Captive Incinerator Maharashtra - Maharashtra …mpcb.gov.in/images/pdf/Captive_Incinerator_Mah_22082014.pdf• Policy regarding no use of captive incinerator within 50 KM radius from

Status of Captive Incinerator

Introduction:

Incineration: Incineration involves burning hazardous wastes to destroy such organic

compounds as dioxins and Polychlorinated

forms of waste, including contaminated soils,

effective in treating inorganic substances such as hydrochloric acid, salts, and

Why is it used?

• Incineration can be a permanent waste disposal solution because it destroys wastes

that would otherwise take up space in a landfill. Incineration effectively destroys over

99 percent of all organic compounds.

• Toxic chemicals are breaks down under heat dur

How does it work?

• Incineration uses high temperatures (between 1600°F and 2500°F) to degrade

contaminants into nontoxic substances, such as water, carbon dioxide, and nitrogen

oxides (nitrogen and oxygen). Properly done, high

effective, odorless, and smokeless process. The process is illustrated in

• Incinerator regulations assume that all leftover ash and material removed from the

incinerator are hazardous. Accordingly, they must be dis

permit to handle hazardous waste. In addition, water used in the incineration process

must meet strict standards before it can be discharged to surface waters.

1

Captive Incinerator in Maharashtra

involves burning hazardous wastes to destroy such organic

Polychlorinated biphenyls (PCBs). Incinerators can handle many

forms of waste, including contaminated soils, sludge’s, solids, and liquids. Incineration is not

effective in treating inorganic substances such as hydrochloric acid, salts, and

Incineration can be a permanent waste disposal solution because it destroys wastes


99 percent of all organic compounds.

Toxic chemicals are breaks down under heat during incineration.

Incineration uses high temperatures (between 1600°F and 2500°F) to degrade


oxides (nitrogen and oxygen). Properly done, high-temperature incineration can be an

effective, odorless, and smokeless process. The process is illustrated in

regulations assume that all leftover ash and material removed from the

incinerator are hazardous. Accordingly, they must be disposed of at a facility that has a



Maharashtra

involves burning hazardous wastes to destroy such organic

. Incinerators can handle many

, solids, and liquids. Incineration is not

effective in treating inorganic substances such as hydrochloric acid, salts, and metals.

Incineration can be a permanent waste disposal solution because it destroys wastes


Incineration uses high temperatures (between 1600°F and 2500°F) to degrade


e incineration can be an

effective, odorless, and smokeless process. The process is illustrated in below Diagram.

regulations assume that all leftover ash and material removed from the

posed of at a facility that has a



2

After incineration, wastes are converted to:

• CO

• CO2

• WATER

• ASH

Depending on the composition of the initial waste, compounds containing:

• HALOGENS

• METALS

• NITROGEN

• SULFUR

may be produced. These compounds, along with CO, are deleterious to the atmosphere, and

needs highly regulation. The destruction efficiency for these hazardous wastes incinerators

need to be equipped with:

• AFTERBURNERS

• SCRUBBERS

• FILTRATION UNITS

• MEMBRANES

To provide secondary treatment for environmentally unsafe compounds, so that they

can be released to the atmosphere at suitable concentration levels. Various types of

incinerators are currently manufactured. The choice of an incinerator depends on the wastes'

combustibility and its characterization as liquid, sludge, solid, or gas. The wastes'

combustibility characteristics, such as ignition temperature, flash point, and flammability

limits determine the necessary operating temperature, O2 concentration, and residence time

for greatest waste minimization. The proper incinerator types can then be identified based on

the waste specifications.

Types of incinerators

The following are types of incinerators:

• ROTARY KILN

• FLUIDIZED BED

• LIQUID INJECTION

• MULTIPLE HEARTH

• CATALYTIC COMBUSTION

• WASTE-GAS FLARE

• DIRECT-FLAME

Of these, rotary kiln, fluidized bed, and liquid injection are the most, prevalent in

industry because of their applicability to large scale use and their versatility. Consequently,

these three kinds will be emphasized.

