roof and concrete floor. 

This is disposed by selling back to the suppliers. 

Quantity of spent lubricating and system oil comes to 5 t/year as per authorization issued by 

KSPCB. There is a facility for storing this in steel drums in shed with roof and concrete floor. 

Disposal of the material is by selling to approved reprocessor. 

Water consumption and Liquid waste generation 

The industry consumes 104 m 3 of water/day. They have provided facility for reusing cooling 

water used in the plant. The overflow from the cooling water tank is discharged into Periyar 

River. The quantity of effluent discharged from the plant is 15000 litres /day as per the 

consent issued by KSPCB. 

Findings/ Recommendation: 

1. Used lead acid battery is disposed by selling back to suppliers. 

2. Hazardous waste generated (spent lubricating and system oil) is seen stored in steel 

drums. 

3. There is facility for recycling of cooling water. 

4. There is overflow from the cooling water storage tank which is discharged through 

the outlet to Periyar River.

81 

5. Industry has obtained consent under the Water (Prevention and Control of Pollution) 

Act 1974(to be renewed) and authorization under Hazardous Waste (Management and 

Handling) Rules 1989 from KSPCB 

6. The company has to renew the consent under the Water (Prevention and Control of 

Pollution) Act 1974. 

7. The unit should obtain zero discharge as its main discharge is from overflow of 

Cooling tower. 




limit 

1. PH 5.5-9 


3. Temperature 

0 C max 

4. ,, 

5. ,, 

Analysis Reports of the Effluent/ Sludge. 

shall not 

exceed 5 0 C 

above the 

receiving 

water 

temperature. 

Source 

: Indian Aluminium Company Limited. 

Date of sample collection : 7-9-05 

Sample Identification No :LAEC 172 (Outlet (Extrusion plant)), 

LAEC 147 (Outlet A), 

LAEC 197 (Inspection well (storage pit)), 

LAEC 199 (From well of Vincent), 

LAEC 49 (From well of flory George) 

Name of the Lab :Central Laboratory, K.S.P.C.B, Gandhi Nagar. 

Sl. 

No. 

Determinant Unit LAEC 

172 

LAEC 

147 

LAEC 

197 

LAEC 

199 

LAEC 

49 

1. PH 6.2 5.5 5.6 5.6 5.6 

2 BOD mg/l 0.18 0.2 0.12 0.18 0.12 

3 SS 7 8 7 8 12 

4 TDS 40 56 112 112 123 

5 Zinc ND ND ND ND 3.0 

6 Lead ND ND ND ND ND 

7 Copper ND ND ND ND ND 

8 Nickel ND ND ND ND ND 

9 Fluorides ND 1.3 2.26 0.36 0.9 

10 Sulphates ND 15 44 44 36

82 

11 Free Ammonia Nil Nil Nil Nil Nil 

12 Ammoniacal Nitrogen 0.44 ND ND ND 0.6 

13 Hexavalent Chromium ND ND ND ND ND 

14 Total Chromium ND ND ND ND ND 

15 Oil&Grease ND ND ND ND ND 

FACT, UYOGMANDAL. DIVISION 


:FACT, Uyogmandal. Division 

Date of inspection :01/06/05,08/07/05,30/07/05 

23/08/05,24/08/05 

Raw material :Naphtha 673 t/day 

:Rock Phosphate 

:Furnace oil 

Sulphur 

325 t/day 

135 t/day 

194 t/day 

Products 

: Sulphuric Acid - 600t/day Sulphuric acid and 

550tonnes/day combined capacity SO 2 /acid 

: Ammonia -900t/day 

: Phosphoric acid -100t/day 

: Ammonium Sulphate -682t/day 

: Ammonium Phosphate - 450 t/day 

: Carbon dioxide -1007t/day 

: Gypsum - 500 t/day 

Production Process: 

1.Sulphuric Acid. 

The process consists of Sulphur melting, Combustion of sulphur-to-sulphur dioxide, Catalytic 

conversion of sulphur dioxide to get sulphur trioxide, Intermediate absorption of Sulphur tri 

oxide in concentrated Sulphuric acid to produce Sulphuric Acid, Final conversion of 

unreacted Sulphur dioxide to Sulphur trioxide and final absorption of Sulphur trioxide in 

concentrated Sulphuric Acid. 

The converter consists of four beds of vanadium pentoxide catalyst. The gas from the furnace 

after passing through the waste heat boilers enters the first bed at 430 o C.In the first layer 

about 57% of SO 2 is converted and the gas leaving the first bed is cooled from 594 o C to 

440 o C in the waste heat boiler, and then enters the second bed where the conversion reaches 

85% and the temperature raises to 520 o C which is brought down to 450 o C in Intermediate

83 

Heat Exchangers. The gas then goes to 3 rd bed where conversion reaches 94% and 

temperature to 475 o C.The gas goes to the final heat exchanger and then to the Intermediate 

Absorption Tower where SO 3 is absorbed and gas leaving the absorber at 65 o C enters the 

fourth bed at 420 o C after passing through the Final Heat Exchanger and then the Intermediate 

Heat Exchanger. The conversion reaches 99.5% and temperature 445 o C.The gas then goes to 

the final absorption tower through an economizer where the temp is brought down to 

180 o C.Gas from the final absorption tower is released to the atmosphere through the stack. 

Process water is admitted to the tower bottom to maintain the acid concentration at 98.4%. 

The acid drawn off from the final absorber is cooled to 40 o C and stored. 

2.Ammonia 

Process involved in the production of ammonia are : 

a. Predesulphurisation of the raw naphtha. The bulk part of sulphur is removed in this 

section. 

b. Final desulphurisation of the hydrocarbon feed in one step: Removal of remaining 

sulphur compounds. 

c. Reforming of the desulphurised hydrocarbon feed in two steps by steam and air. The 

process gas from these steps contains hydrogen and nitrogen as well as carbon 

monoxide (CO), carbon dioxide (CO 2 ), methane and argone. The reforming takes 

place at pressure of about 35kg/cm 2 

d. In the gas purification section, CO is first converted to CO 2 and H 2 yield. CO2 

is then removed in the CO 2 -removal section, and afterwards the remaining CO and 

CO 2 in the converted gas are removed in the methanator. 

e. The purified synthesis gas is compressed to a pressure of about 135kg/cm 2 and 

converted into ammonia by a catalytic reaction. 

f. The plant is designed to a nominal production of 900 MTPD ammonia and 10,800 

Nm3/H of synthesis gas. The ammonia produced in the plant is sent to the 

caprolactam plant and to atmospheric storage. Synthesis gas is consumed in the 

caprolactam plant as well, and in combination with part of the CO 2 produced. 

3.Phosphoric Acid 

Phosphoric acid is manufactured by wet process by the reaction of rock phosphate with 

sulphuric acid. 

The principal steps in the production of Phosphoric acid by this method are the following: 

Grinding of rock phosphate, Reaction of the ground rock with sulphuric acid, and Separation 

of phosphoric acid from the gypsum. 

(a) Grinding of rock phosphate: The phosphate rock is ground dry in mills after drying if 

necessary. There are three grinding mills with a total capacity of 40 tonnes/hr of 

ground ore. The rock is ground so that 95 per cent will pass through a 100-mesh 

screen. 

(b) Reaction of rock phosphate and sulphuric acid: The main aim of this step is to get the 

rock reacted with sulphuric acid in such a manner as to (1) produce the highest 

possible concentration of phosphoric acid, (2) give good coarse gypsum crystals 

which could be easily filtered and washed with minimum of water to give a washed 

gypsum almost free of soluble phosphoric acid and (3) give the maximum yield of 

P 2 O5 from the rock.

84 

The Dorr Oliver single tank reaction system is employed here. 

The slurry formed during the reaction is fed to the filter for separation of gypsum 

from phosphoric acid. 

Counter-current washing of the cake is carried out with 10 to 12% acid, secondly 3 to 

5% acid and finally with water. Wash acid of strength 19%is returned to the reaction 

system. The filtrate of strength 20 to 22% is sent to storage. 

The byproduct gypsum is slurried with water and pumped to the Sulphate plant. 

4.Ammonium Phosphate 

Phosphoric acid, Sulphuric acid and gaseous ammonia are fed to a saturator and 

agitated. Further addition of ammonia is done in the second saturator. The neutralized 

product is a thick slurry and flows to a blunger where it is mixed with undersized 

granules; crashed granules and recovered dust, along with some urea. The granulation 

takes place in the blunger. 

The liquid ammonia at a pressure of 15 psi (g) and 18 o C is injected to the blunger to 

adjust the mole- ratio to 1.8.The amount of dry material recycled to the blunger is 

about 6 to 10 tonnes per tonne of dry material produced .The blunger which operates 

which on fludisation technique is of a double shat paddle mixer set on a slope .The 

granulated wet product from the blunger flows through a chute to rotary co-current 

drier when the material is dried by a current air along with combustion products from 

a combustion chamber. The material leaving the drier is conveyed to set of vibrating 

screens with 8 and 14 mesh screens. The –8 and +14 material is taken out as the 

product. The +8 material is crushed and, along with –14-mesh material is fed back 

into the blunger .The hot airflow is maintained through the driver by fan. The dustladen 

air leaving the drier fan passes through a multiple cyclone where the bulk of the 

dust separates out. The dust coming from the screens and other equipments is driven 

out by a dust fan through a cyclone. The air from the drier cyclone and dust cyclone 

along with the fumes leaving the reaction tank enter the scrubbers for removal and 

recovery of ammonia and dust. The scrubbing is done with phosphoric acid. The 

scrubber solution is fed back to the reaction tank. The product is bagged and sent to 

storage. 

5.Ammonium Sulphate 

The Ammonium sulphate solution fed to the unit consisting of two separate streams 

from the Caprolactum Plant of Petrochemical Division .One feed stream is Lactum 

ammonium sulphate solution and the other feed stream is Oxime ammonium sulphate 

solution. This plant consists mainly of the following four sections. 

1. Concentration and crystallization section 

2. Dewatering section 

3. Drying and cooling section 

4. Storage and bagging section.

85 

1. Concentration and crystallization section: 

The quadruple effect crystalliser and evaporator system with one concentrator are 

used for this purpose. First effect consists of two evaporators, one for oxime and the 

other for Lactum ammonium sulphate solutions. Second and third effects are the 

oxime ammonium sulphate crystallizers, and fourth effect is lactam ammonium 

sulfate crystallizers. 

The 40 % Oxime Ammonium sulphate solution is fed into 1 st Effect Oxime 

Ammonium sulphate Evaporator after preheating at Oxime Ammonium sulphate.S pre 

heater and solution is concentrated to approx. 51-wt % of ammonium sulphate. 

The concentrated solution is sent to No.1 Oxime Ammonium sulphate crystalliser. A 

half of ammonium sulphate contained in Oxime Ammonium sulphate solution is 

crystallized in this crystalliser and the slurry (approx.30 wt %) is sent to dewatering 

section. The rest mother liquor overflows to No.2 oxime Ammonium sulphate 

crystallizer where ammonium sulphate is crystallized and the slurry is sent to be 

dewatering section. 

To prevent accumulation of impurities mainly composed of ammonium nitrate in the 

system and to keep product quality, a portion of mother liquor is purged from No.2 

Oxime Ammonium sulphate Crystallizer.(V4) 40% Lactum ammonium sulphate 

solution is fed to concentrator Cyclone Underflow tank where lactam Ammonium 

sulphate solution dissolves dirty crystals. The mother liquor is fed to 1 st Effect Lactum 

Ammonium sulphateEvaporator (V-2) be concentrated to approx.46 wt %. The 

concentrated solution is sent to Lactum Ammonium Sulphate crystallizer(V-5) and 

the slurry containing high impurities is sent to S-3 Concentrator Cyclone. 

2. Dewatering section: 

There are 5 numbers of continuous pusher type centrifuges used for dewatering of, 

ammonium sulphate crystals. Oxime ammonium sulphate slurry is thickened in a 

prethickner. In the Centrifuges crystals are washed by vapor condensate and 

dewatered simultaneously. Dewatered product crystals are then fed to the next drying 

section through two conveyors. 

Lactum ammonium sulphate slurry is thickened in cyclone and dewatered in 

centrifuge. The crystals are then sent to the dryer. 

3. Drying and cooling section: 

Both of oxime and lactam sulphate crystals from the centrifuges are fed to Dryer 

Cooler through conveyor. One dryer-cooler is in service and an integrated design of 

dryer and cooler is applied. Both dryer and cooler are fluidized bed type. The wet 

crystals are dried by hot air generated in Hot Air Heater. Then, the hot dried crystals 

are cooled down to approx.55 o C by direct air-cooling and indirect heat exchanger 

installed inside the cooler. 

