COMPARATIVE LIFE CYCLE ASSESSMENT OF DIFFERENT MUNICIPAL SOLID WASTE MANAGEME...
Major Project Thesis_Shourjomay
1. ASSESSMENT OF INDUSTRIAL SYMBIOSIS IN
MUZAFFARNAGAR
Major Project Thesis
Submitted by
SHOURJOMAY CHATTOPADHYAY
For the partial fulfillment of the
Degree of Master of Science in
ENVIRONMENTAL STUDIES AND RESOURCE MANAGEMENT
Submitted to
Department of Natural Resources
TERI University
May 2014
2. DECLARATION
This is to certify that the work that forms the basis of this project “ASSESSMENT OF
INDUSTRIAL SYMBIOSIS IN MUZAFFARNAGAR” is original work carried out by
me and has not been submitted anywhere else for the award of any degree.
I certify that all sources of information and data are fully acknowledged in the project
thesis.
SHOURJOMAY CHATTOPADHYAY
Date: 17th
May 2014
3. CERTIFICATE
This is to certify that SHOURJOMAY CHATTOPADHYAY has carried out his major
project in partial fulfillment of the requirement for the degree of Master of Science in
ENVIRONMENTAL STUDIES AND RESOURCE MANAGEMENT on the topic
“ASSESSMENT OF INDUSTRIAL SYMBIOSIS IN MUZAFFARNAGAR” during
January 2014 to May 2014. The project was carried out independently.
The thesis embodies the original work of the candidate to the best of our knowledge.
Date: 17th
May 2014
Nandini Kumar, PhD Chubamenla Jamir, PhD
(External Supervisor) (Internal Supervisor)
Assistant Professor
Department of Natural Resources
TERI University New Delhi
P K Joshi, PhD
Professor & Head
Department of Natural Resources
TERI University
New Delhi
4. Acknowledgement
I want to thank a number of people for their contribution to this project: Mr.
Pankaj Aggarwal, Mayor of Muzaffarnagar and Mr. Neeraj Kedia, owner of
Kedia Fertilizers, for helping in collection of data; Dr. S.C. Kulshreshtha,
Chairman, Shree Ram Group of Colleges, Muzaffarnagar, for his valuable input;
Elsa Olivetti (MIT), for her guidance throughout the project and the
Massachusetts Institute of Technology (MIT), Cambridge for funding the
project.
Special thanks to Dr. Nandini Kumar, my external supervisor; Dr. Chubamenla
Jamir, my internal supervisor and Mrs. Ranjana Ray Choudhury for their
guidance, support and recommendations on the project.
SHOURJOMAY CHATTOPADHYAY
5. i
Table of Contents
List of Abbreviations………………………………………..…………..iii
List of Figures…………………………………………………………...iv
List of Tables…………………………………………………………….v
Abstract……………………………….………………………………....vi
1. Introduction……………………………………………………………..1
2. Background (Literature Review)………………………………………4
2.1 Industrial Ecology and Industrial Symbiosis—Definition & History..4
2.2 Industrial Symbiosis in the world…………………..……………...…5
2.3 Industrial Symbiosis in India…………………………..……………..9
2.4 Snowball sampling and stakeholder interviews……….……….…...10
2.5 Material Flow Analysis (MFA)……………………………….........11
3. Objectives………………………………………………………………12
4. Materials and Methods………………………………………………..13
5. Study Area………………………………………………….………….16
5.1 Physiogeography ………………………………………..….……...16
5.2 Climate……………………………………………………...……...17
5.3 Rainfall Pattern……………………………………………………..17
5.4 Major Industries………………………………………………....…17
6. Results & Discussion……………………………………………….….19
6.1 Objective 1………………………………………………………....19
6.2 Objective 2…………………………………………………..……..26
7. Conclusion……………………………………………………………...41
7. iii
List of Abbreviations
COD: Chemical Oxygen Demand
EID: Eco-industrial Development
EIP: Eco-Industrial Park
GDP: Gross Domestic Product
GIZ: German Development Agency
IE: Industrial Ecology
IIA: Indian Industries Association
IP: Industrial Park
IS: Industrial Symbiosis
Kcal: kilocalorie
Kg: kilogram
KL/Year: Kiloliter/Year
LCA: Life Cycle Analysis
MFA: Material Flow Analysis
Mg/L: milligram/liter
Mg: milligram
PMA: Paper Manufacturers Association
T/Y: Tons/Year
T: Tons
8. iv
List of Figures
Figure 1: Map showing location of study area.
Figure 2: Elements of Industrial Ecology.
Figure 3: Industrial Symbiosis at Kalundborg, Denmark.
Figure 4: Industrial Symbiosis in Kawasaki, Japan.
Figure 5: Industrial Symbiosis in Barceloneta, Puerto Rico.
Figure 6: Industrial Symbiosis in Guayama, Puerto Rico.
Figure 7: Base map of study area.
Figure 8: Flow of materials through selected industries in Muzaffarnagar.
Figure 9: Percentage share of annual production volume in selected industries in
Muzaffarnagar.
Figure 10: Solid and liquid inputs to selected industries.
Figure 11: Solid and liquid waste output from selected industries.
Figure 12: Flow chart showing existing symbiosis network between selected
industries in Muzaffarnagar.
Figure 13: Comparison of final disposal of all wastes (solid and liquid)
generated by selected industries in Muzaffarnagar, including and excluding the
sugar industry.
Figure 14: Flow chart showing a proposed symbiosis network.
Figure 15: Comparison of final disposal of all wastes (solid and liquid)
generated by selected industries in Muzaffarnagar (projected scenario).
Figure 16: Flow chart linking waste streams with environmental impacts based
on IMPACT 2002+ guidelines.
9. v
List of Tables
Table 1: Land use in Muzaffarnagar.
Table 2: Utilization of solid waste from selected industries in Muzaffarnagar
(present situation).
Table 3: Utilization of liquid waste from selected industries in Muzaffarnagar
(present situation).
Table 4: Utilization of solid waste from selected industries in Muzaffarnagar
(projected situation).
Table 5: Utilization of liquid waste from selected industries in Muzaffarnagar
(projected situation).
Table 6: Current use of waste and associated environmental impacts.
Table 7: Proposed use of waste and associated environmental impacts.
10. vi
Abstract
In the present study an attempt has been made to identify and understand
industrial symbiosis in Muzaffarnagar. The region has a number of diverse
industries (brick, paper, steel and sugar). Input and output data pertaining to the
selected industries were collected. This helped identify a material flow for the
region. With the help of this flow, the existing symbiosis network was identified.
A network was proposed using waste streams not used at present in symbiosis.
Key words: Industrial symbiosis, India, Material Flow, Projection
11. 1
1. Introduction
Industrial activity all over the world has increased over the last six or seven
decades or so (Vigneswaran et al., 1999; Geng et al., 2007). Due to large
populations and low capital in developing countries, including India, there has
been a significant rise in manufacturing activities (Bain et al., 2010). As of 2010,
the manufacturing sector accounted for 15% of India’s GDP (The World Bank
Database). The share of these goods in world export has rose from 0.5% in 1980
to 0.9% in 2006 (Winters and Yusuf, 2007). Increased industrial activity is
synonymous with human development and improved life style conditions.
Advancement in extraction, use and disposal of natural resources has been an
integral part of this human development, but not without compromising resource
availability (Ehrenfeld, 2000). This rapid unplanned development has led to
depleting natural resources, waste management and increasing pollution
becoming important concerns in the world today (Vigneswaran et al., 1999;
Geng et al., 2007).