ROTARY KILN CHARACTERISTICS:

• ROTATE WASTES IN CYLINDRICAL CONTAINER, ENABLING THOROUGH MIXING WITH

AIR

• OPERATING TEMPS. FROM 1500

• HAS GREATEST RESISTANCE TO HIGH TEMPS.

• CAN HANDLE LIQUID, SLUDGE, SOLID, OR

• CAN OPERATE IN BATCH MODE, ALLOWING MORE FLEXIBILITY THAN CONTINUOUS

MODE

• CAN BE MOBILE TO ALLOW ONSITE TREATMENT

• CAN ACCEPT ENTIRE DRUMS OF WASTE, A UNIQUE FEATURE

FLUIDIZED BED CHARACTERISTICS:

• vessel contains inert granular material that expands and acts theoretically as a fluid

when gases are injected up through the material bed from nozzles

• OPERATING TEMPS FROM 1400

• CAN HANDLE LIQUID, SLUDGE, SOLID, OR GASES

• WASTE ENTERS THROUGH NOZZLES

• OFFERS NEARLY ISOTHERMAL OPERATION

• CAN'T HANDLE WASTES THAT MELT AND SLAG, DISRUPTING FLUIDIZATION

3

ROTARY KILN CHARACTERISTICS:

ROTATE WASTES IN CYLINDRICAL CONTAINER, ENABLING THOROUGH MIXING WITH

OPERATING TEMPS. FROM 1500-3000 ° F ( 800 - 1650 ° C )

HAS GREATEST RESISTANCE TO HIGH TEMPS.

CAN HANDLE LIQUID, SLUDGE, SOLID, OR GASES IN VERY LARGE QUANTITIES

CAN OPERATE IN BATCH MODE, ALLOWING MORE FLEXIBILITY THAN CONTINUOUS

CAN BE MOBILE TO ALLOW ONSITE TREATMENT

CAN ACCEPT ENTIRE DRUMS OF WASTE, A UNIQUE FEATURE

FLUIDIZED BED CHARACTERISTICS:

vessel contains inert granular material that expands and acts theoretically as a fluid

when gases are injected up through the material bed from nozzles

OPERATING TEMPS FROM 1400-1800 ° F ( 750 -1000 ° C )

CAN HANDLE LIQUID, SLUDGE, SOLID, OR GASES

ENTERS THROUGH NOZZLES

OFFERS NEARLY ISOTHERMAL OPERATION

CAN'T HANDLE WASTES THAT MELT AND SLAG, DISRUPTING FLUIDIZATION

ROTATE WASTES IN CYLINDRICAL CONTAINER, ENABLING THOROUGH MIXING WITH

GASES IN VERY LARGE QUANTITIES

CAN OPERATE IN BATCH MODE, ALLOWING MORE FLEXIBILITY THAN CONTINUOUS

vessel contains inert granular material that expands and acts theoretically as a fluid

CAN'T HANDLE WASTES THAT MELT AND SLAG, DISRUPTING FLUIDIZATION

LIQUID INJECTION CHARACTERISTICS:

• WASTES ARE SENT THROUGH NOZZLES AND ATOMIZED INTO SMALL DROPLETS TO

ALLOW FOR THE GREATEST POSSIBLE MIXING WITH AIR

• OPERATING TEMPS. FROM 1200

• FEED MUST ACT AS A LIQUID HAVING A VISCOCITY LESS THAN 10,000 SSU

• SOLIDS ARE OKAY IF THEY CAN BE MELTED

• CAN COMPLETELY COMBUST NONCOMBUSTIBLES LIKE CONTAMINATED WATER,

ALONG WITH ORGANIC COMBUSTIBLE MATERIAL

• HAS A HORIZ. OR VERT. CONFIGURATION

• A SUSPENSION BURNER, THAT IS THE MOST LABORFREE AND FLEXIBLE KIND OF

INCINERATOR

Diagram Showing FLUIDIZED BED and LIQUID INJECTION Incinerator Mechanism

One other characteristic that all three types of incinerators (rotary kiln, fluidized bed, and

liquid injection) share is that they can all be operated in a pyrolysis or oxygen starved mode.