4. Storage and Bagging section: 

The crystals are then fed to hopper A or B by Product Conveyor. Dehumidified Air is 

fed to the Hoppers to prevent caking of the hygroscopic Ammonium Sulphate 

crystals.The crystals are bagged using four bagging machines.

86 

Waste 

The effluent generated in various plants of the factory are treated in the effluent treatment 

plants and discharged through three outlets. 

The company has obtained Boards consent under the water act for discharging 12,000- 

m 3 /day effluents through outlet no. A into River Periyar, 5000 m 3 /day effluent through outlet 

no. E into Kuzhikandam thodu, and 4800 m 3 /day effluent through outlet No.I into Edamula 

branch of River Periyar. 

An Effluent treatment plant consisting of equalization, neutralization, clariflocculation and 

ammonia stripping are provided for treating the effluent from sulphuric acid plant, 

Ammoniam Sulphate, Ammonium Phosphate and Phosphoric acid plants. The treated 

effluent is discharged through outlet No. A into Periyar river. The new complex Ammonia 

plant effluents are collected separately for neutralization and settling before taking to the 

guard ponds from where it is discharged through the outlet I in to the Edamula branch of 

Periyar river. Outlet carrying storm water and various condensate from ammonium sulphate 

plant are discharged into Kuzhikandam thodu through open drain in the premises of M/s 

HIL.(Outlet No. E) 

The company has obtained Board’s consent under the Air Act for making emissions 

through14 stacks from process plants and 2 stacks from captive Power plant. 

Hazardous wastes generated from the factory are spent catalyst from sulphuric acid plant and 

ammonia complex, sulphur muck from sulphuric acid plant, gypsum from phosphoric acid, 

and sludge from effluent treatment plant. The company has obtained authorization under 

Hazardous Waste (Management and Handling) Rules 1989 for the disposal of (a) 40 t/year 

spent catalyst by sale or transfer to person possessing valid authorization from Board. (b) 

1300 t/year sulphur containing residue in disposal area and 20-t/year waste oil to authorized 

recycler. 

Findings. 

1. Source of water is Periyar River and the treated water from a common water treatment 

plant meets the requirement of FACT-UDL, FACT-PD and FACT Township. Treated 

water is also supplied by FACT to other neighbouring industries. According to the 

company total water consumption in Udyogamandal division is 26522 KL 

2. Sulphuric acid plant was inspected on 30-07-05.There are two sulphuric acid plants 

600 tpd DCDA plant producing 400-t/day sulphuric acid and 200-t/day oleum, and the 

new plant producing 375t/day So 2 and 175-tpd sulphuric acid. Both the plants have 

DCDA conversion process for converting SO 2 to SO 3 . 

3. During the time of inspection 600 tpd sulphuric acid plant called DC DA plant was 

under shut down. Online SO 2 monitor is installed in the sulphuric acid plant. The So 2 

Monitor in DCDA acid plant is seen not working since 26/7/05. On July 7 th , the date 

of occurrence of gas leakage and fugitive emission from DCDA sulphuric acid plant, 

the monitor recorded the upper range value of 1000 ppm, the manual stack analysis 

data showed 1373 ppm. 

4. Production capacity of the Ammonium sulphate plant is 682 t/day. The company 

authorities informed that 30% ammonium sulphate solution brought from FACT-

87 

Petro chemical Division is concentrated, crystallized, centrifuged, dryed and cooled to 

produce ammonium Sulphate. The vapour condensate is used to produce ammonia in 

the HYAM plant of FACT-Petro Chemical Division and the purge liquid containing 

30% ammonium sulphate is reused in the plant. 

5. Overflow of vapour condensate storage tank and spillage are taken to a collection pit 

and pumped to effluent treatment plant. A level controller is provided in the pit. The 

storm water drains and vapour condensate from ammonium sulphate plants are found 

leading to a marshy land near old ammonia plant and finally discharge into 

Kuzhikandam thodu through an open drain ie, outlet no: E through the premises of 

HIL.Immense flow was noticed through the outlet, which according to the company 

authorities was due to storm water infiltration in cable trenches. The effluent through 

the drain is seen contaminated with high pH. 

The monitoring data indicates that SO 2 levels are often exceeded. The emission from 

both the acid plant are let out through one stack. 

6. The ladder provided for monitoring SO2 emission through sulphuric acid plant stack 

is not being used. The company authorities informed that the manual stack sampling 

is done by collecting the air sample through hose connection at ground level. 

7. One storm water drain from the factory premises leading to the Northwest corner, 

after crossing the road passes through the property of M/S.IRE Ltd (hazardous waste 

disposal area) and joins Kuzhikandom thodu before the discharge point of HIL. This 

drain of the company is seen carrying Gypsum on many occasions. 

8. The effluents from the complex ammonia plant are taken to guard pond after 

neutralization and discharged into the Edamula branch of Periyar River through outlet 

No.1.A pH meter is installed at the neutralization tank. Arrangement is provided for 

returning the effluent back to neutralization tank incase the quality of effluent in the 

guard pond is beyond limits. Online pH meter is installed at the guard pond. 

9. The phosphoric acid plant ammonia complex and ammonium phosphate plants are the 

major sources of liquid effluent. Ammonia complex effluents are treated separately 

and discharged. The liquid effluents from sulphuric acid, phosphoric acid ammonium 

phosphate and ammonium sulphate plants are taken to the effluent treatment plant 

consisting of equalization tank having two compartments, flash mixer, clariflocculator 

and ammonia stripper. The effluent generated from various plants are collected in a 

collection tank inside the plant before admitting to the equalization tank. The under 

flow from the clariflocculator is returned to the equalization tank. Accumulated 

sludge from the equalization tank is removed using crane and dumped nearby for 

dewatering. The surface run off from the dumping area is taken to the equalization 

tank. . The dewatered sludge is taken to LDPE lined Gypsum disposal yard of the 

factory approved by the Board, which is away from the factory site. 

10. An oil trap provided in the storm water drain in boiler plant near oil handling area is 

seen not functioning. 

11. The phosphoric acid plant is not working. Imported acid is used for the production 

purpose. 

12. The company authorities informed that the scrubbed liquid from ammonium 

phosphate plant is taken to collection tanks for recirculation. Recirculation 

arrangements are provided for reusing the scrubbed liquor from ammonium phosphate 

plants. 

13. The scrubbed liquid from IV th stage ammonium phosphate plant is seen containing 

oil and black particles. The downward dispersal of emissions from scrubber stacks of 

the (300tpd) IV th stage ammonium phosphate plant close to TCC boundary is creating

88 

air pollution problems of poor visibility, mist and fog formation and health effects in 

the Eloor Edayar industrial area. 

14. The company has obtained Board’s consent under the Water Act for discharging 

12000m 3 /day effluent through outlet no.A. into Periyar River, 5000m3/day effluent 

through outlet E into Kuzhikandom thodu, and 4800 m3/day through outlet no: 1into 

Edumula branch of Periyar River. 

15. The hazardous wastes generated are spent catalyst, sulphur muck, spent lubricating oil 

and system oil, and sludge from effluent treatment plants. Of these spent catalyst such 

as zinc and nickel are disposed by sale to authorized dealer and spent vanadium 

catalyst as hazardous waste in disposal site. Sulphur muck is stored for disposal in 

approved disposal area. Effluent Treatment Plant sludge and filter cakes of phospho 

gypsum from gupsum filters are stored in intermediate storage for final disposal in 

LPDE lined gypsum yard. As per the Environmental statement furnished by the 

company for 2003, the quantity of wastes handled were 

sulphur muck-1158t/year 

spent catalyst-65t/year 

waste oil -17t/year 

ETP sludge -2125.62t/year. 

16. Low chromate treatment system is adopted for treating cooling water. It is informed 

that the company have programme for changing cooling tower treatment system from 

low chromate to non-chromate system in Ammonium Sulphate plant. 

17. Raw material Sulphur spilled over during material handling near the unloading area is 

reaching the river along with surface run off. The company have already taken some 

steps for containing the spillage of sulphur particles escaping through the drain. 

18. Effluent samples were collected from various plants ,effluent treatment plant and 

outlets for analysis. 

19. The company authority informed that they have proposals for improving the quality 

of effluent and elimination of storm water contamination. 

Recommendation : 

a. Proposed to modify the effluent treatment during 2005 in a phased manner. 

b. Scheme for diversion of vapour condensate from new ammonium sulphate 

plant to phosphoric acid plant by 2006. But there is no production of 

phosphoric acid. 

c. Scheme for diverting storm water from pollution control plant area. 

d. Scheme for elimination of E drain, to be commissioned by March 2006. 

1. Effluent treatment plant is to be augmented incorporating measures for reducing 

ammoniacal nitrogen content and effective control over the addition of treatment 

chemicals, sludge removal, dewatering, and disposal. 

2. Delay pond shall be provided in all storm water drains with monitoring facility. 

3. Steps shall be taken for reducing the water consumption, effluent generation and 

achieving zero effluent discharge system. 

4. Adequate steps shall be taken to prevent the escape of gypsum through storm water 

drains. 

5. Oil traps in storm water drains are to be revamped and made functional. 

6. Adequate steps for effective control of S02 emission through Sulphuric acid plant 

stacks shall be taken.

89 

7. The scrubber stack for IVth ammonium phosphate plant 150 t/day is seen creating 

severe air pollution problems. Adequate control measures such as increasing stack 

height and emission velocity shall be provided. 

8. Stack monitoring facilities should be renovated and sampling should be done by 

drawing sample at the sampling point. 

9. Arrangement for avoiding the spillage of sulphur into the storm water drain shall be 

provided. 

10. Sealed Water meters shall be installed at the raw waters intake point in Periyar River 

to measure the water consumption by FACT-UDL, township and FACT-PD separately. 

11. The Board should direct the company to install sealed water meter at the intake point 

and collect water cess according to the reading in the meter . There should be 

periodic for reading water meter. 

12. Remedial measure to prevent spillage by overflow of sulphuric acid to avoid leading 

to periyar. 

13. The discgharge from FACT through outlet E be located near the first culvert over the 

Kuzhikandam thodu and made visible and accessible. 

14. The company should conduct a safety audit with the competent agency periodically. 

2 nd report on FACT Udyogamandal Division 

(Extracts of 70 th meeting held on 29-06-2005) 

Resolution no. 1 

Mr. Purushan Eloor, Member LAEC reported that an incident of fugitive emission on 26-6- 

2005 at Eloor Vadakumbagam where a public sector undertaking namely FACT 

Udyogamandal situate. Huge white smoke spread around the area caused severe discomfort 

for breathing, throat irritation and vomiting sensation to the residents of Kanjirakuzhi and its 

northern area of Eloor Panchayat. 

The fugitive emission is believed to be from FACT and, by the description of discomfort felt 

to the people, the fugitive emission contained sulphur dioxide and sulphuric acid mist. The 

smoke burned even the leaves of the trees. Some residents were treated in the Primary Health 

Center, Eloor. 

The reported fugitive emission was duly informed at the office of the Pollution Control 

Board Ernakulam. LAEC members Mr. Purushan Eloor, Jacob.V.Lazar and official of 

Pollution Control Board Mr. K.S.Soman AEE inspected the affected area and took statements 

from the residents on the incident. The report of the inspection is read over in the meeting and 

is made part of this proceeding. 

The committee deliberated on various aspects of the incident and expressed its anxiety on the 

lack of arrangements for attending to such incidents, which is part of the comprehensive 

chemical disaster management. The committee has been alerted on the fact that despite Eloor- 

Edayar industrial belt being an area with number of chemical industries dealing in hazardous 

chemicals, a program for chemical disaster management is indispensable and the same is yet 

to be evolved.

90 

The district administration, Factories and Boilers and Pollution Control Board should evolve 

a scheme for chemical disaster management for Eloor - Edayar and periodical review is to be 

made. The residents of Eloor –Edayar should also be educated and necessary training be 

given. 

Committee resolved to approach the district collector and seek his indulgence for constitution 

of such a body. Mr. Purushan Eloor and Mr.Asokan are authorized to meet the collector and 

to follow up the matter. 