Concerns like depleting natural resources, waste management led to a change in
development strategies, towards a vision of sustainability. The best example of
sustainability is provided by natural ecosystems which recycle waste products
completely, consume the least amount of energy and work in a cyclic manner
(Ehrenfeld, 2000). Steps could be taken towards sustainability if anthropogenic
systems (industrial set-ups) could be changed to imitate natural ecosystems. This
ideal is the backbone of the concept of industrial ecology (IE) which aims for a
transition towards such an ecosystem (Frosch and Gallopoulos, 1989; Gradel.
1996; Tackels, 2003). IE places emphasis on sustainability of energy and
material flow (Bain et al., 2010).
An important part of IE is to look at the systematic reuse of waste and by-
products, minimizing the need to extract natural resources (Erkman, 1997). This
objective could be achieved through Industrial Symbiosis (IS), since it represents
a collective engagement of traditionally separate industries through exchange of
materials (Chertow, 2000).
12. 2
The current study was carried out in the district of Muzaffarnagar in the north
Indian state of Uttar Pradesh (Figure 1). No formal eco-industrial park (EIP)
exists in the region but the location of many diverse industries (brick, paper, steel
and sugar for example) in a relatively small area makes industrial symbiosis
possible. The first part of this study looks to quantify broadly material flow in
manufacturing units within the study region. With the help of this a flow chart
showing material flow for the entire region would be made. This would help
identify existing linkages in the region. Also, other potential linkages of waste
streams currently not utilized in symbiosis will be suggested using a literature
review and existing research on waste utilization being conducted in the study
area.
14. 4
2. Background (Literature review)
2.1 Industrial Ecology and Industrial Symbiosis―Definition and
History
Industrial ecology (IE) was formally introduced in 1989 with the publication of
an article titled “Strategies for Manufacturing” in which the authors suggested
that industrial systems should be transformed such that wastes of one process or
industry are used as raw material for some other process or industry (Frosch and
Gallopoulos, 1989). Such a transformation would optimize energy and raw
material consumption. Since the publication of that article numerous studies have
been reported in the literature (Ehrenfeld and Gertler, 1997; Deutz and Gibbs,
2005; Lombardi and Chertow, 2005; Chertow et al., 2008; Bain et al., 2010;
Zhang and Liu, 2013). IE can be defined as an area of research that looks at
interactions between industrial and natural systems with the aim of minimizing
the environmental effects of the former on the latter (Frosch, 1992).
IE can be imagined to work at three broad levels—at the firm/unit process level;
at the inter-firm/district/sector level and at regional/national/global level
(Chertow, 2000; Ayres and Ayres, 2002).
15. 5
Figure 2: Elements of Industrial Ecology (Lifset and Graedel, 2002)
Industrial symbiosis (IS) the establishment of a network for waste or byproduct
exchange and utility-sharing among unrelated industries (Chertow 2000; Jensen
et al., 2011). The first occurrence of IS was reported from Kalundborg, Denmark
(Knight, 1990) where a group of industries was found to be intensively sharing
resources. With the help of material, energy and knowledge exchanges among
different units, IS networks aim to reduce the intake of virgin materials and
lower the production of waste (Davies and Domenech, 2011).
Eco-industrial parks are areas where companies are located close to each other.
This facilitates cooperation and a move towards cleaner production (Roberts,
2004) as also the principles of IE.
2.2 Industrial Symbiosis in the world
The Kalundborg IS network is one of the best documented worldwide (Knight,
1990; Ehrenfeld and Gertler, 1997; Jacobsen, 2006; Davies and Domenech,
2011). It developed spontaneously between the different participating elements
Sustainability
Industrial Ecology
Firm Level
Design for
environment
Pollution
prevention
Eco-efficiency
Green
accounting
Between Firms
Eco-industrial parks
(industrial
symbiosis)
Product life cycles
Industrial sector
initiatives
Regional/Global
Budgets & cycles
Materials &
energy flow
studies
Dematerialization
&
decarbonization
16. 6
and has been refined over the decades (Christensen, 2006). The primary partners
taking part in the symbiosis are a power plant, an oil company, a biotechnology
and pharmaceutical company, a plasterboard company, a soil remediation
company, a cement company, few fish farms and the city of Kalundborg
(Jacobsen, 2006). Symbiotic activities have led to a waste exchange of 2.9
million tons annually between the symbionts and a collective water consumption
reduction by 25% (Saikku, 2006). The symbiotic activities led to individual
economic benefits for the stakeholders as well as environmental benefits for the
region as a whole (Jacobsen, 2006). The IS network at Kalundborg, Denmark has
been shown in Figure 2.
Figure 3: Industrial Symbiosis at Kalundborg, Denmark (Christensen,
2006)
17. 7
IS was introduced in Japan as part of the Eco-town project in 1997. Kawasaki
was one of the first cities to be part of this project (Fujita et al., 2004). The firms
taking part in the symbiosis were related to cement, chemical, paper and steel.
These exchanges have resulted in diverting approximately 565,000 tons of waste
from landfills and incineration sites and have led to an annual economic
opportunity of about 130 million USD (Berkel et al., 2009). This is an example
of top-down planning where the government is the implementing agency
resulting in resource conservation and increasing efficiencies (Chertow and Park,
2011). For a country like Japan which imports 35% of its natural resource
requirements, this is an important step (Morikawa, 2000). The IS network at
Kawasaki, Japan has been shown in figure 3.
Figure 4: Industrial Symbiosis in Kawasaki, Japan (Berkel et al., 2009)
Two sites in Puerto Rico-Barceloneta and Guayama, have been reported to be
engaged in IS related activities (Chertow et al., 2009). The symbiotic
arrangements and proposed synergies are illustrated in Figures 4 and 5
respectively. In Guayama the arrangement resulted in the reduction of SO2, NO x
and PM10 emissions from the cogeneration plant by 99.5%, 84.4% and 95.3 %
respectively (Lombardi and Chertow, 2005). Along with these environmental
18. 8
benefits, economic benefits for the participating companies were also reported
(Lombardi and Chertow, 2005; Chertow et al., 2009).
Figure 5: Industrial Symbiosis in Barceloneta, Puerto Rico (Chertow et al.,
2009)
Figure 6: Industrial Symbiosis in Guayama, Puerto Rico (Lombardi and
Chertow, 2005)
19. 9
There are other regions where IS has succeded. In France, IS was first introduced
in 1999 in the town of Dunkerque in two industrial parks (Brullot, 2009). In
Geneva, Switzerland 17 types of flows have been identified for symbiosis
between 19 companies from 10 industrial sectors (Massard and Erkman, 2007).
The flows included material flow (such as building materials, food waste,
plastics, rubber, fly ash), energy flows (heat, steam, etc.) and liquid flows
(cooling water, acids, etc.) (Massard and Erkman, 2007).
Industrial symbiosis where ever it is being practiced yields positive economic
and environmental returns.
2.3 Industrial Symbiosis in India
Very few studies have been done in India on industrial symbiosis (Singhal and
Kapur, 2002; Bain et al., 2010). In India, the material flow through the informal
sector is much larger than that through the organized industrial sector (Erkman
and Ramaswamy, 2000; Chertow et al., 2004). Hence, for a greater impact, any
strategy for symbiosis has to factor in the informal sector (Chertow et al., 2004).
