EM_Glavanising Industry

1
Environmental Management in Galvanizing Industry
from Regulatory Sustainability Perspectives

• dwarak98_at_gmail.com

2
India Status

• Industries account for 41 of Indias electricity
  intake 50 of the final energy consumption.
• India consumes 700 units per 1000 of its
  contribution. Where as China consumes 630 units ,
  the US, Germany Japan consumes less than 250
  units.
• India ranks 16th out of top 25 economies with a
  score of 41.5 of the world in terms of EE
  Performance.
• So there is potential and also opportunity.

3
STATUS GAP ANALYSIS ON EE.2022 American
Council for an EE Economy- report.

• Out of this, Indian Industry ranks 13th in the
  list. However, among the top 5 economies, India
  ranked 3rd with a score of 13 , ahead of US
  China.
• The GAP identified in Indian status are
• - lack of spending on EE on RD.
• - Urgent attention by industries on mobilise
  spending towards reducing energy intensity
  through investment in in manufacturing RD.

4
STATUS GAP ANALYSIS ON EE.2022 American
Council for an EE Economy- report.

• The report identifies that the industrial sector
  has a robust operational performance monitoring
  systems in place.
• This include mandates for plant level energy
  managers, mandatory energy audits for
  manufacturing facilities Voluntary energy
  performance agreements with the manufacturers.
• PAT is a successful ongoing EE program of GOI for
  industries.
• More focus and RD is needed to make economy more
  sustainable.

5
Introduction Overview of Presentation

• Act, rule amendment, notification. 
• Consent or authorisation is not a paper. 
• CDC REPORT ON UNKNOWN ETIOLOGY. 
• FOOD CHAIN AND FOOD WEB. 
• BIO ACCUMULATION AND BIO MAGNIFICATION
• CIRCULAR ECONOMY
• METAL RECOVERY
• RECYCLE AND REUSE AND 9 R PRINICIPLE. 
• COMMON SENSE. 
• BEGINS WITH ME

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Introduction

• ACT is like an umbrella passed by the
  Parliament or Assembly as the case may be. It is
  objective and concise.
• Rules notified under the Act is like spokes of
  the umbrella which is descriptive outlining the
  procedures and has the provisions for forms,
  fees, standards, etc.
• Each spoke can be a rule.
• Amendment to an Act or Rule is like a repair
  works to the main umbrella.
• Substitution in a provisions in the rule is a
  repair work again.
• Supersession of a provision or clause is a
  complete replacement.
• Act or rule can be completely withdrawn or
  superseded and a new one can be introduced.

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Why to do?

• Compliance to laws.
• Clearances from PCBs.
• Occupational exposure.
• Awareness about the public health implications.
• Bio accumulation bio magnification.
• Synergistic effect.
• Brand Consciousness.
• Export requirements.
• Passion for EM WM is required. BE A MAD PERSON. 

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Diseases of unknown Etiology CDC data.

• According to Centre for Disease Control
  Prevention (CDC) there are a number of disease
  for which known cause is not known.
• This is a data of unknown diseases due to
  chemicals and / Toxins in US alone.

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Heavy Metal

• Heavy metal is commonly defined as those have a
  specific density of gt5 g/cm3 .
• Zn s specfic Density is 7.14 g/cm3.
• Exposure to excessive zinc can be harmful and can
  have pathological consequences.
• Zinc is one of the most commonly used metals and
  can enter the environment as a result of numerous
  industrial processes .
• Inhalation of zinc dust and zinc-containing
  particulates in polluted air can cause symptoms
  of airway irritation and inflammation, and in
  severe cases, zinc fume fever, a disease
  characterized by pulmonary inflammation and
  flulike symptoms.

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Typical Galvanizing Process
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Process flow of Zinc enters into the Environment
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Effects On Flora Fauna

• Zinc is a natural substance and is necessary for
  human health, too much of element can be harmful
  to human health.
• Most food, air, water and soil contain certain
  amounts of zinc, but due to industrial
  activities, the level of zinc is rising at an
  unnatural rate. Certain areas around industrial
  sources are considered toxic due to the high
  amount of zinc in the drinking water.
• Health effects for people can include stomach
  cramps, skin irritation, nausea and vomiting.
  Extreme levels can damage internal organs and
  cause respiratory disorders. Acute work-place
  exposure to high-levels of zinc can lead to
  flu-like symptoms for people that are especially
  sensitive.
• With the increase of zinc, effecting people, it
  is also causing an effect on the environment.
• Water is often the first to become polluted where
  industrial plants do not purify/treat their
  wastewater to a satisfactory level.
• This may be a cause in the rise of acid levels
  within water effecting local flora and fauna.
• Certain fish accrue high levels of zinc in their
  bodies which is then passed on to other animals
  and humans when the fish is consumed.
• Zinc can also be found in soil. When farmers grow
  their crops, the zinc is then leeched into the
  food supply and again moves further up the food
  chain through consumption.