3 rd report on FACT Udyogamandal Division 

(Extracts of the 72 nd meeting held on 9-7-2005) 

Resolution No.1 

LAEC members as part of the stack monitoring inspected FACT, Udyogmandal along with 

the officials of PCB viz., Mr. K.S. Soman, Asst. Environmental Engineer; Mr. K.V. 

Shanavas, Asst. Scientist on 8 th July, 2005 at 12:30 p.m. 

The inspecting team before arriving at FACT had received complaints from local people 

including industrial workers regarding suffocation, chest congestion etc., as a result of serious 

fugitive emission, which was found visible in areas near Sud-Chemie, Binani Zinc Ltd., 

Njavallil Latex and other areas in the Edayar industrial belt. A survey conducted by the 

inspecting team in these areas revealed that the source of emission is from FACT, 

Udyogamandal and people have been suffering such discomforts for the past few days. It may 

be recalled that a large scale emission, which caused serious apprehension in the minds of the 

people by the fugitive emission happened on 26/06/2005 was taken note of and this 

Committee had resolved to request PCB for necessary action against FACT, Udyogamandal, 

being the culprit of fugitive emission. 

Mr. Baburaj, Asst. Environmental Engineer of PCB joined the inspecting team at 1:30 p.m. at 

FACT, Udyogamandal. FACT, Udyogamandal Acid Plant was inspected by the team as the 

concern of the team was to find out the source of SO 2 & SO 3 (Sulphur dioxide and sulphur 

tri-oxide) emission. The FACT claims to have on-line recorder for stack monitoring. The 

said system for stack no. 15 (Acid plant) was found to be operational. The needle of the 

recorder is found remaining at the maximum point viz., 1000 ppm, which is equivalent to 

2617 mg/nm 3 as against the permissible concentration of 1500 mg/nm 3 . 

The emission through the stack being highly in excess of the permissible limit, which is even 

beyond the comprehension of the installed on-line recorder was detected as a serious lapse 

causing very grave concern to the environment and local community. The complaints of the 

local community and from the nearby industrial community stands vindicated by the above 

findings of LAEC. The inspecting team asked the Company to furnish the statement of online 

recorder for previous 7 days on-line monitoring. The company refused to provide the 

same on the plea that they have a Chemical Analysis Report of Manual analysis of checking 

concentration of pollutants. The inspecting team then asked as to how a manual analysis is 

conducted. The company confessed that the manual analysis is not done from the stack 

inspection duct by climbing at the sample point. According to them, the ladder provided for 

climbing is rusted and not safe enough to use the same. The sample is therefore collected 

from a pipe connected to the duct of the chimney. When confronted by the LAEC, as to how 

samples were taken from pipe can give the pressure of the emission, the company admitted

91 

the faulty nature of manual analysis. The laboratory reports of the manual analysis furnished 

to the LAEC is thus found to be unreliable. Despite insisting for the on-line recorder 

statement, the same has not been furnished. 

The company is not having adequate system to control the fugitive emission and even the 

system provided for recording the emission is found totally inadequate. The Company has 

not provided necessary arrangement even to the regulatory machinery to monitor the Stack. 

The provisions of the Air Act and the conditions of the Consent issued to the Company is 

thus found violated with impunity. 

During the inspection, Mr. Dandapani, Plant Manager was present throughout. After the 

inspection, the inspecting team also met Mr. Asokan, General Manager and appraised him of 

the situation and the concern of the LAEC. 

After the inspection, Chairman, LAEC had a telecon with the General Manager, FACT in the 

evening to inform him that any future complaints on fugitive emission from the locals would 

be seriously viewed and that the company should immediately arrest the emission beyond the 

consent parameters. Mr. Asokan, General Manager, FACT assured that necessary 

precautionary steps will be taken up. 

Despite these warnings, the Company could not control fugitive emission and as a result at 

around 10:30 p.m., Chairman, LAEC was informed by members of LAEC, Mr. Asokan and 

Mr. Jacob Lazer that they are patrolling in Eloor / Edayar belt on information that there is 

huge smoke in the entire area and some unit is on fire. The workers in the industrial belt was 

found panicky. LAEC members, surveilled the entire area and found 3 fire force engines, 

police force and the Eloor Panchayath President, Smt. Subaida Hamsa were all moving in the 

Industrial area to identify the source of wide spread white smoke. LAEC members, local 

community and industrial workers felt suffocation. The major source of this emission was 

ultimately found to be from FACT, Udyogamandal. 

In the above circumstances, LAEC resolved to recommend that the operation of the Acid 

Plant of FACT, Udyogamandal be directed to stop production forthwith and be allowed to restart 

production only after ensuring that the Unit makes adequate and fool-proof pollution 

control measures to the satisfaction of LAEC and PCB.

93 


Colour code 

Red: Pollutants not conforming to the standards stipulated in consent order. 

Pink: Pollutants in effluent not included in consent order 

Dark red: Pollutants in hazardous waste /sludge exceeding limit as per HW Rules. 

Blue: Presence of heavy metals/pollutants in hazardous waste/sludge. 

Source 

: FACT – UD 


Sample Identification No : LAEC 210(Combined Effluent Ammonium Phosphoric Acid 

Plant (300 TPD plant)), 

LAEC 202 (Ammonium phosphate collection pit 150 TPD 

plant), 


Sl. 

No. 

Determinant Unit LAEC 210 LAEC 

202 

Tolerance 

Limit 

1. pH 2.14 6.7 6.5-8.0 

2 BOD mg/l 1.2 0.8 - 

3 COD ,, 32 32 - 

4 SS ,, 22 15 100 

5 TDS ,, 1329 135 -- 

6 Arsenic ,, ND ND -- 

7 Chlorides ,, 200 80 -- 

8 Fluorides ,, 27.2 2.8 1.5 

9 Nitrates as Nitrogen ,, 0.36 0.23 20 

10 Phosphates ,, 560 25.4 5 

11 Sulphates ,, 190 40 - 

12 Cyanides ,, ND ND 0.2 

13 Free Ammonia ,, Nil 0.098 4 

14 Total kjeldhal Nitrogen ,, 140.2 19.9 150 

15 Ammoniacal Nitrogen ,, 137 19.5 75 

16 Phenolic compounds ,, 1.55 0.84 - 

17 Hexa valent Chromium ,, ND ND 0.1 

18 Total Chromium ,, ND ND 2 

19 Oil & grease ,, ND ND 10 

20 Vanadium ,, ND ND 0.2

94 

Source 

: FACT – UD 


Sample Identification No : LAEC 212(Spillage pit (New NH 4 SO 4 plant)), 

LAEC 204(Guard pond(Ammonia Complex)), 

LAEC 168(Edrain(Collection sump)) 

Name of the Lab 

:Central Laboratory, K.S.P.C.B, Gandhi Nagar. 

Sl. 

No. 

Determinant 

Unit Spillage 

pit 

(New 

NH 4 SO 4 

plant 

Guard pond 

(Ammonia Complex 

Tolerance 

limit 

1. pH 8.2 6.7 6.5-8 5.8 

2 BOD mg/l 0.8 4.2 - 0.8 

3 COD ” 14.7 48 - 8.3 

4 SS ” 8.0 8.0 100 12 

5 TDS ” 255 1548 -- 240 

6 Arsenic ND ND -- ND 

7 Fluorides 0.13 0.19 1.5 0.14 

8 Chlorides 30 590 50 

9 Nitrates as 

7.0 4.0 20 0.45 

Nitrogen 

10 Phosphates ND 0.2 ND 

11 Sulphates 90 170 90 

12 Cyanides ND ND ND 

13 Free Ammonia 6.65 0.31 Nil 

14 Total kjeldhal 96.9 63.5 150 19.9 

Nitrogen 

15 Ammoniacal 95 62.3 75 19.5 

Nitrogen 

16 Phenolic 

2.1 2.4 2.6 

compounds 

17 Hexa valent 

ND ND ND 

Chromium 

18 Total 

ND ND ND 

Chromium 

19 Oil & grease ND ND ND 

20 Vanadium ND ND ND 

Edrain(Collection 

sump 

Source 

: FACT – UD 


Sample Identification No : LAEC 248(Final outlet), 

LAEC 249(Raw Effluent-1), 

LAEC 250(Sludge under flow), 

LAEC 251(Raw effluent-2) 

LAEC 252(Effluent before Ammonia removal) 

Name of the Lab :Central Laboratory, K.S.P.C.B, Gandhi Nagar.

95 

Sl. 

No. 


248 

LAEC 

249 

LAEC 

250 

LAEC 

251 

LAEC 

252 

1 pH 6.9 4.6 8.0 3.2 9.2 

2 SS mg/l 15 52 22 47 8 

3 Arsenic ” ND ND ND ND ND 

4 Fluorides ” 1.39 21 2.42 68.2 0.76 

5 Nitrates as Nitrogen ” 0.33 0.369 7.09 0.06 0.22 

6 Phosphates ” 0.8 36O 1.2 1092 ND 

7 Sulphates ” 320 550 625 1100 750 

8 Cyanides ” ND ND ND ND ND 

9 TKN ” 74 222.4 61 513 118 

10 Ammoniacal Nitrogen ” 71 218 60 503 116 

11 Hexa Chromium ” ND ND ND ND ND 

12 Total Chromium ” ND ND ND ND ND 

13 Oil and Grease ” ND ND ND ND ND 

14 Vanadium ” ND ND ND ND ND 

Source 

: FACT – UD 


Sample Identification No : LAEC 253(Raw effluent After Primary settling), 

LAEC 254(Effluent after Ammonia removal), 

LAEC 255(Raw Effluent (inside plant)) 


Sl. 

No. 


253 

LAEC 

254 

LAEC 

255 

1. pH 5.8 8.8 5.2 

2 SS mg/l 8 10 162 

3 Arsenic ” ND ND ND 

4 Fluorides ” 5.2 0.87 81.6 

5 Nitrates as Nitrogen ” 0.27 0.25 0.43 

6 Phosphates ” 74 ND 4.4 

7 Sulphates ” 425 450 2000 

8 Cyanides ” ND ND ND 

9 TKN ” 112 72 766 

10 Ammoniacal Nitrogen ” 109 71 751 

11 Hexa Chromium ” ND ND ND 

12 Total Chromium ” ND ND ND 

13 Oil and Grease ” ND ND ND 

14 Vanadium ” ND ND ND

96 

FACT- PETROCHEMICAL DIVISION 

Name of the Industry 

:FACT- Petrochemical division 

Raw materials : Name Quantity(Avg. tones /day) 

1. Benzene 150 

2. Synthesis gas as Ammonia 79.5 

3. Caustic Soda (100 %) 19 

4. Sulphur Dioxide 213 

5. Ammonia 236 

6. Carbon dioxide 66.5 

7. Oleum as 100% sulphuric acid 210 

8. Furnace oil 175 

Products: Name Quantity(Metric tonne /day) 

Process: 

The production process consists of 

1. Benzene hydrogenation 

2. Cyclohexane oxidation 

3. Hydroxylamine sulphate preparation 

4. Oximation and Lactum preparation 

5. Lactum flaking and bagging 

1. Caprolactum 152 

2. Ammonium Sulphate (solution) 672 

3. Soda Ash 14 

4. 55% Nitric Acid 11.5 

Benzene hydrogenation Section: In this section, Benzene is catalytically hydrogenated to 

produce Cyclohexane.Benzene is first dried of any moisture contained in it by distillation. It 

is then vaporized, mixed with recycled gases from a subsequent section of the plant and fresh 

make-up hydrogen and passed through tubular reactors containing Platinum on Alumina 

catalyst. After convertion, Cyclohexane is condensed and separated and the uncondensed 

gases recycled back to reactors. A small amount of purge gas is released from the recycled 

gases to prevent build up of inerts. Heat of reaction is removed through heat transfer oil and 

is used to vaporize Benzene and also to generate steam. 

Cyclohexane Oxidation Section: Cyclohexane is oxidized with air to Cyclohexanol and 

Cyclohexanone in a series of stirred reactors in the presence of a catalyst. A number of other 

products are also formed during the oxidation, but the quantity of such products is carefully 

controlled within limits by suitably adjusting reaction conditions. These products are 

removed by saponifying them by adding caustic soda. Unreacted Cyclohexane and products

97 

and Cyclohexane are separated in a series of distillation steps. Cyclohexane is recycled back 

to the reaction section .Cyclohexanol is converted to cyclohexanone in a catalytic 

dehydrogenation reaction. The crude cyclohexane from the above steps is then further 

purified. 