The Naroda EIP at Ahmendabad, Gujrat spread over 30 km2
is one example of
eco-industrial development in India (Lowe, 2001; Unnikrishnan et al., 2004; El-
Haggar, 2007). The region has over 700 companies. Most of the industries in the
area were chemical and engineering works (El-Haggar, 2007). An inventory of
wastes from different facilities was proposed to make a Waste Exchange Bank to
identify and analyze the waste networking potential of the industrial estate
(Indian Express, 2009). The symbioses proposed were (i) conversion of spent
acid with high concentrations of H2SO4 into commercial grade FeSO4, (ii) selling
of sun dried chemical gypsum to cement manufacturers, (iii) reduction of the
amount of iron sludge being produced and reducing the hazardous content of iron
sludge produced by dye manufacturing industries, to make it feasible for use in
brick manufacturing, and (iv) conversion of 100 tonnes per month of industrial
food waste to biogas (vonHauff and Wilderer, 2000).
Another study in Nanjangud, an industrial area 20 km from Mysore in the state
of Karnataka was carried out (Bain et al., 2010). The region had a diverse
industrial set-up including paper, oil extraction, food processing, textile and
sugar industries. Studies revealed that very low amount of disposable waste was
20. 10
generated in the area due to the high level of reuse and symbiosis of industrial
residues.
The Narela Industrial Complex was designed by the Delhi State Industrial and
Infrastructure Development Corporation Limited (DSIIDC) to reduce
environmental and economic costs (Indian Express, 1998). A common effluent
treatment plant (CETP) was proposed, water from which would be used to
irrigate parks in the industrial area. Mis-management caused the project to be
delayed from 1978 to as late as 2013 when it was relaunched (Hindu, 2013). The
DSIIDC also decided to redevelop other industrial belts in the capital (Indian
Express, 2012).
The German Development Agency (GIZ) has undertaken efforts to promote eco-
industrial development in the state of Andhra Pradesh. The 14 industries
supported by the project in the Hyderabad region made savings of electricity
(836 MWh), coal (2,804 tonnes), hazardous waste (300 tonnes), water (1,815
KL) and materials with aggregated financial savings worth more than Rs 20
million. Stakeholders were made aware of the harmful effects of unregulated
waste disposal on the environment through training workshops. This resulted in
stopping of illegal discharges of waste effluents in about 15 IPs (GIZ).
Efforts in India have been few and far between. Most of the projects have not
been managed properly and implementation has been below par (Bain et al.,
2010). Many of the policies have failed to incorporate the small scale industries
which form a major part of the industrial set up in the country.
2.4 Snowball sampling and stakeholder interviews
Snowball sampling is a technique for finding research subjects in highly
scattered populations (Atkinson and Flint, 2001). It is a method that helps locate
sample based on referrals made by people of other people who have the
characteristics of the research interest (Biernacki and Waldford, 1981). In this
method the first respondents who are known as ‘‘seeds’’, are asked to refer the
researchers to their social contacts. These social contacts in turn, are asked to
refer researchers to their social contacts. This process is repeated a number of
times (Kowald and Axhausen, 2014). It is a convenience sampling method which
is both simple and inexpensive, and is extensively used in studies of hard-to-
21. 11
reach populations (Johnston and Sabin, 2010). Snowball sampling is highly
limited by the fact that there is always a selection bias limiting the external
validity of the sample (Kaplan et al., 1985).
2.5 Material Flow Analysis (MFA)
Industrial ecology has three major tools: i) Input-output management, ii) Life
Cycle Assessment (Theis and Seager, 2002; Mattila et al., 2012) and iii) Material
Flow Analysis (MFA) (Sendra et al., 2007). MFA is a tool which helps quantify
material flows and to chart industrial processes, which is one of the primary
goals of industrial ecology (Hong et al., 2011; Sendra et al., 2007). MFA is a
widespread and standardized methodology (Eurostat, 2001) for accounting input
and output material flows for a pre-defined system, and for estimating their
resulting environmental impacts (Bringezu et al., 2004). MFA helps determine
sources of input materials used in processes, providing a quantitative assessment
of flow of materials within a system by calculating quantity of outputs both
desired and not desired (wastes), thus forming a basis for sustainable
environmental management (Huang et al., 2012).
22. 12
3. Objectives
Objective 1: To identify, understand and quantify the flow of materials
through selected industries in the study area.
Objective 2: To identify existing links within selected industries in the study
area.
23. 13
4. Materials and Methods
Objective 1: To identify, understand and quantify the flow of materials
through selected industries in the study area.
It should be noted that flow of materials within Muzaffarnagar refers to material
flow in all manufacturing units within the scope of this study: brick, paper, steel
and sugar. There are a few chemical, plastic and rubber units/factories in the
region, but these were not part of the current work.
The location of industries in the region can be seen in the map in Figure 7. A
classification of the different industries was carried out and was based on
information in a directory brought out by the Indian Industries Association (IIA),
Muzaffarnagar Chapter. Only manufacturing units were considered and the
categorization is based on their primary outputs. The main industries thus
identified were brick, paper, steel and sugar. Brick making units were of two
types: those making red brick and those making ceramic bricks.
The inputs (in terms of raw materials and energy sources) and outputs (in terms
of products and waste streams) from different industries were estimated as part
of the exercise to quantify the flow of material through the selected production
units. Data for different industries were collected using different methods which
are explained below.
Brick:
1. Red Bricks- There are approximately 500 brick kilns in the study area.
Interviews with stakeholders suggested that the production method and
scale of production in all the units is uniform. Workers from five kilns
were interviewed and the data from these were averaged for the entire
area.
2. Ceramic Bricks- There are three ceramic brick units in the study
region. Workers from all of these were interviewed. The production
method was understood through these interactions.
Paper: There are 29 paper mills in the region producing eight different types of
paper. The main difficulty was the reluctance of owners to give out data. Hence,
24. 14
initial data collection was done through the snowball sampling technique: the
willingness of the owners guided the choice of the factory to be visited. The
owner of this factory then guided us to the other industries in a continuing
process (Kowald and Axhausen, 2014). This technique allowed building up a
network of factories from which data was collected. Stakeholder interviews were
conducted at ten paper units using the snowball sampling method. Data for those
units not obtained through stakeholder interviews were obtained from the Paper
Manufacturer Association (PMA), which maintains a database for inputs and
outputs of all paper factories in the Muzaffarnagar region. Data collected in the
interviews were also validated from the database.
Steel: There are 43 steel units in Muzaffarnagar. The steel industry in the region
is very diverse in terms of the finished product. There was a reluctance and lack
of interest among steel mill owners in the study region to give data. Even
through references from other industrialists in the area, meaningful data could
not be obtained. It should be noted that most stakeholders were reluctant to give
out data pertaining to their factories but were eager to give information regarding
the industry in the entire region. Thus data of the total production capacity for
the region was obtained. This data was validated through multiple stakeholder
interactions.
Sugar: There are seven sugar mills in the study area. Stakeholder interviews
were conducted at two factories through referrals. The production methods of
these units were understood. It was concluded through interviews that the
manufacturing process for sugar in the region is uniform. For the remaining five
units data pertaining to the daily sugarcane crushing capacity were collected.
From this data other required inputs and outputs were calculated.
The input and output data from each factory were entered into a Microsoft Excel
spreadsheet. The data for all factories were then aggregated and analyzed.
Objective 2: To identify existing links within selected industries in the study
area.
With the help of data collected in Objective 1, a flow chart showing the flow of
materials through the region focusing on links within the system and waste
streams was extracted from Figure 8. This helped to uncover the existing
25. 15
linkages in the region. There are a number of waste streams in the region which
have potential uses. These uses were identified with the help of other work being
carried out in the study area as well as from work that has been done in the past.