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The basic Galvanizing Process, emissions, wastes
14
Process, emissions, wastes and Management
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Route of Entry

• There are three types of exposure that can lead
  to Zn toxicity inhalation, oral, and dermal.
• Most cases are acute toxicity, so treatment plans
  are minimal such as chelation therapy or
  prescribed medication. 
• Toxic exposures have occurred through the
  gastrointestinal, dermal, respiratory, and
  parenteral routes.

• Inhalational toxicity can vary in severity
  depending on the specific compound involved, as
  well as the duration of exposure.
• For example, smoke bombs containing zinc chloride
  can cause chest pain, airway irritation, and even
  an acute respiratory distress syndrome
  (ARDS)-like clinical picture with pulmonary
  fibrosis as long-term squeal.

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Occupational exposure

• Workers who suffer exposure to fumes through
  welding, alloy production, and soldering of metal
  can present with flu-like symptoms in addition to
  cough and dyspnea, presumably due to zinc's
  direct effects on the pulmonary epithelium.

• Zinc toxicity can occur when an individual is
  exposed to and breathes the heated yellowish
  fumes produced from welding or heating galvanized
  steel.
• For hot-dipped galvanized steel the recommended
  maximum temperature is 392 F (200 C), before the
  metal presents a toxicity risk.

17
Research Paper.

• All workers were interviewed using a
  questionnaire on occupational history and chest
  diseases.
• Ventilatory functions and chest X rays were
  assessed. Complete blood counts were performed,
  and serum zinc, iron, copper, calcium, and
  magnesium levels were tested.
• This study illustrated the relation between zinc
  exposure in the galvanization process and high
  zinc levels among exposed workers, which was
  associated with a high prevalence rate of metal
  fume fever (MFF) and low blood copper and calcium
  levels.

• The study was to assess the effect of
  occupational exposure to zinc in the
  galvanization process on different metals in the
  human body and to detect the association between
  zinc exposure and its effect on the respiratory
  system.
• This study was conducted in 111 subjects in one
  of the major companies in the iron and steel
  industry. There were 61 subjects (workers) who
  were involved in the galvanization process.
• Fifty adult men were chosen as a matched
  reference group from other departments of the
  company.

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Synergistic effects.

• A study was designed in which three sites
  irrigated with ground, canal, and municipal
  wastewater in the District Jhang were selected to
  determine the zinc accumulation and its transfer
  in the soil, plant, and animal food chain.
• Zinc concentration was ranged as 18.85-35.59mg/kg
  in the soil, 26.42-42.67 mg/kg in the forage, and
  0.982-2.85mg/kg in the animal samples. 

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Bio Accumulation Bio Magnification

• Daily intake (0.039 to 0.082 mg/kg/day) and
  health risk index (0.130 to 0.275 mg/kg/day) of
  zinc metal was higher in the buffaloes that feed
  on wastewater-irrigated forages.
• Bio-concentration factor (0.840 to 2.01mg/kg) for
  soil-forage was gt1 which represents that these
  plants accumulated the zinc concentration into
  their tissues and raised health issues in grazing
  animals on consumption of wastewater-contaminated
  forages.
• As animal-derived products are part of human
  food, then zinc toxicity prevailed in livestock
  tissues ultimately affects the human food chain.
• Overall, findings of this study concluded that
  animal herds should be monitored periodically to
  devise preventive measures regarding the toxic
  level of heavy metals availability to livestock.
• Cd, Cu, Ni, and Zn may bio-magnify in specific
  marine food chains consisting of bivalves,
  herbivorous gastropods, and barnacles at TL2 and
  carnivorous gastropods at TL3.
• Zn oxide nano particles can cause synergistic
  effect in combination with temperature, Free
  fatty acid etc.

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CE ZN.

• To study the adoption of strategies for cycling
  resources, three lifecycle stages can be
  considered
• Sourcing of raw materials
• Design production and End of-life stage.
• The input stage includes the extraction and use
  of raw materials to manufacture consumer
  electronics where maximum energy gets consumed
• hence using recycled material/ secondary
  resources holds the potential to yield
  significant savings.
• Limited success has been achieved in phasing out
  the use of hazardous material and it continues to
  remain a concern going forward.
• For Zinc primary production requires 24000 KJ/KG
  amd secondary production reuires 18000 KJ/KG.
  Atleast 25 energy savings happen due to
  secondary metal usage.