Hydroxylamine sulphate preparation: Hydroxylamine sulphate is prepared using the 

RASCHIG process. In this, first ammonium carbonate solution is prepared by absorbing 

carbon di oxide in an aqueous ammonia solution. A mixture of NO and NO 2 is prepared by 

oxidizing ammonia over platinum catalyst. This mixture is then absorbed in the Ammonia 

Carbonate solution to produce a solution of Ammonium Nitrite. Ammonia Nitrite is then 

reacted with sulphur di oxide to obtain Hydroxylamine Di sulphonic Ammonia, which is 

further hydrolsed with water to produce hydroxylamine sulphate and Ammonium Sulphate. 

Oximation and Lactum preparation:Hydroxylamine sulphate is reacted with cyclohexanone, 

with simultaneous addition of Ammonia to control the pH. This results in the formation of 

cyclohexanone oxime and Ammonium Sulphate. The cyclohexanone oxime separated as an 

organic layer from the above mixture is then subjected to a reaction called ‘Beckman 

Rearrangement.’Chemically, both cyclohexanone oxime and Caprolactam have same 

molecular formula; but different molecular structure. This reaction takes place at elevated 

temperature in the presence of oleum. The oluem does not take part in the reaction and it is 

later converted to Ammonium Sulphate by adding ammonium to the reaction mixture. This 

gives a two –phase mixture; one phase containing caprolactam and the other, Ammonium 

Sulphate.The crude Caprolactum solution separated from this is then subjected to a series of 

purification steps to remove the various impurities. The Ammonium sulphate solution is sent 

to the crystallization section. 

Lactum flaking and bagging: The final product lactam from the previous step is in the form of 

a liquid with a solidification temperature of 69 degree Celsius. This is then falked in a 

standard drum flaker cooled with water. The flakes are then bagged. 

Waste: 

The company have obtained consent under the Water(Prevention and Control of 

Pollution)Act 1974 for discharging 5040 m 3 /day effluent into the Edamulla branch of Periyar 

river. The effluent treatment system consists of holding basins, oil traps, equalization tank, 

aeration tank, secondary clarifier and guard ponds. The hot raw effluent generated from 

various sources are taken to holding basin consisting of a series of tanks and fed to aerobic 

biological treatment system. Treated effluent is taken to two guard ponds, pH 

concentration is done , and discharge into Edamula branch of Periyar River. 

The gaseous emissions formed during the process in HYAM plant and anone plant are let out 

through chimneys after treatment .The Company is having thermal oil furnace, two boiler 

stacks, one caustic recovery boiler stack, flare stack and process stack in HYAM plant. In the 

HYAM plant oxides of nitrogen is a major pollutant. The oxides of nitrogen formed during 

the combustion of ammonia and off gas from the nitrate reactor is passed through an absorber 

for the removal of oxides of nitrogen and sent through a mist eliminator. Emission of sulphur 

di oxide during the preparation of hydroxy \amine disulphonic ammonia is controlled by

98 

scrubbing with ammonia water where as oxides of nitrogen is removed by selective catalytic 

reduction. This reactor is incorporated as an inbuilt pollution control measure in the process. 

This off gas with the emissions from nitrate preparation section are emitted through HYAM 

plant stack. 

In the Anone plant from 70 metres stack has been provided for burning uncondensed 

cyclohexane in the off gas from Benzene hydrogenation and cylcohexane preparation section. 

The off gas from benzene hydrogenation is used as a fuel in main boiler and fired gas heater 

of HYAM plant and remaining quantity, if any is vented to atmosphere after adsorption of 

organics in an activated carbon bed. 

In the captive power plant boiler a continuous on line SO2 analyzer is provided. Fuel 

additives and fire side treatment is provided to reduce SPM level in Capture Power Plant 

stack. The ammonia handling and storage area has been provided with a flare stack to burn 

any ammonia vented. 

Soda ash is recovered from the caustic effluents separated during the purification of 

cyclohexaanone and is disposed as by-product. 

Sources of hazardous waste are spent catalysts, Sludge from effluent treatment plant and 

waste oil. The company have obtained authorization as per Hazardous Waste(Management 

and Handling)Rules 1989 for the disposal of the hazardous waste generated in the factory. 

1. Bio sludge: The excess sludge generated from biological treatment are stored in brick 

and plastic lined, constructed lined storage pits. The quantity is generated is 50 

MT/yr. 

2. Spent Raney Nickel Catalyst: The Spent Raney Nickel Catalyst generated from the 

hydrogenation section of lactam plant is sold to registered re processing agencies. The 

quantity is generated is 1.3 to 1.5 MT per year. 

3. Spent Copper Zinc Oxide Catalyst: 10 t/yr of Spent Copper Zinc Oxide Catalyst 

generated from the dehydrogenation section of Anone plant is sold to registered 

reprocessing agencies. 

4. Spent Zinc Oxide Catalyst: The Spent Zinc Oxide Catalyst generated from the 

hydrogenation section of Anone plant is sold to registered reprocessing agencies. The 

quantity generated is 3.6 MT/year. 

5. Waste oil: Waste oil is generated from the plant machineries and transformers and oil 

circuit breakers in the entire plants. The quantity generated is 35000 l/yr. This is 

reportedly burned in the boilers along with fuel oil. 

Findings: 

1. The company has obtained Board’s consent under the Water(Prevention and Control 

of Pollution)Act 1974t, Air(Prevention and Control of Pollution)Act 1981 and 

authorization under Hazardous Waste(Management and Handling)Rules 1989 for the 

disposal of hazardous waste.

99 

2. The source of water is Periyar River .The water consumption according to the 

company is 8762.59 M 3 /day and average discharge is 3556kl/day. The consented 

quantity of discharge is 5040 m3/day into Edamula branch of Periyar River. 

3. The sources of effluent are process effluent, DM plant regeneration effluent and plant 

drains. An effluent treatment plant is provided for treating the effluent. The Effluent 

Treatment Plant was working during the time of inspection. 

The effluent treatment system consists of holding basins, oil traps, equalization tank, 

aeration tank, secondary clarifier and guard ponds. The hot raw effluent generated 

from various sources are taken to holding basin consisting of a series of tanks and 

fed to aerobic biological treatment system. Treated effluent is taken to two guard 

ponds, pH concentration is done , and discharge into Edamula branch of Periyar 

River. 

4. The effluent from the Caprolactum plant is collected in the plant , neutralized, aerated 

in equalization tanks and after pH correction is sent for biological treatment plant in 

the main Effluent Treatment Plant. 

Nitrate containing effluent are segregated and taken for denitrification process. After 

clarification the effluent is taken to equalization tank to complete the remaining cycle 

of operation in activated sludge process along with other effluent streams. 

5. Oil trap is provided for the removal of oil from raw effluent. 

6. The effluent after treatment discharging through the guard pond is mixed with raw 

water and let out into the River Periyar. The Company authorities informed that the 

dilution activity with raw water and DM Plant effluent are being practiced since long 

back. 

7. Separate drains are provided for storm water and oil traps are provided in storm water 

drains for removing oil. 

8. The indicator installed at the Effluent Treatment Plant showed raw effluent pH of 7.39 

and outlet pH 7.8 

9. Recorder shall be installed at the outlet for measuring effluent flow rate. 

10. The hazardous waste of spent catalyst are disposed in dumping yard or solid to 

authorized recyclers. Biosludge is disposed in lined storage pit and waste oil is stored 

for sale to recyclers. 

11. Soda ash is recovered from the caustic effluents separated during the purification of 

cyclohexanone and are disposed as byproduct. 

12. The company authority informed that hazardous waste TSDF exclusively for FACT 

is under construction at Ambalamedu. 

13. House keeping is to be improved by removing wild bush. Scrap is seen dumped in the 

premises. 


1. Huge quantity of water is used for diluting the effluent after treatment at the outlet of 

the guard pond, before discharging through the authorized outlet into the river 

periyar. Dilution activity should be stopped forthwith. The prescribed quality should 

be achieved by proper treatment in the Effluent Treatment Plant itself. 

2. Effluent treatment plant is to be modified for achieving the prescribed quality 

stipulated in the consent order without dilution. 

3. Adequate steps shall be taken for reducing the water consumption and also to reuse 

the treated effluent for achieving zero discharge system. 

4. Oil traps must be provided in all the storm water drains at intervals to curtail 

contamination of storm water.

100 

5. Delay ponds shall be provided in storm water drain with monitoring facility. Oil trap 

existing in oil handling area near boiler house is to be revamped and made 

operational. 

6. The scrap materials in the premises of the factory shall be disposed to registered 

recyclers. 

7. House keeping shall be improved by removing wild bushes. 

8. The oil trap system being an integral part of the treatment plant unit of raw effluent 

holding basin and guard pond, more attention should be provided in maintaining the 

oil traps. 

9. Safety audit has to be undertaken periodically at regular intervals. 


Colour code 

Red: Pollutants not conforming to the standards stipulated in consent order. 

Pink: Pollutants in effluent not included in consent order 

Dark red: Pollutants in hazardous waste /sludge exceeding limit as per HW Rules. 

Blue: Presence of heavy metals/pollutants in hazardous waste/sludge. 

Source 

: FACT – PD 


Sample Identification No : LAEC 191(Holding Sump (Raw Effluent), 

LAEC 152(Final Outlet), 

LAEC 199(Neutralization Pit (Outlet of Guard Pond)), 

LAEC 178(Anion Plant- Neutralization tank), 


Sl. 

No. 


191 

LAEC 

152 

LAEC 

199 

LAEC 

178 

Tolerance 

limit 

1 PH 9.6 7.7 8.5 3.5 5.5-9.0 

2 BOD mg/l 8.2 1.2 1.2 132 30 

3 COD 96 16 16 8880 250 

4 SS 38 18 20 32 100 

5 Free Ammonia 92.3 0.46 0.962 Nil 5 

6 Total kjeldhal 

181.1 18.80 7.6 328 100 

Nitrogen 

7 Amm:Nitrogen 177.5 18.5 7.4 322 50 

8 Phenolic Compounds 2.2 1.91 1.61 4.33 1 

9 Oil and Grease ND ND ND ND 10 

10 Nitrates as Nitrogen ND 5.0 2.5 250 20

101 

Source 

: FACT – PD 


Sample Identification No : L8A (Outlet) 


Sl. Determinant Unit L8A 

No. 

1. PH 7.8 

2 BOD mg/l 2 

3 COD 76 

4 SS 100 

5 TDS 1040 

6 Nitrates as N 7 

7 Sulphate 250 

8 Cyanide ND 

9 Free Ammonia 1.61 

10 TKN 60.4 

11 Ammoniacal Nitrogen 53.7 

12 Phenolic Compounds ND 

13 Oil & grease ND 

Outlet 

INDIAN RARE EARTHS, LTD 


:Indian Rare Earths, Ltd 

Date of Inspection :18/08/05 & 19/08/05. 

Raw materials : Monozite : 7.94t/day 

Caustic soda 

: 4077t/day 

Hydrochloric acid : 4t/day 

Oxalic acid 

: 0.6t/day 

Sulphuric acid 

: 0.13t/day 

Soda ash 

: 0.25t/day 

Sodium hyphochlorite : 3.55t/day 

Hydro Fluric acid : 140l/day 

Process water 

: 83kl/day 

Magnesium sulphate : 10kg/day 

Barium carbonate : 19kg/day 

Sodium sulphide 

: 65kg/day 

Furnace oil 

: 7.0t/day 

Diesel 

: 135l/day 

Kerosene 

: 16l/day

102 

Products : Rare Earths Chloride(Composite) : 11t/day 

Tri Sodium Phosphate 

: 13t/day 

Rare Earths Fluoride 

: 0.3t/day 

Cerium oxides 

: 1.0t/day 

Thorium Oxalate 

: 2.0t/day 

Evaporated Lye 

: 1.5t/day 

Production Process 

The industry is engaged in the processing of Monozite sand ,which is a phosphate mineral of 

Rare Earths and Thorium.This sand constitutes about 4 to 5% of the beach sands of Kerala 

and Tamil Nadu at certain locations towards the tip of peninsula, the other constituents being 

Ilmenite, Zircon, Sillimanite, Garnite, Rutile etc. 

Monozite contains about 60% of Rare Earths expressed as M 2 O 3 , 8-9% Thorium expressed as 

ThO 2, and 27-29% Phosphate expressed as P 2 O 5. Raw monozite sand after being ground to a 

very fine size is mixed with Caustic Soda in the form of Lye, and digested at about 140 

to160 0 C for a few hours when insoluble hydroxides of Rare Earths and Thorium and 

soluble Sodium Phosphate are formed. 

