Demonstration of acid and water recovery systems: Applicability and operational challenges in Indian metal finishing SMEs.

Diffusion dialysis, acid retardation and nanofiltration plants were acquired from Europe and demonstrated in several Indian metal finishing companies over a three year period. These companies are primarily small and medium enterprises (SMEs). Free acid recovery rate from spent pickling baths using diffusion dialysis and retardation was in the range of 78-86% and 30-70% respectively. With nanofiltration, 80% recovery rate of rinse water was obtained. The demonstrations created awareness among the metal finishing companies to reuse resources (acid/water) from the effluent streams. However, lack of efficient oil separators, reliable chemical analysis and trained personnel as well as high investment cost limit the application of these technologies. Local manufacturing, plant customization and centralized treatment are likely to encourage the uptake of such technologies in the Indian metal finishing sector.

Activated carbon from sugarcane bagasse ash for melanoidins recovery.

This work investigates the value added utilization of two sugar-distillery wastes: (i) melanoidins, which are complex Maillard reaction products in molasses distillery wastewater, and (ii) unburnt carbon in sugarcane bagasse ash. Activated unburnt carbon (AUC), prepared by deashing and steam activation, had properties comparable to commercial activated carbon (CAC). Both carbons are suitable for melanoidins adsorption followed by desorption using 25% pyridine solution. For AUC, the equilibrium adsorption data is well described by Langmuir isotherm up to 35 °C while Freundlich model fits better at higher temperature. Adsorption using CAC followed Freundlich isotherm at all temperatures. Both carbons followed pseudo second order kinetics and displayed endothermic physisorption. Recovery of melanoidins from AUC (78%) was close to that observed with CAC (80%).

Carbonised red mud--a new water treatment product made from a waste material.

Proposals to use red mud, the waste produced by the extraction of alumina from bauxite ore in the Bayer process, as a material for treatment of heavy metal-contaminated water are limited by its inherent alkalinity and variability. Attempts to lower its pH have been largely unreliable. However, an alternative strategy is carbonisation of red mud by catalytic hydrocarbon cracking, which results in a magnetic material of greater surface area. The efficacy of this material has been compared with that of the untreated parent red mud and acidified red mud for the sorption of CrO(4)(2-), Cu(2+) and Pb(2+). Carbonised red mud does not remove CrO(4)(2-) from solution, but shows enhancement of Cu(2+) and Pb(2+) removal. There is an approximate ten-fold increase in removal of Cu(2+) and Pb(2+) by carbonised red mud compared with acidified red mud.

Valorization of solid waste in sugar factories with possible applications in India : a review.

Sugar production is a major agro-based industry in India that generates various solid wastes viz. sugarcane trash, bagasse, press mud and bagasse fly ash. This work examines the state-of-the-art in innovative value added products that can be obtained from the transformation of these wastes. Challenges in implementing these waste valorization solutions are also highlighted. It is observed that the extent of research and adoption of these solutions vary considerably. Both industry involvement as well as government encouragement is required in translating the research findings into commercial products.

Carbon deposition and phase transformations in red mud on exposure to methane.

A characterization study detailing the phase transformations and microstructural nature of the carbon deposited during methane decomposition over red mud has been undertaken. In situ XRD was carried out to study the phase transformation sequences of red mud during the reaction. Scanning electron microscopy, high resolution transmission electron microscopy, thermogravimetric analysis, BET surface area determination and CHN analysis were carried out to investigate the properties of the post-reaction samples. Exposure to methane with increasing temperature caused a stepwise reduction of iron oxides in red mud and promoted methane cracking leading to carbon deposition. The presence of carbon nanostructures was confirmed by HRTEM observations. The carbon formed was graphitic in nature and the spent red mud, rich in Fe and Fe(3)C formed as a result of the reduction of the iron oxide, was magnetic in nature. The surface area of the material was enhanced upon reaction. In addition, reactivity comparisons between goethite and red mud were carried out to study the formation of carbon oxides during reaction.

Efficient water use in industries: cases from the Indian agro-based pulp and paper mills.

Agro-based pulp and paper mills in India are one of the most polluting industries; in addition, they are high consumers of raw water. Growing scarcity of high quality freshwater as well as stringent regulatory standards is compelling these units to explore appropriate water management options. Based on data obtained through a questionnaire survey and plant visits, this work provides an overview of the water use and effluent treatment status in Indian agro-residue and recycled pulp and paper mills. The challenges faced by this sector are reviewed and practices adopted by progressive units to minimize freshwater use are illustrated through case studies.

Submerged membrane bioreactor using fly ash filters: trials with distillery wastewater.

This work presents preliminary results for distillery wastewater treatment in a MBR equipped with filters prepared from waste fly ash. The system was fabricated locally and employed submerged membranes in the 2-8 microm pore-size range. Distillery wastewater, after anaerobic digestion, was used as the feed and the bioreactor was inoculated with sludge obtained from a local distillery unit. The MBR was operated for around 250 days. The wastewater quality was monitored in terms of COD (chemical oxygen demand), colour, phenol, and MLSS (mixed liquor suspended solids) concentration. An average COD and phenol removal of 36% and 60% respectively was obtained. The maximum suspended solids retention by the ash filter was as high as 98%. The results were encouraging and further trials are currently underway to improve the performance.