26. 16
5. Study Area
The present study was carried in the district of Muzaffarnagar in the north
western part of the state of Uttar Pradesh state, between 29°11′ N and 29°45′ N
and between 77°3′ E and 78°7′ E. Muzaffarnagar has a geographical area of 4215
km2
. 78% of the area in the district is cultivable. The land use pattern for the
study area is given in Table 1.
Table 1: Land use in Muzaffarnagar (Agriculture Contingency Plan for
District: Muzaffarnagar)
Land Use Area (km2
)
Total area 4215
Cultivable area 3269
Forest area 277
Land under non
agricultural use 500
Permanent pastures 4
Cultivable wastelands 23
Land under
miscellaneous tree
crops and grooves 22
Barren and uncultivable
land 43
Current fallows 51
Other fallows 25
5.1 Physiogeography: The district of Muzaffarnagar is surrounded by
Saharanpur district to the north, Meerut to the south, Yamunanagar to the
east and Bijnor to the west. The main rivers flowing through the district
are the Ganga, Yamuna, Hindon and Kali Nadi. All these rivers flow
from north to south. These rivers divide the region into four distinct
sections― the Ganga Khadir, upland upto Kali Nadi, the Kali-Hindon
doab and the Hindon-Yamuna doab (Umar, 2004).
27. 17
5.2 Climate: The climate regime in the area is sub-tropical with hot
summers and moderately cold winters. The maximum temperature
recorded in the summer months (in June) is 45°C, while the lowest
recorded in the winter (in January) is 4°C (Umar et al., 2006).
5.3 Rainfall Pattern: The rainfall is distributed seasonally over four
periods- 84% of annual rainfall occurs during the south west monsoon
period, 4% in the post monsoon period, 9% in the winter and the
remaining 3% in the summer. About 60 % of the monsoon rainfall in this
region is concentrated in the months June to September (Agriculture
Contingency Plan for District: Muzaffarnagar).
5.4 Major Industries: The major industries in the study area are― brick-
red bricks and ceramic, chemical manufacturing, paper, steel and sugar
and some miscellaneous industries which provide machinery to the paper,
steel and sugar industries. There are about 500 kilns producing red bricks
scattered randomly throughout the region. There are three ceramic brick
units situated in the old industrial belt of the region. Paper mills are
located in two clusters situated to the east and south-east of
Muzaffarnagar town. Many of the steel mills are located in the old
industrial estate of Muzaffarnagar as well as along the National Highway
58. There are seven sugar mills located in the study area. These are
widely scattered but tend to be located near sugarcane fields. The
chemical manufacturing units and ancillary units are located around the
paper, steel and sugar units.
29. 19
6. Results & Discussion
In this section the term ‘industry’ refers to all units of a particular type. For
example, the paper industry refers to all factories (units) within the study area
where paper is manufactured. Also the terms ‘factory’ and ‘unit’ have been used
interchangeably. Gaseous inputs and outputs have been kept outside the scope of
the present study.
Objective 1: To identify, understand and quantify the flow of materials
through selected industries in the study area.
There are 500 brick kilns, 29 paper mills, 43 steel mills and 7 sugar mills in the
area. The paper, steel and sugar industries are organized in nature. The brick
industry is highly unorganized. The paper and steel mills are located in both the
old (within Muzaffarnagar city) and new (outside Muzaffarnagar city, along the
national highway) industrial areas of the region. The brick kilns and the sugar
mills are randomly located in different parts of the district.
Figure 8 shows the flow of materials through selected industries in the study
area. Brick (ceramic and red brick), paper, steel and sugar have been selected,
since these are the major manufacturing industries in the study area based on the
number of units. The thick black line represents the system boundary for the
study. The five boxes within the system boundary show the chosen industries.
The horizontal black arrows represent inputs and outputs from the industry and
have been placed near the box representing the industry. The direction of the
arrow with respect to the system boundary signifies input or output: an arrow
pointing into the system boundary represents input and vice versa. The vertical
brown arrows represent the wastes being disposed into landfills, drains, etc. The
red arrows represent flows within the system boundary. Distilleries have been
kept at the system boundary to signify that only the symbiotic input into the
system has been quantified. The other inputs and outputs to and from the
distilleries have been kept outside the scope of the present work.
30. 20
Figure 8: Flow of materials through selected industries in Muzaffarnagar.
Horizontal black arrows represent inputs and outputs. Vertical brown
arrows represent waste streams. Distillery kept on system boundary to
signify that only the symbiotic input into the system has been quantified.
Production level of selected industries
Figure 9 compares the quantities of primary outputs from paper, ceramic, sugar,
red-brick and steel industries in the study area. It has been represented in terms
of percentage of total output (tons) from the region. Paper, red-brick, steel and
sugar industries have roughly similar outputs. Even though steel and paper have
slightly higher outputs in comparison to brick and sugar. This suggests that equal
importance should be given to all the industries in the region during the start of
any research. But based on economic and environmental impacts this would be
potentially revised. The output from ceramic is almost negligible in comparison
Soil
Grog
Ceramic Bricks
PET Coke
Bauxite
Scrap Metal
PET Coke
Coal
Water
Steel
Sugar
SO2
Bagasse
Coal
Sugarcane
Milk of Lime
Wood Chips
Paper
PET Coke
Wheat Straw
Bagasse
Rice Husk
Waste Paper
Water
SUGAR
PAPER STEEL
DISTILLERY
RED
BRICK
CERAMIC
BRICK
Pins
Bagasse
Refractory
Bricks
Used
Refractory
Bricks
Molasses
Molasses
Water
Ash
PressMud
Ash
Ash
Black
Liquor
Sand
Ash
Ash
Mixed Fuel
Bricks
Soil
Sand
Water
Slag
31. 21
to the other industries. Generally speaking the higher the production volume, the
larger the amount of waste generated. The paper industry has the highest annual
production, marginally greater than that of the steel industry. Both these
industries are in production throughout the year. The sugar and brick industry
have similar production levels but these are less than those of paper and steel.
This could be because both these industries are in production for only a few
months of the year. The point to note is that even though the individual brick
units are unorganized, scattered and very small in terms of production level, the
cumulative annual brick production from the region is similar to that of the other
major industries. Thus, even though the quantity of waste generated by one brick
kiln would be negligible, the total amount of waste generated from all the kilns
in the area would be significant. Thus, equal importance has to be given to this
industry in any research in the region.
Figure 9: Percentage share of annual production volume in selected
industries in Muzaffarnagar.
Inputs to selected industries
Figure 10 shows the solid and liquid inputs in the selected industries. Inputs
include both raw material as well as energy sources. Gaseous inputs are beyond
29
0
2222
27
Paper
Ceramic
Sugar
Brick
Steel
32. 22
the scope of this present study. Detailed industry specific data has been placed in
the annexure. Inputs for the different industries are discussed below-
Brick: Soil is the major solid input (11,89,600 T/Y) for the brick industry. The
volume of water (1,00,000 KL/Y) consumed in this industry is small as
compared to the other industries in the region. A major point of concern is that
the soil used for making bricks is fertile top soil. Even though there are
government regulations concerning the depth to which soil can be excavated for
brick making, these are flouted all over the region. Annually almost 60, 00,000
tons of soil is needed by this industry. Compared to the amount of fertile land in
the area this is not a very large value, but in the long run this will affect
agriculture in the area.