The top solution is decanted, clarified by filtration and cooled by adiabatic evaporation in a 

vaccum crystalliser. This crystallised slurry is centrifuged and the crystals are dried in a hot 

air pneumatic conveyor drier and the dry Tri sodium Phosphate having a P 2 O 5 content of 

17.5% is packed in bags. 

The mother liquor from centrifuge is a weak Caustic Soda solution of about 10% 

concentrtion. This is concentrated by evaporation and re-used for reaction with monozite. 

The slurry of insoluble hydroxides is filtered and washed in rotary drum vaccum filter 

to free it of soluble Phosphate and Lye. The washed hydroxides are then treated with 

commercial Hydrochloric Acid under controlled conditions to dissolve the Rare Earths 

preferentially leaving thorium hydroxide undissolved. The slurry is allowed to settle and clear 

RE Chloride solution is decanted. 

The Crude thorium hydroxide slurry is dissolved in HCL and subjected to a solvent 

extraction process to separate and recover Uranium and produce high purity Thorium 

Oxalate. 

Waste : 

The company have obtained Board’s Consent to discharge 3000 KL of effluent per day into 

River Periyar. For treating the effluent the company have provided an effluent treatment plant 

consisting of 

1. Settling tanks. 

2. Separate pretreatment tanks for acidic and alkaline effluents. 

3. Effluent mixing channels. 

4. Clariflocculator 

5. Treated effluent collection tank and 

6. Sludge filter.

103 

The effluent from the settling tanks inside the main plant is pumped to the pretreatment tanks. 

Acidic effluent and alkaline effluent are collected in separate tanks. This is pumped to a 

mixing channel where HCl/NaOH is added for neutralization of the effluent. Ca Cl 2 and FeCl 3 

are also added for precipitation of hydroxy apatite of Calcium Phosphate and Calcium 

Fluoride. The slurry from flash mixer is sent to the clariflocculator and allowed to settle. The 

over flow from the clarifloculator is collected in a storage tank and discharged into the river. 

Underflow of the clariflocculator is pumped to an intermediate storage tank from where it is 

filtered in a precoat type rotary drum filter. The filter cake is collected in HDPE laminated 

bags and disposed in earthern pit in the waste dumping yard of the factory situated in the 

western side. 

The filtrate is either pumped to post treatment tank or pre treatment tank for further treatment 

or disposal depending on the quality. The treated effluent from post treatment tank is 

discharged into the River Periyar. 

Sources of gaseous emissions are extraction and deactivation plant, Cerium hydrate 

precipitation tank, Rotary kiln, solvent extraction plant and acid dilution tank. The company 

have got valid consent under the Air Act upto 31-12-05. 

The company has obtained authorization as per Hazardous Waste(Management and 

Handling)Rules 1989 for the disposal of the following hazardous wastes generated in the 

factory. 

1. 745 kg/day Insoluble waste separated as undigested sand from raw material is 

stored and disposed in RCC trenches /silos. 

2. 465kg/day Sludge separated while deactivation of rare earth chloride is Stored and 

disposed in underground FRP lined RCC trenches. 

3. 460kg/day dried sludge generated from the effluent treatment plant is disposed in 

trenches in open land at the disposal site. 

Three concrete silos containing thorium hydroxide near river side is being removed to 

another silo through mechanical retrieval system and pure thorium oxalate is recovered. 

Ammonium di uranate recovered is supplied to BARC. The waste generated is disposed in 

concrete tank called muck silo. 

Findings: 

1. Factory rules regulation of M/s IRE is done by the Atomic Energy Regulatory Board 

(AERB) and is looking after the health physics aspect of the plant. Dr.P.M.B.Pillai of 

AERB informed that radiation level inside the factory is As Low As Reasonably 

Achievable and public exposure is also low. Internal dose is taken care of by limiting 

the personal doses and direct dose is measured by various methods. AERB is 

providing advanced medical check up to the exposed workers. 

As part of the environmental protection and abatement programme the company have 

also constructed monitoring wells and have been monitoring 20 bore wells inside the 

factory, open wells, four open wells outside the factory, Periyar river and back water 

stretch. 

2. Three concrete silos containing thorium hydroxide near river side is removed to 

another silo through mechanical retrieval system and pure thorium oxalate is

104 

recovered. Ammonium di uranate recovered is supplied to BARC. The waste 

generated is disposed in concrete tank called muck silo. 

3. The source of water is Periyar River. Water consumption as reported by the company 

is 1971 M 3 /day. 

4. The company is having one authorized oulet and obtained consent for discharging 

30,00,000 litre /day of effluent into the river. According to the company authorities 

the daily average discharge is 1500 m 3 /day. 

5. According to the company authorities only deactivated effluent is brought to the 

treatment plant. Raw effluent generated are collected and settled at the plant before 

taking to the ETP. Activated part is taken to FRP lined concrete tank by pumping 

6. Effluent treatment plant consists of acidic and alkaline effluent collection tanks, flash 

mixers, clariflocculator and sludge storage tank rotary drum filter. The dried ETP 

sludge from the filter is collected in HDPE laminated bags and disposed in trenches in 

open land owned by the company. 

7. For inplant emission, control filters and scrubbers are provided. 

8. The company have obtained Board’s authorization under Hazardous 

Waste(Management and Handling)Rules 1989 for the disposal of hazardous waste. 

Solid wastes of mixed cake generated during deactivation containing BaSO4, PbS, 

Ra228 is taken to trenches of FRP lined underground RCC tanks and capped. The 

solids are transferred to the disposal trenches by admitting water and pumping to FRP 

lined, roofed RCC tanks. The effluent layer is pumped back. Insoluble sand wastes are 

also disposed of in RCC trenches. 

9. At the dumping site capped hazardous waste tanks, FRP lined concrete tanks under 

use, and two FRP lined tanks ready for use are seen. FRP lined concrete tanks at the 

dumping site under use and new tanks ready for commissioning are seen protected 

from rain by providing roofing. 

10. As per condition no.13 of the consent order issued under Air Act dt 3-4-2004 

continuous emission monitors for chlorine and its compounds ,and sulphur dioxide in 

Mohur Plant Chimneys shall be provided. Also furnish a bank guarantee for an 

amount of 10% of the cost of monitors on or before 15-05-04 with the Board. 

According to the company authorities order for procuring the monitor were placed 

but not executed due to some technical problems raised by the supplier regarding 

Chlorine and Chlorine compounds monitor. 

11. Emission from Material processing plant(Oxide Plant) are scrubbed with caustic soda 

lye and let out through chimney No. 4. The scrubbed liquid is taken to Effluent 

Treatment Plant. 

12. MOHUR plant is renamed as SEP- I. Process emission through Stack No 3 of 

MOHUR Plant is scrubbed and discharged to E-T-P. for treatment. 

13. There is no helium recovery and HERO Plant is named as SEP II., Emission from 

SEP II are let out through Stack No.6 

14. Dust collector is provided for recovering the particulates from the emission of rotary 

kiln and vent out through Chimney No. 5. 

15. The captive power plant is not operated. There is no emission through Stack No.7 

There are two gensets 160 KVA and 330 KVA. Stack No 8, 9 

There is one boiler (Now IBR) 

16. Coloured effluent from the land property of M/s IRE Ltd. used as disposal trench for 

Effluent Treatment Plant sludge is seen entering the storm water drain in the 

adjacent property owned by M/s Merchem Limited, Eloor. 

17. Effluent samples are collected from various stages of the effluent treatment plant for 

analysis.

105 

18. The other concern of LAEC is the radiation from Indian Rare Earth. The radiation 

effect from this unit range between 24 to 82 micro Sv at the points starting from 

Gypsm yard of FACT and along the route at FACT junction, HIL, North gate of 

FACT, reaching at IRE southern closed gate. The maximum reading of the radiation 

was recorded at the southern closed gate of IRE itself. The radiation exceeds the limit 

and pose great health hazard. This is a matter call for immediate attention. 


1. Steps shall be taken for reducing the water consumption and effluent discharge. 

2. Canteen effluent is to be treated before discharging into the river. The storm water 

drain is to be included as an authorized outlet in the consent order as there are chances 

of contamination of storm water. 

3. Delay pond shall be provided in the storm water drain with monitoring facility. 

4. Even though the hazardous waste disposal site of FRP lined concrete tanks under use 

are roofed properly, rain water is seen entering the tanks through the sides. Hence 

precautionary measures are to be taken to prevent the entry of rain water into the 

tanks. 

5. Take steps for complying with consent conditions under Air(Prevention and Control 

of Pollution)Act 1981 by providing online monitors. 

6. The hazardous waste of Effluent treatment plant sludge is disposed in earthern 

trenches at the disposal site. There is leachate from this earthern pit. Therefore 

Effluent Treatment Plant sludge should be disposed of any in percolation free 

trenches. 

7. The committee recommends relocation of the thorium waste stored in huge 

quantity, which is the source of radiation. 


Source 

: Indian Rare Earths LTD. 


Sample Identification No :LAEC L10 (River Water near IRE outlet), 

LAEC L10 A(Effluent through pipe flow), 

LAEC L10 B(Effluent through Channel) 


Sl. Determinant Unit L10 L10A L10B 

No. 

1. pH 6.4 85 8.6 

2 BOD mg/l 1.2 1.2 0.8 

3 COD 24 28 16 

4 SS 40 15 12 

5 Zinc ND ND ND 

6 Lead ND ND ND 

7 Fluoride 1.66 1.4 1.89 

8 Chlorides 770 290 340 

9 Phosphate 0.9 0.85 0.9 

10 Sulphate 200 25 44 

11 Sulphide ND ND ND 

12 Ammoniacal Nitrogen 0.72 9.5 2

106 

M/S KEMO GRAVURES , EDAYAR 


:M/s Kemo Gravures , Edayar 

Date of inspection :05/03/05 and 25/05/05 

Raw Material 

: M.S.Pipes , Copper plates, 

Rochellte salt solution, Chromic acid. 

Products 

: Rotograver printing rollers 

Process: 

Manufactures Rotograver printing rollers by electroplating operation .MS Pipes after 

fabrication and turning is subjected to conditioning by both alkali copper plating and acid 

copper plating by dipping in Rochelle salt solution. After polishing, the materials are exposed 

to photochemical action and etching, is done using ferric chloride solution. The material is 

then taken for chrome plating. Polishing is done before and after chrome plating. 

Waste: 

Sources of wastewater are batch solution from vats and rinse water, acidic and alkaline 

solutions, rinse water, chromate waste after cyanide dipping , chromium plating, anodizing, 

electroplating solutions, and floor washings. The quality of effluent is reported as 100 liter/ 

day. 

Findings: 

1. An underground tank is provided for collecting the effluent. The company authorities 

are not sure about the conditions of the tank whether the floor of the tank is plastered 

or not. 

2. The effluent is found to be highly acidic. The factory authorities reported that 

neutralization of the effluent using sodium bi Sulphate Solution is regularly done. 

But no provision for treatment is seen provided at the time of inspection. 

3. The wastewater generated due to the floor washing is allowed to flow to the storm 

water drain. The sample collected from the storm water drain was found to be 

acidic.(pH 2.5). 

4. Well in the premises is the source of water. Water consumption is 1000 l / day. 

Quantity of effluent is reported as 100 l/day. 

5. A chimney of 3 meter high is attached to the Chromium plating reactor. An exhaust 

fan is provided inside the Chimney. 

6. Fugitive emission of acid fumes is felt around the reactor. 

7. A D.G set of 63 KVA is installed in the unit. 

8. The factory is working without the Board’s consent under the Air(Prevention and 

Control of Pollution)Act 1981, & Water(Prevention and Control of Pollution)Act 

1974 . 

9. Open burning of the solid waste is noticed in one corner of the compound. 

10. A proposal for efficient effluent treatment is reportedly submitted to the Board.

107 

Recommendations: 

1. Should obtain consent under Water(Prevention and Control of Pollution)Act 1974, 

Air(Prevention and Control of Pollution)Act 1981, and Authorisation under 

Hazardous Waste(Management and Handling)Rules 1989. 

2. Should provide an effluent treatment plant of adequate capacity to treat the effluent 

generated. 

3. The unit is functioning without any consent / authorization. It has not even applied for 

obtaining necessary consent. The committee hence recommend closure and should 

be allowed to start only after providing adequate pollution control measures and 

obtaining necessary consent. 


Source 

: Kemo Gravures 

Date of sample collection : 5.3.05 

Sample Identification No :LAEC 30 


Sl. 