Wastes with high caloric value that are capable of releasing great heat content are most

appropriate for this kind of operation. The other types of incinerators are described as follows.

4

LIQUID INJECTION CHARACTERISTICS:

WASTES ARE SENT THROUGH NOZZLES AND ATOMIZED INTO SMALL DROPLETS TO

ALLOW FOR THE GREATEST POSSIBLE MIXING WITH AIR

OPERATING TEMPS. FROM 1200-3000 F

FEED MUST ACT AS A LIQUID HAVING A VISCOCITY LESS THAN 10,000 SSU

SOLIDS ARE OKAY IF THEY CAN BE MELTED AND PUMPED

CAN COMPLETELY COMBUST NONCOMBUSTIBLES LIKE CONTAMINATED WATER,

ALONG WITH ORGANIC COMBUSTIBLE MATERIAL

HAS A HORIZ. OR VERT. CONFIGURATION

A SUSPENSION BURNER, THAT IS THE MOST LABORFREE AND FLEXIBLE KIND OF

IDIZED BED and LIQUID INJECTION Incinerator Mechanism



th high caloric value that are capable of releasing great heat content are most


WASTES ARE SENT THROUGH NOZZLES AND ATOMIZED INTO SMALL DROPLETS TO

FEED MUST ACT AS A LIQUID HAVING A VISCOCITY LESS THAN 10,000 SSU

CAN COMPLETELY COMBUST NONCOMBUSTIBLES LIKE CONTAMINATED WATER,

A SUSPENSION BURNER, THAT IS THE MOST LABORFREE AND FLEXIBLE KIND OF

IDIZED BED and LIQUID INJECTION Incinerator Mechanism



th high caloric value that are capable of releasing great heat content are most


Example of flue gas cleaning technology

As has been stated, there are several technologies for flue gas cleaning, differing in the

amount of water which is used. The

the stages for flue gas cleaning technology which uses a wet scrubbing process.

5

Example of flue gas cleaning technology


amount of water which is used. The below the flow chart for a rotary kiln incinerator including



the flow chart for a rotary kiln incinerator including


6

KEY FEATURES OF A COMBUSTION INCINERATOR:

• WASTE STORAGE AND HANDLING

• WASTE FEEDING

• COMBUSTION

• STEAM AND ELECTRICITY GENERATION (OPTIONAL)

• AIR POLLUTION CONTROL

• ASH RESIDUE HANDLING

COMMON HAZARDOUS INCINERATION FACILITIES:

Common hazardous waste incineration facilities are those facilities, which handle

hazardous waste from more than one industry either installed as an integral part or located

elsewhere. Various concerned components of common incineration facility include proper

transportation, storage, analytical laboratory facilities, feeding mechanism, incineration

system (rotary kiln & post combustion chamber), gas cleaning system, tail gas monitoring

facilities with automatic on-line monitoring & control facilities, ash/slag management,

bleed/scrubber liquor management and measures for health protection of workers. Guidelines

for maintaining each of these components in order to comply with the prescribed standards

are given in (referred Annex-I).

In Maharashtra State 3 numbers of Common Hazardous Waste Incinerators is available

in the area of Nagpur, Pune, Navi Mumbai; Central Pollution Control Board has setup

Guidelines for Common Hazardous Waste Incineration in the year 2005.

Central Pollution Control Board has also setup guidelines for storage of Incinerable

Hazardous Wastes by the Operators of Common Hazardous Waste Treatment, Storage and

Disposal Facilities and Captive HW Incinerators in year 2006.

7

Captive Incinerators Status in Maharashtra:

Major captive incinerators pertaining to the following sector in the state of

Maharashtra.

1) Pharmaceuticals

2) Organic Chemical

3) Petrochemical

4) Paints

5) Automobiles.

6) Pesticide

The issue of captive incinerators comes in discussion many times .So, in the CAC

Meeting dtd. 07/07/2014 it was decided to list out numbers of captive incinerator present in

industry and whether they are complied with CPCB guidelines .From the Submission of

Regional Office data it is observed that 14 Numbers of Captive HZW Incinerator present in

industries in the state of Maharashtra out of this 2 Nos of Incinerator are not in operation, list

of incinerators detail are enclosed in Annexure No II. The industry category wise details

mentioned in below table.