The data for the brick industry was collected from five kilns in the area and was
averaged out over the entire area. This was done because of the large number of
units in the region.
Paper: The major solid raw material input (20,06,551 T/Y) for the paper
industry is waste paper and bagasse both of which are used for pulping. Bagasse
coming from sugar mills is also used as a power source. The paper industry is a
highly water intensive industry (1,76,03,511 KL/Y) (Figure 10). Paper
manufacturing consumes more than 5 times the amount of water used in the
sugar industry. Large quantities of water are used to wash waste paper pulp.
Groundwater is the source. Most of the units have boreholes within the factory
boundaries and water is pumped throughout the day. This has had an effect on
the availability of water in the surrounding farms where farmers have to use
more powerful pumps for their needs.
Steel: The major solid input to the steel industry in the area is scrap metal which
is brought in from all over the country. Moulds from the ceramic industry in the
region are also used. Coal and Pet Coke are used as energy sources. Data for
liquid (water) input could not be obtained.
Sugar: The solid input (78,54,611 T/Y) for the sugar industry is the highest
among all industries considered. It is about four times the solid material input of
the paper industry. The liquid input (water) (34,27,503 KL/Y) for this industry is
33. 23
also considerably higher than that for the brick industry but less than that used in
paper manufacturing in the region.
Most of the industries in the area depend heavily on fossil fuels as a power
source. Coal and PET coke are extensively used in the steel and sugar (during
off-season) mills. Even though the paper and brick industry use bio fuels these
do not always meet the demands. The paper industry is the most water intensive
industry in the region. About 80% of the industrial water consumption in the
region can be attributed to paper-making. Since this area is situated in a water-
rich belt of the country there is a general lack of regard for water. It was
concluded through stakeholder interviews that years of unchecked groundwater
extraction has caused the groundwater table to fall drastically. Even though the
industry hasn’t yet faced any shortage of water, it is possible that water
availability will become a concern in the future. Hence, importance has to be
given to the paper industry from a water conservation point of view.
Figure 10: Solid and liquid inputs to selected industries. Inputs include raw
material and fuel used. *Input data for steel industry could not be
completed.
0
5000000
10000000
15000000
20000000
25000000
Paper Sugar Steel Brick Total
Solid (T/Y)
Liquid (KL/Y)
34. 24
Waste from selected industries
Figure 11 shows the solid and liquid waste output from selected industries.
Gaseous wastes have been kept beyond the scope of the present study. Detailed
industry specific waste output has been placed in the annexure. Most of the
wastes are disposed of in an unorganized manner. There are no official industrial
landfills in the region for disposing of industrial wastes. Solid wastes are
generally dumped in low lying land or on the side of roads. These have been
referred to as ‘unofficial landfills’. Liquid waste is put into drains which
ultimately reach the major rivers flowing in the district. Wastes from different
industries are discussed below:
Brick: Solid waste generated from the brick industry includes ash from the
different fuels used such as rice husk, mustard husk and wood chips as well as
waste bricks from the production process. Quantitative data for the different
waste streams could not be obtained. The exact combination of fuels used is not
constant and depends on market price and availability. Hence the combinations
used vary from kiln to kiln and there is no spatial or temporal pattern.
Paper: Solid waste outputs from the paper industry include boiler ash from the
different fuel combinations used, pins, plastic and sand. Most of the boiler ash is
rice husk. This is because about 20% by weight of rice husk is converted into
ash. The total solid waste from the industry in the area is 1,30,891 T/Y. The
major problem of the industry is the liquid output, which is 14,25,600 KL/Y.
This is marginally higher than the liquid waste produced in sugar manufacturing.
The liquid waste from the paper industry is black liquor which drains into
channels passing through fields; these drains empty into the major rivers in the
region. Discussions with stakeholders suggest that crop productivity in these
fields has been affected by the black liquor. Hence there is soil contamination
caused due to the black liquor flowing through the fields. Depending on the type
of soil and location of aquifers, soil contamination may lead to groundwater
contamination in the long run. Thus, black liquor is a big environmental burden
for the region.
Steel: More than 180000 T/Y of solid waste is generated by the steel industry in
the form of ash, slag and used moulds. Exact figures for the quantities of ash and
moulds could not be obtained. Slag is disposed of in unofficial landfills while
35. 25
most of the used moulds are sent back to the ceramic units where they were
produced to be reused in the production processes. Data for liquid waste (water
used for cooling steel) from the industry could not be obtained.
Sugar: Large quantities of solid waste are generated in the manufacture of sugar
in the form of bagasse which is remains after crushing sugarcane. About
5,00,000 tons of bagasse is annually generated in sugar mills. This account for
about 60% of the solid waste generated by sugar mills. Almost 70% of this
bagasse is used in the cogeneration plants within the sugar industry.
Approximately 2,56,365 tons of press mud, which is the residue left after
clarification of sugarcane juice, is generated in these mills annually. The amount
of liquid waste (1144312 KL/Y) generated is also very large and includes
molasses and waste water. Molasses is sent to distilleries for production of
alcohol while the waste water is discharged to drains.
Figure 11: Solid and liquid waste output from selected industries. *Waste
data for steel and brick could not be completed.
0
500000
1000000
1500000
2000000
2500000
3000000
Paper Sugar Steel Brick Total
Solid (T/Y)
Liquid (KL/Y)
36. 26
Objective 2: To identify existing links within selected industries in the study
area.
The findings of this objective have been divided into two sections. The first
section documents the current situation of industrial waste disposal/usage in the
region. The second section is a projected scenario where suggestions have been
given for utilization of different waste streams.
The waste streams have been placed in three categories- reuse/use within facility,
symbiosis and disposal. The usage of the three terms is explained as follows.
‘Reuse/use’ within the facility means the waste is used within the unit.
Symbiosis refers to the waste being sent to some ‘other industry’. By ‘other
industry’ it is meant that the waste is being sent out of the boundary of the
originating unit and is being transferred to another unit which belongs to a
different industry. Disposal refers to the waste being sent to landfills or
discharged through drains. ‘Landfills’ refer to any place where the solid wastes
are dumped. Mostly these are low lying farm lands, waste lands or sides of roads.
There is no official landfill site in the region where all industrial waste can be
sent. ‘Drains’ refer to channels leading effluents out of the factory boundary.
Present Scenario
From Figure 8 the symbiosis network is extracted and has been shown below. In
this flow chart the red arrows indicate the symbiosis networks.
37. 27
Figure 12: Flow chart showing existing symbiosis network between selected
industries in Muzaffarnagar. Red arrows represent material flow direction
of symbiotic exchange.
From Figure 8 it is evident that symbiosis is being undertaken in the region; the
network has been shown in Figure 12. About 92,000 tons of bagasse is sent from
sugar mills to paper mills each month to be pulped and also to be burnt to
produce electricity. Waste paper is used in the paper industry as raw input from
these about 600 tons/month of pins is segregated both manually and during the
production process. These are sent to the steel rolling mills in the region. The
ceramic brick industry supplies moulds to the steel industry. These moulds are
used to make a variety of products but can only be used once. So after use they
are returned to the ceramic industry to be put back into the production process.
SUGAR
PAPER STEEL
DISTILLERY
RED
BRICK
CERAMIC
BRICK
Pins
Bagasse
Refractory
Bricks
Used
Refractory
Bricks
Molasses
Molasses
Water
Ash
PressMud
Ash
Ash
Black
Liquor
Sand
Ash
Ash
Slag
38. 28
Molasses which is a byproduct of the sugar manufacturing process is sent to
distilleries within the study area. About 59452 KL of molasses is sent to
distilleries each month. A very small amount of molasses is also sent to the
ceramic brick industry where it is used as a binder. This amount could not be
quantified.