No. 


30 

1. pH 3.2 

2 COD mg/l 496 

3 SS 1442 

4 TDS 2000 

5 Zinc 2.0 

6 Iron 100 

7 Lead 1.78 

8 Cadmium ND 

9 Copper ND 

10 Hexa chromium 50 

11 Total Chromium 115 

MERCHEM INDIA PVT.LTD.,EDAYAR 


:Merchem India Pvt.Ltd.,Edayar 

Date of Inspection :29/11/04,08/06/05;04/10/05 

Products : Name Quantity(kg/day) 

Average. 

Maximum 

TMT 1300 1700 

ZMBT/Mertard 800 1500 

Mertiser 250 700 

SDMDC/PDMDC 350 1500 

SP 100 400 

TBBS --- ---

108 

Raw materials : Name Quantity (Avg. t/day) 

Di methyl lamine (40 %) 2.35 

Caustic Soda lye, 0.81 

Carbon disulphide, 1.53 

Chlorine . 0.77 

Process oil 0.03 

Sodium bicarbonate 0.036 

NaMBT 1.006 

Zinc Chloride 0.463 

Teritary Butyl Amine 0.077 

Sulphuric Acid 0.123 

Sodium hypochlorite 0.061 

Sodium sulphite 0.095 

Hexa Chloro benzene 0.217 

Sodium sulphide 0.179 

Methylated spirit 0.158 

China clay 0.256 

Stearic acid 0.035 

Phenol 0.050 

Styrene 0.117 

Fatty acid 0.030 

Caustic potash 0.013 

Boroquat 0.036 

Ammonium Chloride 0.009 

Iso Propyl Alcohol 0.0006 

Di Ethanol Amine 0.0001 

Styrenated Phenol 0.031 

Sulphur 0.024 

Xylene 0.002 

Iron P. Cyanine 0.006 

Process: 

1. Mercure TMT: Di methylamine, caustic soda lye and carbon disulphide are reacted 

in the first reactor to give sodium salt solution. The solution is then oxidized with the 

mixture of Chlorine & Air in the second reactor and gives the slurry of product and 

water. The resultant slurry is filtered and washed in a centrifuge to give wet 

product. This wet product is then dried in a drier and milled in a pulveriser to get 

dry and powered product. This product is then weighed and packed in specified 

packing bags. 

2. Mercure ZMBT 

NaMBT solution is taken in the reactor . the zinc chloride solution is used for the 

precipitation of product in this reactor. The required product will be in slurry from 

with water, which is then is filtered and washed in a centrifuge to give wet product. 

This wet product is then dried and milled in a pulveriser to get dry& powdered 

product. This product is then weighed and packed in specified packing bags. 

3. Mercure TBBS. 

NaMBT solution , TBA, sulphuric acid and hypo are reacted in the reactor. After the 

addition of caustic solution, the product containing slurry is filtered in a centrifuge to

109 

get wet product. This wet product is then dried in drier and milled in a pulveriser to 

get dry & powdered product. This product is then weighed and packed in specified 

packing bags. 

4. Mertiser 

Hexa Chloro benzene and sodium sulphide is reacted in first reactor to give sodium 

salt of PCT solution. This solution is then oxidized with Chlorine in the second 

reactor and gives the slurry of product and water. The resultant slurry is filtered and 

washed in a centrifuge to give wet powder. This wet powder is then dried in a drier 

and milled in a mill to get dry & powdered PCTS. This product is then mixed in 

Nauta mixer along with China clay, Stearic acid and iron Pthalao cyanine to get a 

mixer. This mixed powder is then milled in a pulveriser and this product is weighed 

and packed in specific packing bags. 

5. Mernox SP 

Styrene monomer is reacted with phenol in a reactor at controlled temperature under 

stirring for around eight hours. This liquid product is cooled and filled / packed in 

suitable containers. 

6. Mernox SP(E) 

Styrenated Phenol and hot water is agitated in an emulsifier at controlled 

temperature. This liquid product is then cooled and filled / packed in suitable 

containers. 

7. Merstabfs 

Ammonium chloride and Boroquat is reacted in a reactor at room temperature by 

stirring for around 5 hours. This liquid product is filled / packed in suitable containers. 

8. Antitack Agent VC 

Fatty acid and caustic soda lye is reacted in a reactor at controlled temperature by 

stirring for 8 hours. This liquid product is filled / packed in suitable containers. 

9. SDMDC 

Raw materials are; Di methylamine, Caustic soda lye , Carbon disulphide. 

Di methylamine, Caustic soda lye , Carbon disulphide are reacted in the reactor to 

give SDMDC solution. This liquid product is filled / packed in suitable containers. 

Waste: 

The company have obtained Board’s consent under the Water(Prevention and Control of 

Pollution)Act 1974 for discharging 10000 l/day effluent into periyar river. The effluent 

generated in the factory is taken to the Effluent treatment plant in the premises of M/s 

Merchem Limited , Edayar for treatment . The combined effluent after treatment is 

discharged into periyar river. 

A temporary facility of concrete tank with lining of HDPE provided in the premises of 

Merchem Limited Edayar is used for storing the hazardous waste of Effluent treatment plant 

sludge generated from sludge drying beds.

110 

The Effluent treatment system comprises of Primary & Secondary treatments . Liquid 

effluent from the plants is collected in a sump in the premises of the factory and taken to the 

raw effluent collection tank of ETP for equalization .The effluent is then pumped to the 

mixing channel where it is treated with chemicals such as lime, alum to coagulate the 

dissolved & suspended solids. This is allowed to settle in a primary settling tank and the 

overflow is subjected to secondary treatment of activated sludge process. 

After secondary treatment the effluent is allowed to settle in the secondary settling tank. 

The overflow is discharged through a V-notch chamber into periyar river through an open 

channel. The sludge generated is pumped to the sludge drying bed and then it is stored in 

temporary TSDF . 

Findings: 

1. The factory is producing Rubber accelerators , liquid type antioxidants, peptiser , 

Form Stabilizer, Anti tack agents and the production rate specified in the consent 

order is 

Mercure TMT 40 t/month 

ZMBT/Mertard 25 ,, 

Mertiser 15 ,, 

Mercure TBBS 5 ,, 

Mernox SP 5 ,, 

SDMDC/PDMDC 30 ,, 

2. Obtained consent under the Water(Prevention and Control of Pollution)Act 1974 for 

discharging 10,000 litre /day effluent into Periyar river. 

3. Effluent Treatment Plant constructed in the premises of Merchem Limited, Edayar is 

used for treating the effluent generated from both the factories. 

4. The effluent generated in the factory is collected in an effluent sump and taken to the 

Effluent Treatment Plant of Merchem Limited., Edayar in the adjacent plot by 

gravity flow. The treatment facility provided at Merchem limited comprises of 

Chemical treatment followed by, Activated Sludge Premises . 

5. The effluent treatment plant was not working at the time of inspection on 29-11-04. 

There was no overflow from the secondary settling tank. But there was considerable 

discharge from the outlet from the overflow channel of the secondary settling tank. 

Effluent samples were collected for analysis. 

The quality of supernatant effluent sample collected from the secondary settling tank 

and effluent in the overflow channel indicate that the effluent quality is varying to a 

great extent, instead of being similar. The overflow sample discharged through outlet 

is well within the limits whereas the effluent in the secondary settling tank is highly 

contaminated as noted below. 

No Determinants Unit Effluent from 

Secondary 

Settling tank. 

1 pH 5.9 7.0 

2 Suspended Solids mg/l 647 15 

3 TDS (inorganic) ,, 6900 382 

4 Zinc ,, 1.60 ND 

5 Chlorides ,, 4000 68 

Effluent from overflow channel 

of Secondary 

Settling tank

111 

6 Sulphates ,, 800 25 

7 Phenolic Compounds ,, 30 0.2 

8 Oil and grease ,, ND ND 

6. The result reveal that bypass line is provided for admitting fresh water to the outlet 

for diluting the effluent and achieving the prescribed quality. 

7. On seeing the inspection team the effluent treatment plant was started by pumping 

raw effluent from the collection tank to the mixing channel for chemical treatment. 

8. According to the company about 3kg/day sludge is generated from the effluent 

treatment plant which is dewatered in the sludge drying beds and disposed in the 

recently constructed temporary storage facility for hazardous wastes. 

9. Both the units namely M/s Merchem Limited, Edayar and M/s Merchem (India ) Pvt. 

Ltd have not obtained authorization under the Hazardous Waste(Management and 

Handling)Rules 1989 for the disposal of hazardous wastes. 

10. No Hazardous waste was seen stored in the temporary storage facility during the 

inspection on 29-11-04. The company authority informed that solid wastes and sludge 

generated so far from the effluent treatment plant ,since its inception were land 

disposed after drying in sludge drying beds. 

11. During the subsequent inspection on 08/06/05 hazardous waste disposal in temporary 

facility is seen started. 

12. The report of analysis of effluent collected on 29-11-04 and 08/06/05 show that the 

raw effluent contains high BOD,COD,TDS,Chlorides, Sulphates and high COD/BOD 

ratio. 

Date of Sampling 29-11-04 

No Determinants Unit 

Raw 

Effluent 

Tank 

Raw 

Effluent 

ZDC tank 

Primary 

Settling 

Tank 

Effluent 

from 

secondary 

Settling 

tank 

1 pH 7.4 8.6 6.5 5.9 7.0 

2 Suspended mg/l 30 788 18 647 15 

Solids 

3 TDS ,, 16632 9542 8748 6900 382 

(inorganic) 

4 Zinc ,, 0.35 0.1 3.5 1.6 ND 

5 Chlorides ,, 11400 3700 6000 4000 68 

6 Sulphates ,, 280 2000 400 800 25 

7 Phenolic 

Compounds 

8 Oil and 

grease 

,, 0.24 31 10 30 0.2 

,, ND ND ND ND ND 

Overflow 

channel of 

Secondary 

Settling 

tank

112 

Date of Sampling 08/06/05. 

Sl. 

No. 

Determinant Unit Merchem, 

India 

Raw 

effluent I 

(from 

Merchem 

India 

Over flow 

Raw 

effluent II 

Merchem 

India 

collection 

sump 

Merchem 

India raw 

effluent 

from line 

Merchem, 

Edayar 

Tolerance 

limit 

ETP) 

1. pH 6.5 6.6 6.9 5.9 9.6 6-8.5 

2 BOD mg/l 920 152 120 212 50 

3 COD ,, 2560 1432 1416 2400 552 

4 SS ,, 486 596 673 172 87 30 

5 TDS ,, 34518 26578 32414 3754 1420 2100 

6 Zinc ,, 12.5 15 11.5 17.5 ND 5 

7 Iron ,, 2.94 2.04 1.37 1.46 0.84 

8 Fluoride ,, ND ND ND ND ND 

9 Chlorides ,, 13700 14800 15100 14300 100 1000 

10 Phosphates ,, ND ND ND ND ND 

11 Phenolic ,, ND ND 1.51 1.51 ND 1 

Compounds 

12 Manganese ,, ND ND ND ND ND 

13 Oil and ,, ND ND ND ND ND 10 

Grease 

14 Sulphates ,, 1200 1500 750 500 110 1000 

15 Cyanide ,, ND ND ND ND ND ND 

16 Sulphides ,, ND ND ND ND ND ND 

13. A boiler is operating in the unit. The company have obtained Board’s consent 

under the Air(Prevention and Control of Pollution)Act 1981 

14. During the inspection on 04/10/05 raw effluent from both the factories are seen taken 

to the equalization tank for mixing. But the treatment plant was not working. 

Recommendation: 

1. The effluent generated from the factory contains high Chlorides,TDS and high 

COD/BOD ratio. The existing biological treatment system is ineffective for achieving 

the prescribed quality. Hence the company shall be directed to provide alternate 

treatment techniques such as evaporation system for eliminating pollution problems 

and achieving zero discharge system. The unit despite notice , have not taken any 

initiative to treat the inorganic toxic effluent generated . The discharge of toxic 

effluent by employing dilution technology after the biological treatment system is 

violation of Water(Prevention and Control of Pollution)Act 1974. A sister concern of 

this unit generating similar toxic effluent had to go for other non-biological 

treatment system. Until such system is installed the unit must be asked to stop 

production as the present ETP is found inadequate and ineffective. 

2. The actual production rate, water consumption and quantity of effluent generation 

are to be assessed.

113 

3. Water meter shall be provided at the intake point for measuring the actual water 

consumption. 

