Disclosure to Promote the Right To Information

Whereas the Parliament of India has set out to provide a practical regime of right to information for citizens to secure access to information under the control of public authorities, in order to promote transparency and accountability in the working of every public authority, and whereas the attached publication of the Bureau of Indian Standards is of particular interest to the public, particularly disadvantaged communities and those engaged in the pursuit of education and knowledge, the attached public safety standard is made available to promote the timely dissemination of this information in an accurate manner to the public.

इंटरनेट मानक

“!ान $ एक न' भारत का +नम-ण”Satyanarayan Gangaram Pitroda

“Invent a New India Using Knowledge”

“प0रा1 को छोड न' 5 तरफ”Jawaharlal Nehru

“Step Out From the Old to the New”

“जान1 का अ+धकार, जी1 का अ+धकार”Mazdoor Kisan Shakti Sangathan

“The Right to Information, The Right to Live”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता है”Bhartṛhari—Nītiśatakam

“Knowledge is such a treasure which cannot be stolen”

“Invent a New India Using Knowledge”

है”ह”ह

IS 12112 (1987): Code of practice for control of airpollution in refractories industry [CHD 32: EnvironmentalProtection and Waste Management]

IS : 12112~-1987

Indian Standard CODE OF PRACTICE FOR

CONTROL OF AIR POLLUTION IN REFRACTORIES INDUSTRY

Air Quality Sectional Committee, CDC 53

Ctiairman

DR B. B. SUNDARESAN

Members

Representing

University of Madras, Madras

DR H. KOTHANDARAMAN ( Aftcrnafe to Dr B. B. Sundaresan )

DRA. L. A~ARWAL National Environmental Engineering Research Institute ( CSIR ), Nagpur

SHRI P. K. YENNAWAR ( Alternate ) DR J.S. AHLUWALIA Indian Oil Corporation Ltd, Faridabad

SHRI V. S. MORE ( Altnnatt ) SHRI N. G. ASHAR Dharmsi Morarji Chemical Co Ltd, Bombay

DR M. S. V AIDYA ( Alternate ) DR B. B. BANSAL Central Mechanical Engineering Research Institute,

Durgapur SHRI B. BHADURY ( Alternate )

SHRI A. K. BASU Calcutta Metropolitan Development Authority, Calcutta

SHRI RANJIT KUMAR SENGUPTA ( Alternate )

SRRI~S. CHAKRABARTY

DR PHTJLEEAR ( Alternate 1

Directorate General Factory Advice Service & Labour Institutes, Bombay

SHRI P. CHATTERJEE ’ National Organic Chemicals Industries Ltd, Bombay SHRI K. D. A~KE ( Alternate )

DR NILAY CHAUDHURI Central Board for the Prevention and Control of Water Pollution, New Delhi

MEMBER-SECRETARY ( Alternate ) SHRI J. M. DAVE Jawaharlal Nehru University: New Delhi DR P. J. DEORAS Society for Clean Environment, Bombay

DR S. B. CHAPHEKaR ( AhrnUtC ) SHRI M. V. DESAI Indian Chemical Manufacturers’ Association, Calcutta

SHRI B. SARAN ( Alternate ) DR V. S. GUPTA Projects & Development India Ltd, Sindri

SHRIYATI M. CHANDRA ( Alternate )

( Continued on page 2 )

@ Copyright 1988

BUREAU OF INDIAN STANDARDS

This publication is protected under the Indtin CoPyright Acr ( XIV of 1957 ) and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act.

IS : 12112 - 1987

( Continued from page 1 )

Members Representing

SHRI A. LAHIRI Hindustan Lever Ltd, Bombay SHRI A. MITRA ( Alternate )

DR N. K. MEHROT~A Industrial Toxicology Research Centre ( CSIR ), Lucknow

SHRI M. M. LAL ( Alfernate I ) SHRI J. L. KAW (‘Alternate II’)

SHRI A. K. MISSER Cement Manufacturers’ Association, New Delhi SKRI P. A. MITRA Union Carbide of India Ltd, Bombay

SHRI Y. G. PATANKAR ( Alternate ) SERI A. K. MOORT~ERJEE Flakt India Ltd, Calcutta

SHRI M. CH.~UDHRY ( Alternate ) DR P. N. MUICHERJEE Central Fuel Research Institute ( CSIR ), Dhanbad

DR R. U. ROY ( Altcrnafc ) DR V. PACHAIYAPAN Fertilizer Association of India, New Delhi