About 55% of solid waste generated in the region is reused within the units
where it is generated. 23% of solid waste is sent for symbiosis. The remaining is
disposed of. Disposal of solid waste is done in unofficial landfills. The share of
solid waste is large in the reuse category because of the large amount of bagasse
used in the sugar industry’s cogeneration plants. If the sugar industry is removed
from the system then the percentage share of symbiosis in solid wastes goes
down to 1%. The amount of waste going into disposal in such a scenario goes up
to 95%. The only ‘reuse’ within the facility which is quantified in such a
condition is the plastic segregated from the paper industry. Large amounts of the
waste paper used for pulping are laminated with plastic. These are segregated
and are at present being burnt in the boilers to generate power.
Ash from the burning of fuel in all the industries is at present sent to landfills.
Sand a waste from the paper industry is disposed in dumps. A small amount of
the press mud is used by farmers in the region but most of it is dumped around
the sugar mills. In total almost 70,000 tons of solid waste per month is disposed
in the region. About 2, 90,000 KL per month of effluent is thrown into drains in
the area. This includes black liquor from paper mills and water from sugar mills.
39. 29
Table 2 shows data for solid waste in the study area. It can be seen that a major
share (55%) of solid waste is reused within the factories. Only 21% of the solid
waste is disposed of. The remaining is utilized in symbioses within the study
area.
Table 2: Present scenario with respect to utilization of solid waste from
selected industries in Muzaffarnagar (tons/month)
Waste
Stream
Output
(tons/month)
Within
facility
(tons/month)
Symbiosis
(tons/month)
Disposal
(tons/month)
Ash 15332 0 0 15332
Bagasse 308060 215642 92418 0
Pins 662 0 662 0
Plastic 3311 3311 0 0
Press Mud 51273 0 0 51273
Refractory
Bricks
? ? ? ?
Sand 2666 0 0 2666
Slag 15000 0 0 15000
Used
Refractory
Bricks
? ? ? ?
396304 218953 93080 84271
40. 30
Table 3 shows data for liquid waste in the study area. Most of the liquid waste is
thrown into drains. Only 17% of the total liquid waste of the region is utilized in
the symbiosis network.
Table 3: Present situation with respect to utilization of liquid waste from
selected industries in Muzaffarnagar (kl/month)
Waste
Stream
Output
(kl/month)
Within
facility
(kl/month)
Symbiosis
(kl/month)
Disposal
(kl/month)
Black
Liquor
118800 0 0 118800
Molasses 59452 0 59452 0
Water 169410 0 0 169410
347662 0 59452 288210
Figure 13: Comparison of final disposal of all wastes (solid and liquid)
generated by selected industries in Muzaffarnagar, including and excluding
the sugar industry. (%)
0% 20% 40% 60% 80% 100%
All waste (Liquid)
Waste excluding sugar
industry (Solid)
All waste (Solid)
Within Facility
Symbiosis
Disposal
41. 31
Projected Scenario
Figure 14 shows a projected scenario where uses for the waste streams have been
proposed. These are based on work being carried out on waste utilization in the
study area as well as work that have been done in the past. The thick black
arrows identify proposed additions to the symbiosis network.
Figure 14: Flow chart showing a proposed symbiosis network. Thick black
arrows represent material flow direction of proposed symbiotic exchange.
Even though there is some symbiosis in the region, there are other waste streams
in the region which can be used but are not. Figure 14 represents the ideal
scenario. In this scenario it is assumed that all the waste streams will be
Molasses
Molasses
Black
Liquor
Plastic
UsedRefractoryBricks
Ash
Ash
Sand
Ash Ash
Pins
Bagasse
RefractoryBricks
Molasses
Molasses
PressMud
Water
DISTILLERY
BIOGAS
CERAMIC
BRICK
SUGAR
PAPER STEEL
RED
BRICK
SODA ASH
RECOVERY
PLASTIC-
TO-FUEL
Slag
CONSTRUCTION
42. 32
completely used. However, viability and feasibility of these suggestions in the
study area has not been studied yet.
Several studies have been carried out on the use of coal fly ash in making of
bricks (Wei et al., 2005; Cao et al., 2008; Sebastian and Cultrone, 2009). Coal fly
ash is generated in a few steel and sugar (during their offseason) mills. It is
suggested that this ash be sent to the existing brick kilns for utilization. There is
work being done in the area on the utilization of boiler ash from paper mills in
the brick industry. Sand is used in the brick industry as a lining for moulds in
which the clay is shaped. Sand which comes out of wheat straw in the paper
industry could be used in the brick industry. It is suggested that black liquor be
sent to a soda ash recovery plant. Research on the same is being done in the
study area presently. There is also work being done on the use of black liquor as
source of energy (Wallberg et al., 2003; Naqvi et al., 2010). Conversion of
plastic to oil or gas is suggested for the plastic recovered from waste paper.
Work on this is also being conducted in the region. Press mud can be used to
make biogas (Ratnam, 2014). At present a part of it is used by farmers as
fertilizers. But a major part of the press mud generated is not used and is
scattered on the land around sugar mills. Slag from the steel mills can be
extensively used in the construction industry (Geiseler, 1996; Xue et al., 2007). It
should be noted that the feasibility and viability of these suggestions in the study
area has not been looked into.
43. 33
Table 4 below shows how the quantities of solid waste will change in the area. It
has been assumed that all the waste generated will be used.
Table 4: Projected scenario with respect to utilization of solid waste from
selected industries in Muzaffarnagar (tons/month)
Waste
Stream
Output
(tons/month)
Within facility
(tons/month)
Symbiosis
(tons/month)
Disposal
(tons/month)
Ash 15332 0 15332 0
Bagasse 308060 215642 92418 0
Pins 662 0 662 0
Plastic 3311 0 3311 0
Press Mud 51273 0 51273 0
Refractory
Bricks
? ? ? ?
Sand 2666 0 2666 0
Slag 15000 0 15000 0
Used
Refractory
Bricks
? ? ? ?
381304 215642 180662 0
44. 34
Table 5 shows an ideal situation where most of the liquid waste is used in the
study area. The manner in which the liquid waste can be used is mentioned in the
text below.
Table 5: Projected scenario with respect to utilization of liquid waste from
select industries in Muzaffarnagar in an ideal scenario (kl/month)
Waste
Stream
Output
(kl/month)
Within
facility
(kl/month)
Symbiosis
(kl/month)
Disposal
(kl/month)
Black
Liquor
118800 0 118800 0
Molasses 59452 0 59452 0
Water 169410 0 0 169410
347662 0 178252 169410
Figure 15: Comparison of final disposal of all wastes (solid &liquid)
generated by selected industries in Muzaffarnagar (projected scenario)
Environmental and socio-economic impacts of existing industrial network
It is important to look at any industrial network from an environmental
perspective, i.e. to look at the effects on environment due to industrial activity.
0% 20% 40% 60% 80% 100%
All Waste (Liquid)
All Waste (Solid)
Within Facility
Symbiosis
Disposal
45. 35
The environmental burdens over a long period of time may directly or indirectly
lead to socio-economic problems in the area also. Even though the environmental
burden may be quantifiable, these socio-economic problems may or may not be
quantifiable. The environmental burdens in the present study have been listed
through stakeholder interviews and work done in the past on environmental
impacts of industrial waste. The socio-economic burdens have been listed
through perception and stakeholder interviews. These interviews were not
structured interviews but were merely interactions with stakeholders directly
affected by the waste streams in the region. An attempt has been made to make a
link between the waste streams and the socio-economic effects felt in the region.