Major MPCB concern issue regarding Captive Incinerator:

• Emission Standards was incorporated for incinerators in Pesticide and Pharmaceutical

sector in the Environment (Protection) Rule, 1986, but for others sectors like

automobile, chemical, Pesticide and explosive separate standards are not available.

• Emission Standards for incinerator are not incorporated in Consent .The parameters

like oxygen (O2), carbon monoxide (CO), carbon dioxide (CO2), hydrogen chloride

(HCl), sulphur dioxide (SO2), oxides of nitrogen (NOx) and total hydrocarbons (THC).

Oxygen, carbon monoxide, carbon dioxide and total hydrocarbons are not monitored

by MPCB to measures of combustion efficiency & Air Pollution Scrubber efficiency.

• The Incinerator shall contain Double Chamber and minimum temp in primary chamber

shall be 800+ ℃ and in secondary chamber shall be maintained upto 1100 + ℃ in order

to ensure complete burning of waste.

• Data regarding destruction of Hazardous Waste are difficult for authentication as said

system not having manifest mechanism. Industry may use paint sludge or plastic waste,

oil contaminated cotton in boiler without adequate air pollution control system.

Sr No Type of Industry No of Industry

1 Chemical 06

2 Pharmaceutical 03

3 Automobile 02

4 Paint 02

5 Process Metal recovery 01

Total. 14

8

• In house Laboratory facility required in order specifying the waste characterized for

appropriate operating parameters during hazardous waste incinerator. Most of

industry has not provided in house lab facility

• Online parameter monitoring facility is not provided by most of Industries.

• Concern of proper disposal of incinerated ash to CHWTSDF landing site and treatment

of scrubber effluent as effluent carrying most dangerous pollutants like heavy metals

etc.

Proposed Action Plan /Guidelines of Captive Incinerators:

• Industry shall provide separate storage area with shed and spillage /seepages

collection facility for hazardous waste which is to be incinerated.

• Scientific analysis from reputed institute of hazardous waste which is to be incinerated

shall be carrying out so as to know emitting pollutant from hazardous waste.

• Based on study adequate air pollution control devices for cleaning of particulate matter

& gases scrubbing shall be made.

• Emission Standards for Captive Incinerator shall be formulating in consultation with

Central Pollution Control Board or Standards of Common Hazardous Waste Incinerator

shall be incorporated in consent (referred Annex-I).

• Policy regarding no use of captive incinerator within 50 KM radius from Common

Incinerator Facility shall be made for economical viability of Common Hazardous

Waste Treatment Facility. Except Explosive unit which may required in house waste

destruction as per Explosive Rules.

• Industry shall made water treatment facility for treatment of effluent generation from

scrubber & spillages /seepages of hazardous waste.

• Incinerated ash from shall be send to CHWTSDF for secured land filling.

• Time Bound Program with Bank Guarantee shall be carried out for Non-Complied

Captive Incinerators:

Sr. No. Compliance Time Bank Guarantee

1

Closure Plan for Non-Complied Incinerator

which are not commissioned as per CPCB

site criteria & CPCB Compliance & Shifting

to CHWTSDF for Hazardous waste disposal

6 month 5 Lakh

2 Those Units Complied with CPCB Guidelines

for Incinerator. Separate B.G for Operation Continues 5 lakh

9

and Maintenance shall be obtained

3

Analysis results from MoEF approved lab of

Parameter Prescribed by CPCB for

incinerator shall be submitted to MPCB on

Monthly Basis.

Continues 1 Lakh

4

Submission of quantity of Incinerated

Hazardous Waste details to MPCB on

monthly basis

Continues 1 Lakh

5

Formation of internal 3 person committee

above the managerial rank within industry

for verification & necessary submission to

MPCB regarding incinerated hazardous

waste

1 Month 1 Lakh

6 Online continuous Monitoring System for

CPCB prescribed standards 6 Months 5 Lakh

7 Setup Laboratory Facility at Site for proper

operation of incinerators 6 Months 5 Lakh

------xx--------

10

11

Annexure –II

List of Captive Hazardous Waste Incinerators in Maharashtra

1 2 3 4 5 6 7 8 9

Sr. No.