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CE ZN.

• FICCI and Accenture have established that there
  is an estimated 500 bn worth of value at risk
  (by 2030) in India that can be protected through
  circular models.
• A consensus is emerging among large corporate
  that measuring circularity and disclosing
  progress is critical (65).
• Approximately 50 of the companies surveyed are
  aware of at least three or more standards or
  assessment frameworks.
• Moreover, 60 of the companies surveyed are
  planning to report under any available circular
  economy measurement frameworks in the next one
  year.

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CE ZN.

• The concept of circular economy promises a way
  out, through improved longevity of products,
  waste minimization, sharing, renting, repair and
  reuse to maximize product value before returning
  it to the environment safely.
• Given its USD 4.5 trillion global opportunity,
  innovative businesses and start-ups are already
  venturing into this space.
• More is required to come. Big industries can hand
  hold such initiatives.

23
CE ZN.

• There is a significant value creation potential
  from circular initiatives.
• The estimated total demand for iron and steel in
  2030 from the automobile sector will be almost 80
  million tonnes, followed by aluminium (11 million
  tonnes), plastics and composites (8 million
  tonnes), copper (0.6 million tonnes), zinc and
  nickel (0.7 million tonnes) (TERI-GIZ-DA(2016)).

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Bottle Necks in CE Implementation

• While there are multiple existing circular
  economy measurement frameworks, there are certain
  gaps which need to be addressed.
• These include
• - a) missing linkage with existing regulatory
  requirements (e.g., SEBI's BRSR, EWM 2016, PWM
  2016, BWMR 2022),
• b) lack of local contextualization such as
  applicability for MSME, coverage of green job
  creation in informal sector,
• c) complex data requirements,
• d) lack of sectoral guidance, and
• e) lack of direct linkage with business
  imperatives.

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Zn Consumption World
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Zn consumption
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Sector wise Consumption
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CE ZN.

• Indias material requirements are projected to be
  nearly 15 billion tonnes by 2030 and little above
  25 billion tonnes by 2050 under medium growth
  scenario.
• This means that India would nearly triple its
  demand on primary materials compared to 2010,
  particularly the demand of energy carriers,
  metals and non-metal minerals.
• Using best available technology will help in
  environmentally sound recycling and recovery of
  various metals thereby leading to low GHGs when
  compared to extraction of these metals from ores
  (MoEFCC 2016).
• A longer life-span not only saves on the material
  resources but allows the carbon footprint of the
  product to be spread out over a large number of
  years.

29
CE SD Opportunities

• Circular economy is a key idea which is emerging
  in political mainstream and has been one of the
  important discussion point in G20 Agenda, whereby
  G20 countries are integrating circular economy as
  part of implementation strategies for Sustainable
  Development Goals (SDGs) .
• The current Indian Government has launched many
  ambitious programmes to support Indias
  commitment towards achieving the SDGs and Paris
  accord commitments, which have certain elements
  of circularity enshrined.
• Examples include reducing the emission intensity
  of its GDP and generating electric power from
  non-fossil fuel based energy resources.
• However, these policies still focus on individual
  areas and themes, and tend to be fragmented,
  lacking a systemic approach.
• Businesses often find that they lack the critical
  mass and financial support needed to start
  large-scale efforts to substitute scarce
  resources or hazardous materials with cleaner,
  restorative or more regenerative ones.
• Necessary mechanisms of incentives and
  dis-incentives holds the huge potential guiding
  the transition.

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CE SD Opportunities

• Incidentally the low carbon growth trajectory
  positively impacts the circular economy
  principles leading to creation of innovative
  business models.
• It is estimated that circular economy has the
  potential to reduce 44 of total GHG emissions.
• As India currently contributes to 6.9 of global
  CO2 emissions which is expected to further
  increase if a linear economy is followed, any
  possibility of significant GHG emission reduction
  is a major environmental benefit.
• As Indias resource requirements are projected to
  reach 15 bn tons by 2030 and 25 bn tons by
  2050,it becomes important to decouple economic
  growth with resource consumption by leveraging on
  principles of circular economy.

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CE SD Opportunities

• While increase in economic value is a well
  understood benefit of circular economy, the
  social and environmental benefits are
  underestimated.
• Environmental benefits are also derived from
  effective waste management and resource
  efficiency, including decarbonization.

32
Legislative requirements

• EC
• CTE CTO.
• HWTMR.
• DG set Clearance.
• PAT,REC, etc.
• Export oriented certification requirements.