The effects of wastes have been discussed below:
Ash: Ash from all the units in the study area is dumped in low lying land, unused
farmlands and on road sides. Unmanaged disposal of ash leads to soil
contamination from leaching (Kakaras & Vamvuka, 2011; Valentim et al., 2011).
Soil contamination over long periods may cause the leachates to reach
groundwater aquifers, thus causing groundwater contamination. Soil and
groundwater contamination will affect the agricultural productivity in the region.
A fall in productivity is likely to lead farm owners to spend more money on
fertilizers. Because ash is very fine it can be blown into the air and impact human
health.
Bagasse: Bagasse which is the fibrous remains after crushing of sugarcane is
largely associated with its use in cogeneration plants within the sugar industry
for power generation. A part of it is sent to paper mills to be used as a power
source. The environmental impact of bagasse transported to paper mills by
trailers pulled by tractors is emissions during transportation.
Black Liquor: An evaporator unit is installed in one of the paper mills to extract
lignin from black liquor. But it is still not under operation. Black liquor flows out
of paper manufacturing units through drains. These drains pass through
agricultural land and ultimately reach the major rivers in the area. Groundwater
contamination has been seen in many areas which is affecting crop productivity
(stakeholder interview). The presence of sandy loamy soil which is very porous
could be attributed to this.
46. 36
Discarded Moulds: These are sent back to the ceramic facilities where they are
produced. There these are grinded into powder form and used as grog which is a
raw material for the production of ceramic bricks. The used moulds are
transported to the ceramic facilities by tractor trailers. Thus the effects from this
are the emissions due to transportation.
Moulds: These are the primary products of the ceramic brick industry. These are
sent to the steel industry. The environmental burden associated with this would
be the emissions during transportation.
Pins: These are segregated from waste paper, both manually and during the
production process in the paper industry. These pins are then sent to steel mills.
Even though the quantity of this is very small compared to the amount of scrap
metal required by the steel industry in the area, it still plays a part in the
symbiosis. The environmental burden associated with it is the emissions during
transportation.
Plastic: This is at present burnt in the boilers of paper mills to generate
electricity. Burning of plastic causes numerous environmental and health
impacts. Burning of plastic directly causes air pollution through release of a
number of Volatile Organic Compounds (VOC’s) and semi-VOC’s. Burning of
plastic leads to severe degradation through soil contamination and groundwater
contamination (Molgaard, 1995).
Press Mud: Press mud is a by-product of the sugar industry. About 2,56,365
tons of press mud are annually produced from sugar mills in the area. A part is
sold to farmers to aid in bio-composting (Ratnam, 2014; stakeholder interview).
While a major share is left in the fields around the mills. This causes over
fertilization of fields leading to heavy metal contamination and spillage to
waterways (Ratnam, 2014). Spillage to waterways and groundwater
contamination would directly affect the health of the residing population since
they rely on both surface and groundwater.
Slag: Slag is at present disposed on the sides of roads leading to the steel mills.
Due to its high silica content the slag binds very well with the soil, not allowing
water to penetrate the surface.
47. 37
Table 6: Summary of present utilization of waste and associated
environmental impacts.
Symbiosis Within
facility
Disposal Environmental
Burden
Reference
Ash
Y
Groundwater
contamination, soil
contamination
Kakaras &
Vamvuka
(2011),
Valentim et al.
(2011)
Bagasse Y Y
Black
Liquor Y
Groundwater
contamination, soil
contamination
Stakeholder
interview
Discarded
moulds
Y
Emission from
transportation
-
Discarded
steel
Y
N/A (going back into
process)
-
Molasses Y - -
Moulds
Y
Emission from
transportation
-
Pins
Y
Emission from
transportation
-
Plastic
Y
Bio accumulation in
food chain, air
pollution, water
contamination, soil
contamination
Medeiros et al.
(2005), Lithner
(2011),
Molgaard
(1995), CAEPA
Press
Mud
Y Y
Over fertilization of
soil, heavy metal
Leena Ratnam
(2014)
48. 38
Table 7: Summary of projected utilization of waste and associated
environmental impacts.
Symbiosis
Within
facility Disposal
Avoided direct
burden Environmental Benefit
Ash
Y
Avoiding
landfilling helps
with particulate
matter emission
to air
Less material needing to
be extracted for brick
making, potential fuel
savings because of
internal carbon
Bagasse
Y Y
Less input material or
fuel needed
Black
Liquor
Y
Avoid water and
soil emissions Fuel savings
Discarded
moulds
Y ?
Discarded
steel
Y
Lower energy
Molasses Y ?
Moulds Y ?
Pins Y
Plastic
Y
Avoided air
emissions Fuel savings
Press Mud
Y
Avoid water and
soil emissions
Sand
Y
Less material needing to
be extracted for brick
making
Slag Y ? ?
Waste
Paper
Y
contamination,
spillage to waterways
Sand Y
Slag Y Groundwater table -
Waste
Paper
Y
N/A (going back into
process)
-
49. 39
The impacts stated above have been grouped together to form the flow chart
given below (Figure 16). The flow chart is based on LCA IMPACT 2002+
guidelines.
Figure 16: Flow chart linking waste streams with environmental impacts
based on IMPACT 2002+ guidelines.
According to the IMPACT 2002+ guidelines different life cycle inventory results
are linked to damage categories (human health, ecosystem quality, climate
change, and resources) via several mid-point categories (human toxicity,
respiratory effects, ionizing radiation, ozone layer depletion, photochemical
oxidation, aquatic ecotoxicity, terrestrial ecotoxicity, aquatic acidification,
aquatic eutrophication, terrestrial acidification/nutrification, land occupation,
water turbined, global warming, non-renewable energy consumption, mineral
extraction, water withdrawal, and water consumption) (IMPACT 2002+ User
Guide). Based on these guidelines environmental burdens associated with
impacts due to different waste streams can be calculated.
As an extension of the present study an attempt has been made to quantify one of
the impacts associated with the discharge of black liquor. The impact selected is
aquatic eutrophication. Eutrophication is a major issue faced by most water
Ash
Black
Liquor
Plastic
Press Mud
Slag
Human Toxicity
Respiratory Effects
Aquatic Ecotoxicity
Terrestrial
Ecotoxicity
Aquatic
Eutrophication
Eco-system Quality
Human Health
Mid-point Categories
Damage Categories
50. 40
bodies. High concentrations of phosphorus cause eutrophication in freshwater
lakes, reservoirs, streams (Correll, 1998).Through the LCA database it was found
that each kg COD introduces 0.022 kg phosphate into water. The COD of the
black liquor generated in the area was 99680 mg/L (analysis report attached in
annexure). About 118800 KL of black liquor is generated annually in the region.
Thus about 2605 T of phosphate are added annually into the water bodies of the
region from disposed black liquor. 21.96 mg of phosphate is added per liter of
black liquor generated. If black liquor could be used in some other way, 2605 T
of phosphate can be stopped from entering water bodies. One such way is to use
black liquor as a source of fuel. This would help reduce consumption of other
fuels used. Black liquor has a calorific value of 90 kcal/kg. Thus, burning all the
black liquor produced would generate 12,40,27,20,000 kcal of energy. This
would help reduce consumption of bagasse, rice husk and wood chips,
respectively by 0.27%, 0.07% and 0.38%.