Name and Add. Of Industry

Type of Incinerator

Capacity of Incinerator

Incinerated wastes

Category of

wastes

Quantity of Wastes

APCS Provided

Remark

1

NOCIL LTD C-37 TTC

Industrial Area, Off

Thane Belapur Road, Navi

Mumbai 400705.

Liquid injector down fired Static type

115kgs/Hr Distillation

residue 20.3 65.7MT/A Provided

Not Operational

2

Hindustan Platinum Pvt.

Ltd.C-122 T.T.C.

Industrial Area, Pawane Navi Mumbai-

400703

Roller Hearth 240 Kg /Hr Used Precious

Metal Catalyst of Pt, Pd, Ag etc

Carbon Base

Catalyst 750 MT/A

Yes ( Spray Evaporative

Cooler, Cyclone

Separator, Filter Bag House,

Packed bed Scrubber & Chimney

--

3

METROPOLITAN

EXIMCHEM LTDB,CFC,

MIDC, PHASE II, DOMBIVLI

(E)

Stationary three pass aqueous

600 Kg/Hr

Anhydrous Sodium Sulphate

( Captive consumption)

36.2 ash from incinerat

or for Hazardous waste

6 MT/A

Ventury Caustic

scrubbers along with 30

mtr height chimney

connected with standard

system

--

4

Monarch Catalyst Pvt.

Ltd. Plot No.F-1/2,MIDC,Phase-I,Dombivli (East) Dist-

Thane

Furnace Oil Fired (Tray

Type) 50 Kg /Hr

Spent Nickel Catalyst,Spent

catalyst containing Noble metals,Pd, Pt, Ru

& Rh.

B1120,B1130,B11

30

2000 MT/A Recycler

permission from CPCB & 500 MT/A

Spray Cyclone type wet scrubber

Provided

--

5

Sudarshan Chemical Ind.

Ltd. 46, MIDC Estate,

Dhatav, Roha, Dist. Raigad

402116.

Solid & Liquid incinerator

(Double Chamber)

100 kg/hr. Solid

50 kg/hrs. Liquid

Non Haz.-Paper, Card board,

contaminated waste

1. Waste residue containing oil

2. Spent carbon 3. process

residue etc.

1. Cat. 5.2

2. Cat. 26.1

2.824 MT/A Venture type

Caustic scrubber

--

12

6

M/s. Finolex Industries Ltd., A/p- Ranpar-Golap, Tal &

Dist. Ratnagiri

Liquid and gaseous

waste Incinerator

467 Kg/hr

Liquid residue (High Boils and

Low boils) and off gases from

process

N.A 1752 MT/A

1 Water Scrubber

2 Oxygen Analyser

3 Free

chlorine Analyser

4 Regular monitoring

flue gases

--

7

M/s. Finolex Industries Ltd., A/p- Ranpar-Golap, Tal &

Dist. Ratnagiri

Solid Waste Incinerator

20 kg/hr.

1. Coke 2. Cotton waste 3. Filter and filter

material contaminated

with oil

22.3 3.3

35.1

43.8 MT/A

1. Water scrubber 2. free

Chlorine Analyser

3. Regular 4.

monitoring of Flue gases

Not in Opera

tion

8

Gharda Chemical

limited Plot No.D-1/2 & B-1/7, MIDC

Lote Parshuram Ta.Khed.

Dist.-Ratnagiri-415722

Rotary Kiln with Primary ( Temp- more

than 850 degree

centigrade) & Post

combustion Chamber

(Temp - more than 1100

degree centigrade

1) Hazardous Solid

Wastes.-150-200 Kg/Hr 2) Liquid

Wastes/Residue:- 80-100 Kg/Hr

3) Garbags:- 50-100 Kg/Hr Total:- 280- 400 Kg/Hr

1.35 Million

Used / Spent Oil. (Liquid),Contamin

ated Cotton Waste.