4. The actual quantity of effluent generated shall be assessed. 

MERCHEM LIMITED ,EDAYAR 


:Merchem Limited ,Edayar 

Date of Inspection :29/11/04,30/12/04,23/03/05,08/06/05 

Name of the Products : Name Quantity(kg /day) 

Average Maximum 

F 400 kg 900 kg 

ZDC 600 kg 1500 kg 

ZDBC 200 kg 700 kg 

ZBEC 30 kg 500kg 

Raw materials : 

Name 

Quantity(kg/day) 

Carbon di sulphide - 345 

Zinc Oxide - 143 

Zinc Chloride - 62 

Di ethyl Amine - 256 

Di n Butyl Amine - 113 

Di Benzyl Amine - 19 

Caustic Soda - 38 

Hexamine - 56 

DPG - 56 

MBTS - 288 

Process: 

1. F is manufactured by formulation of MBTS with DPG and hexamine. The raw 

materials are pulverized, mixed and again pulverized. 

2. ZDC is manufactured by reacting diethylamine and zin oxide with carbon 

disulphide with C 1 as catalyst .the resultant solution is filtered, washed dried and 

pulverized to get ZDC. 

3. ZDBC is manufactured in two steps.In step-1 SBDC is manufactured by reacting 

Di-n- butylamine and caustic with carbon disulphide.In step-2, ZDBC is 

manufactured by precipitation with SBDC and Zinc chloride along with dispersal- 

F.The resultant solution is filtered,washed,dried and pulverized. 

4. ZBEC.sodium dibenzyle dithio carbonate(SDBC) is manufactured by reacting 

DBEA (di benzyl amine)and caustic with carbon disulphide.The SDBC formed is 

reacted with Zinc chloride along with dispersal F to Precipitae ZBEC.

114 

Waste: 

Sources of liquid waste are centrifuge washings during the process of manufacture of 

ZDC, ZDBC and ZBEC. For storing the hazardous waste of effluent treatment plant 

sludge removed from sludge dying bed, a roofed temporary storage tank is 

constructed. 

Findings: 

1. The factory is engaged in the production of Rubber and accelerators 

(ZDC,ZDBC,ZBECF). The raw material used are Carbon Di sulphide, Di ethyl 

Amine, MBTS, Di Benzyl Amine, Di n Butyl Amine , Hexamine, DPG,MBTS,Zinc 

Oxides and Zinc chloride. The board has issued consent for manufacturing 53 t/m of 

accelerators where as the max production rate reported by the firm is 83 t/m. 

2. The source of water is an open well near the bank of the river Periyar.The total 

quantity of water consumed by the company is reported as 6000 litre /day. The 

production process reveals that the actual water consumption is much higher than the 

quantity reported by the company. 

3. An effluent treatment plant is provided in the factory premises which is used for 

treating the effluent generated from Merchem Limited and a mother unit functioning 

in the adjacent property namely Merchem (India)Pvt.Ltd. . The quantity of effluent 

discharge as per the consent issued to the unit is 13900 litre/day. 

4. The effluent treatment plant consists of two raw effluent collection tanks, mixing 

channel, primary settling tank, aeration tank, secondary settling tank, and sludge 

dying beds. The effluent generated from both the units are collected in two collection 

tanks and treated with lime and alum. The effluent after settling is taken to aeration 

tank for aerobic biological treatment, and settled in secondary settling tank. The 

overflow from secondary settling tank is discharged into the River Periyar through an 

open drain. 

5. The effluent treatment plant was not working at the time of inspection on 29-11-04. 

There was no overflow from the secondary settling tank. But there was considerable 

discharge from the outlet from the overflow channel of the secondary settling tank. 

Effluent samples of supernatant from the Secondary settling tank and effluent in the 

overflow channel of secondary settling tank were collected. Water sample was 

collected for analysis from the well in the factory premises which was found reddish 

in colour. Solid wastes accumulated and effluent stagnated as a pond just outside the 

factory boundary in the adjacent land owned by M/s Kunnath Chemicals was also 

collected for analysis. 

Source : Sludge from the premises of Kunnath Chemicls near compound of Merchem Edayar 

Date of sampling : 29-11-2004 

Sl. 

No. 

Determinant Unit 15 

448.4 

2 Iron 86535.0 

3 Lead 337.4 

4 Cadmium 9.3 

5 Total Chromium 1344.0 

6 Manganese 1098.7

115 

This lab report indicates the presence of effluent and ETP sludge in the adjacent 

premises. 

6. Effluent treatment plant was started on seeing the inspection team(08/06/05) by 

pumping raw effluent from the collection tank to the mixing channel for chemical 

treatment. 

7. According to the company about 3kg/day effluent treatment plant sludge is generated 

which is dewatered in the sludge drying beds and disposed in the recently constructed 

temporary storage tank for hazardous wastes. The unit has not obtained authorization 

under Hazardous Waste(Management and Handling)Rules 1989 for the disposal of 

hazardous wastes. 

8. No Hazardous waste was seen stored in the temporary storage facility during the 

inspection on 29-11-04. The company authority informed that solid wastes and sludge 

generated so far from the effluent treatment plant ,since its inception were land 

disposed after drying in sludge drying beds. During the inspection on 8-6-05 sludge 

disposal in the temporary facility was seen started . But during the inspection 

conducted on several occasions effluent is seen discharged into the Periyar River 

violating the consent condition. 

9. The company have obtained Boards consent under the water act upto 31-12-04 for 

discharging 13,900-l/day effluents. 

10. The quality of supernatant effluent sample collected from the secondary settling tank 

and overflow channel indicate that the effluent quality is varying to a great extent, 

instead of being similar. The overflow sample discharged through outlet is well 

within the limits whereas the effluent in the secondary settling tank is highly 

contaminated as noted below. The result reveal that bypass line is provided for 

admitting fresh water to the outlet for diluting the effluent. 

No Determinants Unit Effluent from 

Secondary 

Settling tank. 

1 pH 5.9 7.0 

2 Suspended Solids mg/l 647 15 

3 TDS (inorganic) ,, 6900 382 

4 Zinc ,, 1.60 ND 

5 Chlorides ,, 4000 68 

6 Sulphates ,, 800 25 

7 Phenolic Compounds ,, 30 0.2 

8 Oil and grease ,, ND ND 

Effluent from overflow channel 

of Secondary 

Settling tank 

11. The report of analysis of effluent collected on 29-11-04 show that the raw effluent 

contains high Chlorides(11400 mg/l), Sulphates(2000 mg/l) and Phenolic compounds.

116 

Date of Sampling 29-11-04 

N 

o 

Determinant 

s 

Unit Overflow 

channel 

of 

Secondar 

y 

Settling 

tank 

Primar 

y 

Settling 

Tank 

Raw 

Effluen 

t Tank 

Raw 

Effluen 

t ZDC 

tank 

Well 

Water 

Merche 

m 

Effluent 

from 

secondar 

y 

Settling 

tank 

1 pH 7.0 6.5 7.4 8.6 6.1 5.9 

2 Suspended mg/ 15 18 30 788 8 647 

Solids 

l 

3 TDS ,, 382 8748 16632 9542 688 6900 

(inorganic) 

4 Zinc ,, ND 3.5 0.35 0.1 ND 1.6 

5 Chlorides ,, 68 6000 11400 3700 190 4000 

6 Sulphates ,, 25 400 280 2000 250 800 

7 Phenolic 

Compounds 

8 Oil and 

grease 

,, 0.2 10 0.24 31 ND 30 

,, ND ND ND ND ND ND 

Sl. 

No. 

Determinant Unit Merchem, 

Edayar 

Merchem, 

India 

Raw from 

ETP 

Merchem 

India 

Over flow 

Raw II 

Final 

outlet 

Well 

Merchem 

1. pH 9.6 6.5 6.6 6.6 6.7 

2 BOD mg/l 50 920 152 3.2 0.2 

3 COD ,, 552 2560 1432 48 16 

4 SS ,, 87 486 596 48 45 

5 TDS ,, 1420 34518 26578 1158 1788 

6 Zinc ,, ND 12.5 15 0.1 0.27 

7 Iron ,, 0.84 2.94 2.04 1.602 6.29 

8 Fluoride ,, ND ND ND ND ND 

9 Chlorides ,, 100 13700 14800 440 510 

10 Phosphates ,, ND ND ND 3.5 ND 

11 Phenolic 

,, ND ND ND 0.96 0.18 

Compounds 

12 Manganese ,, ND ND ND ND ND 

13 Oil and Grease ,, ND ND ND ND ND 

12. During the enquiry of a complaint received from M/s Kunnath Chemicals Pvt. Ltd 

regarding the escape of Chlorine gas through the exhaust fan of Merchem Ltd, Edayar on 

23-3-05 the company authorities reported that chlorine is one of the raw materials used for 

production purpose. But it is noted that chlorine is not shown among the list of raw materials 

and name of the product manufactured using chlorine are not mentioned in the Proforma 

submitted to LAEC.

117 

Recommendations: 

1. The effluent generated from the factory contains high Chlorides,TDS and high 

COD/BOD ratio. The existing biological treatment system is ineffective for achieving 

the prescribed quality. Hence the company shall be directed to provide alternate 

treatment techniques such as evaporation system for eliminating pollution problems 

and achieving zero discharge system. The unit despite notice , have not taken any 

initiative to treat the inorganic toxic effluent generated . The discharge of toxic 

effluent by employing dilution technology after the biological treatment system is 

violation of Water(Prevention and Control of Pollution)Act 1974. A sister concern of 

this unit generating similar toxic effluent had to go for other non-biological 

treatment system. Until such system is installed the unit must be asked to stop 

production as the present ETP is found inadequate and ineffective. 

2. The actual quantity of effluent discharge should be assessed for the maximum 

production rate. 

3. Maximum production rate reported in the proforma is found to exceed the quantity 

specified in the consent order. 

4. Chlorine gas is admittedly used in the factory for processing purpose. But Chlorine 

gas is not included among the list of raw materials furnished to the committee. It is 

noticed from the proforma submitted by Merchem (India) Pvt. Ltd. Chlorine gas is 

used for producing MBTS/MBS. It should be ascertained whether M/s Merchem 

Limited, Edayar is manufacturing these products, which are not disclosed in the 

application submitted to the committee /PCB. 

5. Products manufactured and Production rate shall be verified. 

6. During the inspection of the factory it was noticed that fresh water dilution is 

employed at the discharge point of Effluent treatment plant for achieving the 

prescribed effluent quality. This should be stopped forthwith. The company should go 

for zero effluent discharge system by providing other treatment techniques such as 

evaporation. 

7. The premises of the effluent treatment plant near the well found containing effluent 

and slurry from Effluent treatment plant 

8. House keeping is to be improved. 

SUD CHEMIE INDIA PVT LTD 


: Sud Chemie India Pvt Ltd 

Date of Inspection :20-11-2004. 

Name of the Products 

:HT shift catalyst- 60 t/ month 

LT shift catalyst- 20t/ month 

Zinc oxide catalyst- 25 t/month 

Dechlorination catalyst or 

Hydrodesulphurization catalyst—20 t

118 

Raw Materials: 

Name of materials Process where used Consumption 

in t/day(Max) 

1. Ferrous Sulphate HT Shift catalyst 8.0 MT 

2. Sulphuric Acid HT Shift catalyst and ETP 4.8 MT 

3. Caustic soda HT Shift catalyst 2.5 MT 

4. Sodium bicarbonate HT Shift catalyst 0.5 MT 

5. Zinc LT Shift+zinc oxide catalyst 1.5 MT 

6. Copper HT+ LT Shift catalyst 1.5 MT 

7. Alumina LT Shift catalyst 0.5 MT 

8. Ammonia LT Shift catalyst 1.0 MT 

9. Carbon dioxide LT Shift catalyst 2.5 MT 

10. Magnesium oxide LT Shift catalyst 0.1 MT 

11. Soda ash Zinc oxide catalyst 1.6 MT 

12. Commercial Zinc oxide Zinc oxide catalyst 1.6 MT 

13. Ammonium molybdate Hydro desulphurisation catalyst 1.0 MT 

14. China Clay Zinc oxide / dechlorination catalyst 0.1 MT 

15. Lime Powder Dechlorination catalyst 0.2 MT 

16. Graphite HT+ LT Shift catalyst 0.2 MT 

17. Ammonium bicarbonate Dechlorination catalyst 0.2 MT 

18. Barium Hydroxide Dechlorination catalyst 0.08 MT 

19. Furnace oil HT+ LT Shift catalyst 3000 litre/day 

20. MTO HT+ LT Shift catalyst 2800 litre/day 

Process. 