33
Legislative requirements

• Hazardous and Other Wastes (Management and
  Transboundary Movement) Rules, 2016 (HW Rules
  2016)
• Zinc ash and residues including zinc alloys
  residues in dispersible form - Basel No
• B1080 (i) Zinc content more than 65 (lead and
  cadmium equal to or less than 1.25 and 0.1
  respectively) are allowed for import without
  Director General of Foreign Trade license to
  recycling units registered with State Pollution
  Control Boards (SPCBs).
• (ii) Zinc content less than 65 ( lead and
  cadmium equal to or more than 1.25 and 0.1
  respectively) permitted for import against
  Director General of Foreign Trade license and
  only for purpose of processing or reuse by units
  registered with the SPCBs.
• Import of Zinc Skimming (Zinc Ash) need
  permission of the Ministry of Environment, Forest
  Climate Change, Govt of India.

34
Legislative requirements For the G Industry

• Y-17 (-Annexure I) Waste resulting from surface
  treatment of metals
• H11 (Annexure III )
• Toxic (Delayed or chronic) Substances or wastes
  which, if they are inhaled or ingested or if they
  penetrate the skin, may involve delayed or
  chronic effects, including carcinogenicity.
• H12 (Annexure III) Ecotoxic Substances or
  wastes which if released present or may present
  immediate or delayed adverse impacts to the
  environment by means of bioaccumulation and /or
  toxic effects upon biotic systems

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Legislative requirements For the G Industry

• ? R4 (Annexure IV B ) Recycling/reclamation of
  metals and metal compounds
• ? B1080 (Annexure IX List B) ? Zinc ash and
  residues including zinc alloys residues in
  dispersible form unless containing Annex I
  constituents in concentration such as to exhibit
  Annex III characteristics.
• ? B1100 (Annexure IX List B) ? Galvanizing slab
  zinc top dross (gt90 Zn) ? Galvanizing slab zinc
  bottom dross (gt92 Zn) ? Hot dip galvanizers slab
  zinc dross (batch)(gt92 Zn) ? Zinc skimming
  Indian Legislation for Import of Galvanizing
  Wastes

36
Legislative requirements

• Zinc Dross
• Basel No. B1100 ? Galvanizing slab zinc top dross
  (gt90 Zn) ? Galvanizing slab zinc bottom dross
  (gt92 Zn) ? Hot dip galvanizers slab zinc dross
  (batch)(gt92 Zn)
• Import permitted for the actual users, recyclers
  and authorised traders permitted in India without
  obtaining permission from the Ministry of
  Environment, Forest Climate Change, Govt of
  India.

37
Future requirements Capacity Building/ Training

• EPR requirements
• Sustainable supply chain certification and
  standards covering ISO 20400 2017 (Sustainable
  Procurement), Eco Vadisetc.
• Digital tools in Waste Management Sustainable
  Supply Chain
• Importance of Waste Management in SDG, ESG,
  Carbon Neutrality.
• Complete Legislations on SWM,BMW,EW,BWM,PWM,CDWM,
  HWM. Provisions, System Requirement for
  compliance.
• GHG Inventroisation. Sector wise identification
  Assessment. Carbon Neutrality
• BRSR assessment reporting.
• Carbon Disclosure Project, Principles,
  Methodology Disclosures. Climate related Risk
  Assessment.

38
Future requirements Capacity Building/ Training

• CC National International Agreements, Treaties
  and the Commitments.
• SDGs Waste Mgt inter Linkages.
• LCA of waste management, waste mapping. Circular
  Economy SCM inter-linkages. Circularity of
  materials Frame work.
• Global Reporting Initiative GRI. GRI
  Indicators.
• Basic Knowledge on mass balance, material
  balance.
• SASB Standards.
• TCFD ( Task Force on Climate related Financial
  Disclosures). TNFD ( Task Force Nature Related
  Financial Disclosure.
• SDG Wheel and inter linkages among the SDGs.

39
Way Forward.

• Win Win situation for all.
• Green Branding.
• Gives competitive edge.
• Reduction in resources consumption and waste
  generation.
• Reduction in the risk of accidents/injuries/ailmen
  ts.
• Easy and beyond the Environmental and other
  regulatory compliances.
• Easy insurance coverage/claims.
• Improved employee- management relations.
• Easy obtaining of the Import and other
  permissions.
• Better staff stability/Reduction in the attrition
  of human resource.
• Reduction in the market competitive pressure.
• Better preparedness for international
  recognitions/certifications such as ISO 9000,
  14001 etc.
• Avoids external influences and pressures.

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No End

• Sky is the limit.
• Be a MAD person.
• Thanks for the Patience.