(Solids),Residue of fluid or pasty organic material

made with aromatic,

aliphatic or napthenic

hydrocarbon. (Solids & Semi Solids),Residue of fluid or pasty organic material

made with halogen

containing hydrocarbon.

(Solids & Semi Solids),Contaminated Saw Dust.

(Solids),Residue from Organic Material,Date expired & Off Specification Pesticides.

(Solids & Liquids)

5.1,5.2,21.1,20.3,29.1,36.4

,29.3

5.1-250 MT/A,5.2-4.8 MT/A,20.1-1000 MT/A, 20.3-500 MT/A,29.1-5 MT/A,36.4-150 MT/A,29.3-400 MT/M Total=2309.8MT/A

1) Mist eliminator, 2) Spray Cooler,

3) Ventury Scrubber. provided

--

13

9

Alkyl Amines Chemicals Limited., D-

6/1, Kurkumbh Industrial area, Tal-

Daund, Dist-Pune.

Double Chamberd 10 Kg/hr

Spent Carbon, Contaminated

Aromatic, Alliphatic, Napthenic Solvent.

35.3 & 20.1 51.50 MT/A.

Scrubber Provided with

stack of height 30.0

Mtrs.

--

10

M/s Bajaj Auto Ltd., Chakan, Plot No. A-1,

At Post Mhalunge

MIDC Chakan Tal-Khed, Dist-Pune.

Pipe Natural Gas, Industry has provided

Primary Chamber, Secondary Chamber &

Tertiary Chamber Treatment Incinerator.

100Kg/hr Waste Paint Hazardous Waste

401MT/A

Industry has Provided

Ventury Type Waste

scrubber to Incinerator (2 Step) and 30 meter height of Stack is provided.

--

11

Asian Paints Ltd.,Plot A-1.,

MIDC Khandala,

Phase-1, Tal. Khandala,

Dist.: Satara

Double Chambered

(Primary chamber & Secondary

Combustion chamber)

designed as per CPCB

guidelines with PLC based

online temperature monitoring

system.

100 Kg/Hr.

Solid,Semi Solid ,Tarry Waste,

Waste Residues &

Distillation Residues

23.1, 33.1 ,

33.3 etc. 27.25 MT/A

Venturi Scrubber,

Packed bed scrubber with

allied arrangement

s

--

12

Asian Paints Limited,

LBS Road, Bhandup

west, Mumbai - 400078

H.W. Waste incinerator

60 Kgs feed per hour

(Max)

1) Oil-containing cargo residue, washing water

and sludge. 2)Sludge and

filters contaminated

with oil.3) Distillation residues.4)

Process wastes.5)Wastes

/ residues (not made with

vegetable or animal

materials).6)Chemical-containing residue arising

from decontamination.

7) Flue gas cleaning

residue.8) Chemical sludge from waste water

3.1,3.3,20.3,21.1,23.1,33.1,33.3,34.1,34.3,34.4,35.3

2.0 Tonne,1.0 Tonne,70 Tonne,60 Tonne,27 Tonne,33 Tonne,10

Tonne,53.5 Tonne,1.28 Tonne,190 Tonne,7.0 Tonne,1.5

Tonne Total=

456.28MT/A

Wet Scrubber system (Venturi

Scrubber)

--

14

treatment.9) Oil and grease skimming

residues. 10) Spent carbon

13

Bajaj Auto Limited, A1,

MIDC, Waluj, Aurangabad

HW Incinerator

100 kg/hr Waste Paint 21.1 510 MT / A

Wet Scrubber system (Venturi Scrubber

--

14

M/s Multi Organics Pvt.

Ltd.,A-I, MIDC,

Chandrapur

Not reported 800 Liter/hr

Mother liquor is being incinerated for the recovery

of sodium sulphate.

-- 3504 MT/A

Wet Scrubber system (Venturi Scrubber

--

Documents

Captive Incinerator Maharashtra - Maharashtra …mpcb.gov.in/images/pdf/Captive_Incinerator_Mah_22082014.pdf• Policy regarding no use of captive incinerator within 50 KM radius from