DR S. NAND ( Alternate ) SERI G. K. PANDEY Department of Environment Government of India,

New Delhi Da T. S, PATEL National Institute of Occupational Health ( ICMR ),

Ahmadabad SHRI S. K. PATIL Maharashtra Pollution Control Board, Bombay

SHRI D. R. RASAL ( Alternate ) SHRI C. R. MADHAVA RAO Steel Authority of India Ltd, Ranchi

SHRI I. JAYARAMAN ( Alternate ) SHRI A. N. RAO Directorate General of Technical Development,

New Delhi SKRI P. K. RAMACRANDKAN

DR B. V. RAYANI ( Alternate ) Ministry Df Defence ( DGI )

SHRI Ca V. RAMANAMURTXY Central Electricity Authority, New Delhi SHIZI R. K. SHARMA ( Alternate )

DR S. G. RETARKA~ Municipal Corporation of Greater Bombay, Bombay SHRI DHIRENDRA J. VYAS ( Alternate )

SHRI S. B. SARKAR Coal India Ltd, Calcutta SHRI B. F. S.4LuJA Gujarat Pollution Control Board, Gandhinagar

DR U. I. BHATT ( Afternate ) DR V. V. SHIRVAIKAR Bhabha Atomic Research Centre, Bombay

DR R. K. KAPOOR ( Alternate ) DR J. K. SINHA Central Mining Research Station ( CSIR ), Dhanbad

SHRI A. K. BOSE ( Alternate ) SHRI SATISH CHANDER, Director General, BIS ( Ex-o&cio Member )

Director ( Chem )

SRRI S. ARAVAMUDHAN Joint Director ( Chem ), BIS

( Co&stud an page 10 )

2

IS : -12112 - 1987

Indian Standard CODE OF PRACTICE FOR

CONTROL OF AIR POLLUTION REFRACTORIES INDUSTRY

0.1 This Indian Institution on 26 Quality Sectional Division Council.

0. FOREWORD

IN

Standard was adopted by the Indian Standards Feburary 1987, after the draft finalized by the Air

Committee had been approved by the Chemical

~0.2 Protection and improvement of air quality for present and future generations should be ensured. Also for uniform application of techno- logy and operating practices, a code of practice containing the latest available information on air pollution sources, determination of emissions, control techniques, measurement and monitoring of emissions would be useful in the design and operation of dust control equipment for refrac- tory industry.

0.3 Refractories industry is one of the major source of pollution of the atmosphere because of the type of operations in these plants. Raw materials of various kinds, depending upon the type of refractories to be made, undergo physical processing as given in material flow sheet ( see Fig. 1 ).

0.4 This standard is formulated to help the industry to identify the sources of pollution and to take suitable action for pollution abatement.

1. SCOPE

1.1 This standard prescribes a code for controlling air pollution from various processes/sections of refractories industry. The code covers the following:

a) air pollutants,

b) source of air pollutions,

c) pollution control techniques,

d) location and lay out, and

e) air pollution survey.

3

IS: 12112 - 1987

c SCALE CARS (DUST)

1

MIXER (DUST)

4

I DRIER (SO,) 1

I t

KILN i-302) I

FIG. 1 MATERIAL FLOW SHEET FOR TYPICAL REFRACTORIES PLANT

4

IS : 12112 - 1987

2. AIR POLLUTANTS

2.1 The raw materials undergo various types of physical processing as givenin the material flow sheet ( see Fig. 1 ).

The handling process of these raw materials may give out mainly dust and sulphur dioxide as main pollutants.

3. SOURCES OF AIR POLLUTANTS

3.1 Raw Materials - The processing of raw materials is responsible for release of huge amount of particulates. Calcining of raw materials in oil fired kilns causes emission of oxides of sulphur and particulates. In case af gas fired kilns only particulates are emitted. The concentration of particulates in the exhaust gas of kilns go as high as 30 g/Nm3. The oxides of sulphur depend upon the, sulphur content of fuel. For furnace oil with 3’5 percent sulphur, for example, the sulphur dioxide emission rate may be as high as 20 g/s.

-3.2 To reduce the occupational health hazard inside work place, a proper atmosphere is maintained by enclosing all dust generating points and connecting them lo dust extraction system through dust extraction hoods and ducting. ‘The concentration of particulate matter in the exhaust air depends upon the raw materials and their processing.