Metal carbonates and hydroxides on support like alumina are made through metal amine 

carbonate complex .These metal carbonates are calcined to form oxides ,which are formed 

into extrudates or tablets 

C12 Catalyst (Iron and Chromium catalyst) manufacturing process. 

Ferrous Sulphate solution and sodium bichromate are mixed and dilute sodium hydroxide is 

added. After precipitation the slurry is transferred to precipitator after adding required 

quantity of proper solution and graphite. The slurry is washed, filtered and dried in band 

drier or box drier. Wastewater from C18 filtrate is used for washing. 

C18 Catalyst 

Zinc Amine solution is prepared by reacting Zinc, Ammonia, and carbon dioxide in water or 

scrubber solution and stored. Copper ammine solution is prepared by reacting Copper, 

Ammonia, and Carbon dioxide in water or scrubber solution in Copper reactor. Zinc solution 

and Copper solution are blended in C18 premix to get the specified ratio. DM water or 

scrubber solution is filled in decomposer I and required quantity of alumina is charged into it. 

Carbon dioxide is bubble through the solution and steam heated. Premix solution is pumped.

119 

The boiling is continued when the metal concentration in the slurry reaches the desired level 

of 0.01 %, the slurry is quenched in decomposer II. It is settled, decanted and graphite is 

added. The slurry is filtered, dried and fed to granulating / tabletting machine. 

C7 (intermediate) and G1 Catalyst 

Commercial Zinc oxide is activated in decomposer with ammonium bicarbonate and water. 

It is heated to about 70 0 C and maintained for about 4 hours and soluble metal boiled down. 

This solution is filtered to get the cake and the cake is washed. The cake is dried in the box 

drier and the dried lump is stored as HSA zinc oxide(C7). For G1 the specified quantity of 

HSA zinc oxide is mix mulled with ammonium molybdate, Copper solution and graphite to 

get the required zinc oxide in the finished product. The feed so made is fed to the pelletizer 

to form pellets.These pellets are collected in drums and kept for steam curing. After curing 

the pellets are loaded into racks and dried in box drier to reduce the LOI below 5%. 

C11-18 

Zinc amine solution and copper amine solution are made using the process similar to 

C18.Zinc and cuprous free copper solution are blended in C18 premix to get the specified 

ratio. DM water or scrubber solution is filled in decomposer I. Steam is admitted into the 

coils. When boiling starts the scrubber system is switched on. Premix solution is pumped 

continuously. When the predetermined batch size of total metal is pumped from premix tank, 

pumping is stopped. Boiling is continued and soluble metal in the slurry is brought down to 

less than 0.01%. When the soluble metal is below 0.01% the slurry is transferred to 

decomposer II or C18 hold tank. The slurry from the hold tank is filtered in filter press and 

the cake is collected in racks for drying. The cake is dried in box drier. 

C18 G. 

C18 powder (rework), barium hydroxide and ammonium bicarbonate is charged to the 

decomposer already filled with DM water. It is heated to about 50-55 0 C and start injecting 

CO2. Check for turbidity at regular intervals. Once turbidity is ok, the solution is filtered to 

get the cake. This cake is washed and collected in racks for drying. The cake is dried in box 

drier. 

Waste: 

The company generates 150 to 200 m3 per day of effluent which is discharged in to the 

Periyar River after treatment. 

The sludge generated from the effluent treatment plant containing Chromium, Zinc, Iron, 

Copper, and Aluminium etc is the hazardous waste (category – 34.3 ETP sludge). Waste 

generation per 100 tonne product is 600 kg and the maximum waste generation is 50 kg /day. 

A roofed concrete tank is used for storing the hazardous waste. Before constructing this new 

tank, sludge was being disposed in open pits in the premises of effluent treatment plant by the 

riverside.

120 

Findings 

1. The factory situates by the river side at about 60m away from the river. There is no 

direct intake from Periyar River. The Water requirement of 200 to 250 m 3 /day is 

met by M/s FACT (80%) and three nos ground wells in the factory premises 

2. The company authorities reported that the hazardous waste generated since 1997 is 

stored in the roofed concrete storage tank (without lining) and the quantity of waste 

stored till date is 169 tonne. The capacity of the tank is 225 m3. The unit has got valid 

consent under the Water (Prevention and Control of Pollution) Act 1974, Air 

(Prevention and Control of Pollution) Act 1981 and authorization under Hazardous 

Waste (Management and Handling) Rules 1989. The company authorities have 

informed that they have requested for Board’s permission to use the newly 

constructed R.C.C tank of 10.5 x 21 x 2.4 m after providing polythene lining. 

The sources of emissions are Boilers (2nos) band driers (2nos) ammonia scrubber 

stack (30 m high), box driers (2nos), tableting machines (2nos), generator (2nos, 500 

KVA and 100 KVA) 

Effluent and emission monitoring reports as stipulated in the consent order and 

environmental audit report are submitted to the Board periodically. 

The company authorities informed that there is a proposal for installing sulphuric acid 

catalyst manufacturing plant. 

3. The effluent treatment plant was working during the inspection. The effluent 

generated from the factory are passed through oil taps for removing oil and collected 

in equalization tank. The wastewater from the canteen is taken to the equalization tank 

after removing the suspended solids. 

The effluent is then taken to the flash mixer for chemical treatment, settled and passed 

through sand filters. The treated effluent is discharged into the river Periyar. The 

underflow from the settling tank is fed through a plate and frame filter press and the 

dewatered sludge is disposed in the hazardous waste storage tank. The filtrate from 

the filter press is taken to sand filter after pH correction. The pH of the effluent from 

the filter press was noted as 6.5 during inspection. 

4. The sludge pump used for pumping the sludge to the filter press is kept in a roofed tank. 

Solid wastes from the canteen are collected in a roofed tank provided with a grilled 

cover. 

5. The spillage from furnace oil storage tanks are collected inside the dyke wall, passed 

through oil traps and recovered. Considerable spillage was noticed near the storage tanks. 

The waste water discharged from the oil trap is taken to the ETP.Used oil is collected in 

drums for final disposal to authorized dealers. The quantity of used oil as reported by the 

company is 150 litre in 90 days. Scrap is stored separately. 

6. A Delay pond is provided in storm water drain. 

7. During the inspection of the factory the surrounding areas of effluent treatment tanks 

were seen covered with crushed metals. Over all housekeeping is satisfactory. 

The cooling water (20m 3 /day) after passing through cooling towers (2nos) is recirculated 

8. The raw material FeSo 4 is stacked in a partially roofed yard. An underground cement 

plastered pit with tin sheet roofing is provided for collecting the leakage from old wooden 

pit, which was used for collecting the spillage from FeSo 4 storage area.

121 

9.Greenbelt provided is inadequate. During the subsequent inspection conducted it is noticed 

that the company have taken positive steps for planting more trees and more trees and 

developing greenbelt . 

10. Effluent and water samples are collected for analysis. 

The report of analysis of the effluent collected from the authorized outlet of the factory 

on 20-11-04 and 15-7-05 are noted below. 

Parameters Analyzed 

Parameters Tolerance limits in the 

consent book 

1. PH 7.1 pH - 6.70 5.5-9.0 

2. BOD 0.9 mg/l 

3. COD 3.2 ,, 

4. SS 6.0 ,, SS - 9.0 100 

5. Zinc 0.04 ,, Zinc - 0.12 5 

6. Iron 0.11 ,, 

7. Lead 0.88 ,, 

8. Mercury ND 

9. Cadmium 0.07 ,, 

10. Copper 0.068 ,, copper - ND 3 

11. Nickel 0.03 ,, Nickel - ND 3 

12. Chlorides 34.0 ,, 

13. Cyanides ND ,, 

14. Phenolic compounds ND ,, 

15. Hexavalent Chromium ND ,, Hexavalent Chromium- 0.1 mg/l 

16. Total Chromium 0.03 ,, Total Chromium- 2mg/l 

17. Manganese 0.15 ,, 

18. Oil and grease ND ,, Oil and grease -10 mg/l 

19. Titanium ND ,, 

20. Free available Chlorine ND ,, 

The analysis report of the hazardous waste collected from the waste storage tank 

on 12-1-05 is given below. A/R no;1131 The report shows the presence of copper, 

Chromium compounds II exceeding the limits specified in class B schedule II and 

also high content of Zinc. 

Recommendation: 

1. A decision is to be taken by the Board on the company’s proposal to use the newly 

constructed hazardous waste storage tanks after providing required lining. 

2. Effluent treatment plant should be augmented for complete recycling of treated effluent. 

3.Chromium bearing effluent should be segregated and treated separately. 

4. Chromium recovery plant should be installed. 

5. Test wells are to be provided near the effluent treatment plant and hazardous waste 

storage tank. 

6. Greenbelt is to be improved.

122 




limit 

1 PH 5.5-9 

2 Suspended Solids mg/l 100 

3 Oil and Grease ,, 10 

4 Hexavalant Choromium ,, 0.1 

5 Total Chromium ,, 2.0 

6 Copper(as Cu) ,, 3.0 

7 Nickel (as Ni) ,, 3.0 

8 Zinc (as Zn) ,, 5.0 


Source 

: Sud Chemie India Pvt. Ltd. 


Sample Identification No :LAEC 45(Sludge pond) 


Sl. 

No. 


45 

1. PH 6.7 

2 Zinc mg/kg 14812.5 

3 Lead 180 

4 Mercury BDL 

5 Cadmium 6.8 

6 Copper 6460 

7 Nickel 201 

8 Arsenic BDL 

9 Chlorides 800 

10 Nitrates (as N) 1000 

11 Sulphate 6390 

12 Cynide BDL 

13 Sulphide BDL 

14 Free ammonia 0.36 

15 Ammoniacal Nitrogen 45 

16 Phenolic Compounds BDL 

17 Total Chromium 9812 

18 Manganese 1030

123 

Source 



Sample Identification No :LAEC 240(Raw Effluent Incoming line), 

LAEC 242(Effluent +Canteen Effluent after Oil trap), 

LAEC 241(Effluent Composite Tank), 

LAEC 243(Flash mixer Outlet), 

LAEC 244(SettlingTank) 


Sl. 

No. 


240 

LAEC 

242 

LAEC 

241 

LAEC 

243 

LAEC 

244 

1 pH 12.3 12.3 10.3 5.8 5.3 

2 SS mg/l 898 132 296 284 35 

3 Zinc ,, 0.1 0.2 0.08 0.1 0.1 

4 Copper ,, 1.1 ND ND ND ND 

5 Nickel ,, ND ND ND ND ND 

6 Free Ammonia ,, 86.23 267.38 249.48 ND ND 

7 Ammoniacal Nitrogen ,, ND 267.38 297 409.4 159.4 

8 Hexa Chromium ,, ND ND ND ND ND 

9 Total Chromium ,, ND ND ND ND ND 

10 Oil and Grease ,, ND ND ND ND ND 

Source 



Sample Identification No :LAEC 245(Filter Pin Outlet), 

LAEC 246(Fixed Outlet), 

LAEC 247(Sand Filter), 


Sl. 

No. 


245 

LAEC 

246 

LAEC 

247 

1. pH 6.6 6.7 6.5 

2 SS mg/l 12 9 8 

3 Zinc ,, 0.14 0.12 ND 

4 Copper ,, ND ND ND 

5 Nickel ,, 0.53 1.12 1.3 

6 Free Ammonia ,, ND ND ND 

7 Ammoniacal Nitrogen ,, 105 224 260 

8 Hexa Chromium ,, ND ND ND 

9 Total Chromium ,, ND ND ND 

10 Oil and Grease ,, ND ND ND

124 

Source 



Sample Identification No :LAEC 1(Outlet) 


Sl. Determinand Unit LAEC1 

No. 

1. pH 7.1 

2 BOD mg/l 0.9 

3 COD ,, 3.2 

4 SS ,, 6.0 

5 Zinc ,, 0.04 

6 Iron ,, 0.11 

7 Lead ,, 0.88 

8 Mercury ,, ND 

9 Cadmium ,, 0.07 

10 Copper ,, 0.068 

11 Nickel ,, 0.03 

12 Chlorides ,, 34.0 

13 Cyanides ,, ND 

14 Phenolic Compounds ,, ND 

15 Hexa Chromium ,, ND

Indian Aluminium Company Limited, Alupuram Smelter Eloor.

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