51. 41
7. Conclusion
The study identified the existing symbiosis network in the region. Currently this
network is dominated by the contribution from the sugar industry. There are
other links but the quantity of residuals transferred through those is small in
comparison to contributions from the sugar industry.
Objective 1: To identify, understand and quantify the flow of materials
through selected industries in the study area.
A material flow chart was made for the region with the help of data collected for
the selected industries. All the industries in the region have similar outputs in
terms of tonnage. The brick industry even though having very small outputs from
individual units has outputs comparable to those of the other industries when
aggregated for the entire region. Thus, equal importance has to be given to all the
industries in any research towards symbiosis in the region. There is a high
dependence on fossil fuel in these industries. Paper making is the most water
intensive industry in the region. Water is an important natural resource and its
consumption must be prioritized. The industries release a number of waste
streams that pose environmental and health related issues which need to be
looked into.
Objective 2: To identify existing links within select industries in the study
area.
Quantification and characterization of different type of industrial waste was
done. The wastes were classified into three― symbiosis, reuse within facility
and disposal. An existing symbiosis network was identified in the region. But
this is dominated by the contribution from the sugar industry. The sugar industry
contributes to about 80% of the total solid residuals undergoing symbiosis and
reuse in the area. If the sugar industry is taken out of the system then the amount
of wastes going into symbiosis and residuals goes down drastically. Uses for
other waste streams have been suggested.
As an extension of the study an effort was made to look at environmental
impacts of the existing industrial network. These impacts were suggested with
52. 42
the help of stakeholder interviews and work done in the past by other
researchers. With the help of IMPACT 2002+ guidelines an attempt was made to
quantify aquatic eutrophication caused by release of black liquor in the region.
Fuel savings by utilization of black liquor as fuel was also quantified. The
extension was done to give an idea to readers about the future scope of such a
study.
53. 43
8. Limitations
There are a number of areas which could have been looked at in more detail.
Theses have been mentioned below-
i. Limited input/output data for:
a. Steel Industry — Due to the reluctance of owners and lack of time
individual data from steel units could not be obtained.
b. Brick Industry — Fuel input could not be quantified because the
combination of fuels used in the kilns differ from kiln to kiln and
do not follow any trends. Since fuel input could not be quantified
hence the waste which is ash from burning of fuel could not be
quantified.
ii. Error due to lack of on-site measuring instruments: All
input/output data were collected through stakeholder interviews and
association databases. No instruments were used to validate the
values collected though the interviews. Thus, there could be a small
error in the data obtained.
9. Scope for Future Work
The present study can be extended to add more value to the work. Some areas of
work are
i. Detailed work on utilization of waste streams from steel industry
ii. Quantification of the environmental burdens due to the present
industrial set-up.
iii. Risk analysis studies for impact of different waste streams on
stakeholders in the region.
iv. Feasibility studies for the suggested utilizations.
v. Proper disposal mechanism for industrial wastes.
54. 44
References
Abduli, M.A. (1996) Industrial waste management in Tehran. Environmental
International, 22, pp.335-341.
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Annexure
The names of the factories have been withheld due to request from the
stakeholders.
Production level of paper units in Muzaffarnagar
Type of Product (T/M) TOTAL
Agro
Kraft
Waste
Paper
Kraft
Agro Writing
& Printing
Waste Paper
Printing
Duplex
High
BF
Kraft
Other Tissue T/M
Unit 1 1500 1500
Unit 2 2000 2000 4000
Unit 3 1200 800 2000
Unit 4 6000 6000
Unit 5 900 900
Unit 6 8000 8000
Unit 7 2000 2000
Unit 8 1200 1200
Unit 9 2000 400 2400
Unit 10 1800 1800
Unit 11 2500 2500
Unit 12 3500 3500
Unit 13 2500 2500
Unit 14 600 600
Unit 15 1000 1000
Unit 16 2500 4500 2000 9000
Unit 17 1200 1200
Unit 18 1200 1200
Unit 19 2000 2000
Unit 20 800 800
Unit 21 600 600
Unit 22 600 600
Unit 23 1500 1500
Unit 24 1500 1500
Unit 25 600 600
Unit 26 2500 2500
Unit 27 2000 2000
Unit 28 800 800
Unit 29 1000 1000
TOTAL 21700 16900 8000 900 9500 5500 1500 1200 65200
64. 54
Sugar Industry Data
Input
Primary Output
Waste Output
Sugarcane Bagasse
Bagasse
Used Bagasse
Fly
Ash Sugar
Milk
of
Lime Water Molasses
Press
Mud
Waste
Water
Crushing
Capacity
In
Industry
Sent
Out
Production
T/M T/M T/M T/M T/M T/M KL/M KL/M T/M T/M KL/M
Unit 1 180000 55800 39060 16740 24 16200 324 90720 8100 6300 22500
Unit 2 360000 3600 2520 1080 72 30960 648 181440 15480 14400 45000
Unit 3 50280 15335 10735 4601 157 4425 91 25341 2212 1886 6285
Unit 4 240000 73200 51240 21960 1204 21120 432 120960 10560 9000 30000
Unit 5 75000 22875 16013 6863 376 6600 135 37800 3300 2813 9375
Unit 6 150000 45750 32025 13725 753 13200 270 75600 6600 5625 18750
Unit 7 150000 45750 32025 13725 753 13200 270 75600 6600 5625 18750
Unit 8 150000 45750 32025 13725 753 13200 270 75600 6600 5625 18750
TOTAL 1355280 308060 215642 92418 4091 118905 2440 683061 59452 51273 169410
65. 55
Brick Industry Data
Dimensions of bricks-
Length-230 mm
Breadth-115 mm
Height-75 mm
Volume-19,83,750 mm3
=0.001983750 m3
Number of bricks made annually-2,00,00,00,000
Sand per brick-0.014 kg
Total Sand-28000 Tonnes
Water per brick-0.25 L
Total Water- 500000 KL
Weight of soil used per brick-2.96 kg
Total weight of soil used-5,92,00,00,000 kg = 59,20,000 Tonnes
Average Density of Soil=960 kg/ m3
Volume of Soil required annually- 6166667 m3
Depth to which excavation is allowed-4m
Area lost annually to brick making-1.54 km2
66. 56
Table for calculation of reduction in fuel consumption due to utilization of
Black Liquor as fuel.
Values Units
Black Liquor (BL) Volume 1
118800 KL/Y
CV BL
2
90 kcal/kg
Density of BL 1160 kg/m^3
Mass of BL 137808000 Kg
Energy from BL 12402720000 Kcal
Bagasse Quantity 1
22600 T/Y
CV Bagasse
1
2000 kcal/kg
Energy from Bagasse 45200000000 Kcal
Mass of Bagasse needed for energy equivalent to that
from BL 6201360 Kg
% of Bagasse saving in using BL 0.27 %
Rice Husk (RH) Quantity 1
57500 T/Y
CVRH
1
3200 kcal/kg
Energy from RH 184000000000 Kcal
Mass of RH needed for energy equivalent to that from
BL 3875850 Kg
% of RH saving in using BL 0.07 %
Wood Chip (WC) Quantity 1
18080 T/Y
CVWC
1
1800 kcal/kg
Energy from WC 32544000000 Kcal
Mass of WC needed for energy equivalent to that from
BL 6890400 Kg
% of WC saving in using BL 0.38 %
1 Stakeholder interaction
2 SGS report (attached in annexure)