3.2.1 The concentration of dust and particulate size distribution is predictecl to select a proper dust catcher. In case of refractories plants, the concentrarion of dust in extracted air may vary from as low as 200 mg/rna to as high as 15 000 mg/m 3 depending on the place of dust generation, the temperature, moisture of material processed, the bulk density of material processed aa;l it< breaking characteristics. Experimental figures show that whereas in the air extracted from the cover of jaw crusher processing quartz of size up to 400 mm with moisture content of 1-2 percent, the average dust concentration is 150-200 mg/m3, the same from covers of vibratory screen processing calcined clay of 0.5 pm size with moisture of 0’5 percent is about 15 000 mg/m3. As dust extraction hoods are connected to common dust extraction systelns, the average concentration of dust is 3 000 to 5 000 mg/mz of air with large percentage of particulate of low micron size.

4. POLLUTION CONTROL TECHNIQUES

4.1 The exhaust gases from kilns and extracted air from dedusting operations cannot be emitted to atmosphere without cleaning. The kiln gases are, therefore, cleaned in gas cleaning plants to reduce the con entration of particulate matter to the prescribed limits. If oxid es of sulphur are also present in the kiln gases, the gases are emitted through chimney of suitable height to dilute and disperse the gases to conform to concentration at ground level within the prescribed ambient

5

IS I 12112 - 1987

air quality standards. The height of the selected chimney is-also check- ed to ensure that particulate matters at ground level are within ambient air quality standards.

4.2 The kiln gases are cleaned in one of the following types of gas cleaning plants:

a) Electrostatic precipitators;

b) Venturi scrubbers;

c) High efficiency centrifugal scrubbers as second stage gas cleaning plant and I yclones as first stage; and

d) High efficiency battery cyclones ( smaller diameter cyclones ).

4.3 The exhausted air from local dust extraction hoods are cleaned in dust catchers to reduce the-emission limit of dust as follows:

a) For volume of air emitted to atmosphere more than 15 000 ma/h, the emission limit is calculated by formula:

Cl = 100 k . . . . . . . . . . ..(l)

b) For volume of air emitted to atmosphere equal to 15 000 ms/h and less, the emission limits is calculated by formula:

C, = ( 160 - 4 V) k . . ..(2)

where

V = volume of air in thousand m3 per hour .

ET = factor depending on concentration of dust allowed in workplace atmosphere ( see Table 1 ).

TABLE 1 VALUE OF K

( Clause 4.3 )

SL No.

(1)

i) ii)

iii)

iv)

ALLOWEI, WU:~I<PI,AC~ CONCENTUATION OL’ DUST

( =%P3 )

(2)

2 and less

More than 2 and up to 4

More than 4 and up to 6

More than 6

x

(3)

0.3

0%

0.8

1.0

4.4 The values of C, and Cz are rechecked to ensure that total concentra- tion of dust at ground level from all stacks and chimneys are within permissible ambient air quality standards. If this is not complied with, at any point on the ground level, the emissions are reduced and/or chimney heights increased selectively to achieve optimum results.

6

4.5 The exhausted air from dedusting the following types of dust catchers:

a) Cloth bag filter;

operations are cleaned in one of

b) Combination of internal dust collect& and cloth bag filter; and

c) High efficiency cyclones.

4.6 Stack

IS : 12112 - 1987

4.6.1 In addition to rate of emission of air pollution, their heiqht of release plays a very important role in the control of air pollution. Higher is the plume centre line from ground level, the better is the dispersion of pollutants in atmosphere and lower is the concentration at ground level.

4.6.2 The height of centre line of plume is known as effective height of stack as shown in Fig. 2.

/cl----.. _--- /

*’ -- -4 __ --- -- /’

____M. __i_-_-_ --- ---_

PLUME CENTRE LINE

FIG. 2 PLUME RISE

4.6.3 The effective height of stack ( Hc ) is the summation of physical height of stack ( H ) and plume rise (AH ). Plume rise is caused by two reasons:

a) Momentum of plume, and

b) Buoyancy of plume. 7

IS : 12112 - 1987

4.6.4 For cold emissions, as is common in dedusting systems, the efflux velocity ( V ) of the air causes plume rise (AH) and for hot emissions, for example, emissions from kilns, plume rise is caused by efflux velocity as well as thermal energy. To keep the effective stack height maximum possible, the following general measures are adopted:

4

b)

c>

4

4

f)

Effort is made to use dry gas cleaning system for hot kiln gases. Wet gas cleaning reduces temperature of discharged plume thus reducing plume rise due to buoyancy;

Efflux velocity of cleaned air emission should be greater than 15-20 m/s;

Conventional caps which deflect the exhausted air downwards is avoided. Instead, specifically designed weather cowls which allow air to move vertically up, and prevent rain water to enter duct, is used;

Pollutants are not emitted in areas of aerodynamic shadow. The stack height is kept higher than the shadow zone or the discharge velocity is increased to produce ‘plume jets’;

The height of discharge oi air from dedusting systems is kept at least 2 m higher than the nearest building top;

The height of all stacks are checked by overall calculation of ground level concentration at selected points.

5. LOCATION AND LAYOUT OF REFRACTORIES INDUSTRY

5.1 While deciding the location for new plant or expansion of the existing operations environmentally acceptable approach has to be ensured. This task will include:

a) b) cl 4 e)

Selection of suitable site;

Appropriate technology available for the industry to be adopted;

Cleanir g equipment be installed together with the whole plant;

Cleaning equipment have to comply with specifications;

It is advisable to monitor air pollution levels before start up of the plant; and

f ) The slant should be so located that the predominant wind direc- the-residential localities and

area should be located much ground level concentrations

tion do not carry the gases towards green belts. Alternately, residential away from the plant to keep the within ambient air quality limits.

8

IS : 12112 - 1987

6. AIR YOLLUTION SURVEY

6.1 It is advisable to conduct air pollution survey of the locality around new plants or proposed expansion. Pollution control unit of the plant should be designed to take care of the already existing background -pollution level.

6.2 All plants should have independent pollution monitoring facilities. A systematic record of emissions in working areas and also in the ambient air within a diameter of 5 km should be maintained by the pollution monitoring and control group. A fully equipped analytical laboratory and trained personnel is an asset to the industry.

9

IS : 12112 - 1987

( Continued from page 2 )

Codes of Practice for Control of Air Pollution Subcommittee, CDC 53 : 4

COIlV0I.9 Representing

SHRI N. G. ASKAR Dharamsi Morarji Chemical Co Ltd, Bombay

Members

SHRI L. K. JAIN ( Alternate to Shri N. G. Ashar )

DRA.L. AGARWAL National Environmental Engineering Research Institute ( CSIR ), Nagpur

SRRI G. K. PANDEY ( Alternate ) SRRI S. CHAKRARARTY Directorate General Factory Advice Services and

Labour Institutes, Bombay DR PEELEKAR ( Alternate )

SHRI P. CHATTERJEE National Organic Chemical Industries Ltd, Thane SHRI K. D. AXRE ( Alternate )

SHRI P. R. GHARY: KHAN Indian Petrochemicals Corporation Ltd, Vadodara SHRI M. K. PRA~HU ( Alternate )

Da V. S. GuPra Projects & Development India Ltd, Sindri SHIlI S. B. SINHA ( Alternate )

SRRI D.B. IRANI National Council for Cement and Building Materials, New Delhi

SHRI R. GANAPATHY ( Alternate ) SRRI J. P. KAPUR Indian Chemical Manufacturers’ Association,

Calcutta De N. C. MEHTA ( Alternate )

SHRI M.M. LAL Industrial Toxicology Research Centre ( CSIR ), Lucknow -

SHRI S. K. MAIRA Flakt India Ltd, Calcutta SHRI B. MAJUMDAR ( Alternafc )

DR V. PACEAIYAPAN Fertilizer Association of India, New Delhi DR S. NAND ( Alternate )

SRRI T. C. PARTHASARATHY Bharat Heavv Electricals Ltd, Hyderabad SHRI P. R. KRISHNA MURTHY

( Alternate ) SHRI R. RAMANAN Batliboi & Co Ltd, Bombay

SRRI J. N. MEHROTRA ( Alternate ) DR K. R. RANQANATH~N Central Board for the Prevention and Control of

Water Pollution, New Delhi DR B. SENCUPTA ( Alternate )

DR B. SIN~H Central Mining Research Station ( CSIR ), Dhanbad DR J. K. SINHA ( Alternate )

SURI S. A. SUBRA~ANIAN Central Electricity Authority. New Delhi SERI S. VENKATARA~AN Indian Oil Corporation Ltd, New Delhi

SHRI M. KANNAN ( Alternate ) SIIRI R. VIRUPAKSHIAH Voltas Limited, Bombay SHUI DEIRENDRA J. VYAS Municipal Corporation of Greater Bombay, Bombay

SHRI S. G. R~TARKAR ( Alternate )

10