Air Pollution by Industries

Tikam chand M.Tech. (Energy) Deptt. of Mechanical Engg. , MNIT, Jaipur (email: tikam.eca@gmail.com)

Abstract
addition Industries play major part of increasing air pollution which effects the environment. Today it is necessary to take action over pollution and take some actions to reduce it. This paper discuss the pollutants generate by the industries, there effects. Control techniques used in the some countries in their industries of steel, cement, oil etc are also discuss of

Air pollution is defined as the various hazardous chemicals, particulate matter, toxic substances and biological organisms into the Earth's atmosphere Industries can discharge contaminants into the air. Approximately 11% of public complaints about air quality in the region are about odour or dust from industry. The problem with industrial air pollution is that the release of toxins from plants and industrial institutions is very high for the per capita natural resource allowance. More air pollution problems are caused by industrial institutions than anything else, and many of these institutions are in chronic violation of air pollution regulations. Industrial air pollution is one of our biggest air pollution problems in the world. In every country we have problems with the toxic gases that are released into the air every day while our products are made and our trash is burned.

1. Introduction
Air is an important providing the basis of life on earth. Pollution had been known to exist for centuries, but it became an issue of serious concern only in the last 200 years or so, mostly due to the industrial revolution. Atmospheric pollution occurs because the release of air pollutants takes place at a rate much faster than they can be accommodated by the environment and removed from the atmosphere without causing serious harm. Air pollution is a release into the atmosphere of any substances, e.g. Chemicals or airborne particles, which are harmful both to the human and animal health as well as the health of wider environment.

2. Origin of industrial pollution

Industrial air pollution can be from the following:-Pollution from thermal power plants. -Pollution due to chemical fertilizers, food, pesticide and pharmaceutical industries.

-Pollution due to cement, steel, paper, sugar industries. -Pollution due to textile and textile related industries. -Pollution industries. -Pollution due to atomic units. due to petroleum and other

the so-called Greenhouse Effect that prevents a drastic cooling of the Earth during the night. This so-called Greenhouse Effect is responsible for GLOBAL WARMING. Currently Carbon Dioxide is responsible for major portion of the global warming trend.

3. Types of air pollutants

Carbon Dioxide (CO2) This is one of the major gas pollutants in the atmosphere. Major sources of CO2 are due to burning of fossil fuels and deforestation. Industrially developed countries like USA, Russia etc., and account for more than 65% of CO2 emission. Less developed countries with 80% of worlds population responsible for about 35% of CO2 emission. Due to high growth reported from less developed countries in last decade, it is estimated that, the Carbon dioxide emissions may rise from these areas and by 2020 their contribution may become 50%. It has also been seen that, Carbon dioxide emissions are rising by 4% annually. As ocean water contains about 60 times more CO2 than atmosphere; CO2 released by the industry leads to disturbance of equilibrium of concentration of CO2 in the system. In such a scenario, the oceans would absorb more and more CO2 and atmosphere would also remain excess of CO2. As water warms, oceans ability to absorb CO2 is reduced. CO2 is a good transmitter of sunlight, but partially restricts infrared radiation going back from the earth into space. This produces

Nitrogen oxides (NOx) They come mainly from nitrogen based fertilizers, deforestation, and biomass burning. mostly Nitrogen as oxides contribute atmospheric

contaminants. These gases are responsible in the formation of both acid precipitation and photochemical smog and causes nitrogen loading. These gases have a role in reducing stratospheric ozone.

Sulfur Dioxide (SO2) Sulfur dioxide is produced by combustion of sulfur-containing fuels, such as coal and fuel oils. SO2 also produced in the process of producing Sulfuric Acid and in metallurgical process involving ores that contain sulfur. Sulfur oxides can injure man, plants and materials. As emissions of sulfur dioxide and nitric oxide from stationary sources are transported long distances by winds, they form secondary pollutants such as nitrogen dioxide, nitric acid vapor, and droplets containing solutions of sulfuric acid, sulfate, and nitrate salts. These chemicals descend to the earths surface in wet form as rain or snow and in dry form as a gases fog, dew, or solid particles. This is known as acid deposition or acid rain.

Chlorofluorocarbons(CFCs) Chlorofluorocarbons, also known as Freons, are greenhouse gases that contribute to global warming. CFCs are responsible for lowering the average concentration of ozone in the stratosphere. Smog Smog is the result from the irradiation by sunlight of hydrocarbons caused primarily by unburned gasoline emitted by automobiles and other combustion sources. Smog is created by burning coal and heavy oil that contain mostly sulfur impurities.

greenhouse gases often result in an increase in the atmospheric temperature, causing global warming. Global warming has various serious implications both on the ecological balance as well as human health. It often results in the melting of glaciers and snowcapped mountains, resulting in an increase in the water levels of seas and rivers, eventually increasing the risk of floods. Apart from this, global warming also often has numerous serious health risks on humans such as increase in diseases like Lyme, malaria, cholera, dengue and plague, among others.

Dust - Generation of fine particulates and dust are inherent in the process of Cement industries, but most are recovered and recycled. The sources of dust emission include clinker cooler, crushers, grinders and material-handling equipments. Materialhandling operations such as conveyors result in fugitive dust emission. Acid Rain - Industries often emit large amounts of nitrogen and sulphur gases into the Earth's atmosphere. When these gases react with water vapors in the atmosphere, they often change into more aggressive gases, namely nitric acid and sulphuric acid respectively. The rain containing large amounts of these acids is known as acid rain. Acid rain has various health and natural dangers. It results in the erosion of monuments and buildings, makes the Global Warming - Global warming is largely considered one of the most hazardous and serious complications associated with air pollution caused by industries. The liberation of certain gases such as methane, or CH4, and carbon dioxide, or CO2, together known as greenhouse gases, is often considered to be prime factors causing global warming. These soil acidic in nature, resulting in reduction of plant and animal growth, among other issues. Apart from these, acid rain causes such as serious cancer, health skin disorders

4. Effects of industrial pollution

disorders and even death.

Respiratory Disorders - The emission of various gases such as carbon monoxide, or CO, often results in various respiratory disorders such as bronchitis, asthma, chronic obstructive pulmonary disease, or COPD, in individuals. CO damages air passages in individuals, leading to respiratory disorders. However, if carbon monoxide is present in increased levels in the atmosphere, it can even cause the death of the person, by inhibiting oxygen intake by combining with hemoglobin. Ozone Layer Depletion - The ozone layer is a gaseous blanket that helps in supporting and sustaining life on Earth by protecting us from various hazardous radiations such as UV rays. Hence, the addition of some of the above mentioned pollutants often damages the atmosphere, thus causing various health risks in humans such as skin disorders like rashes, irritation and even cancer in severe cases.

measures to provide financial or other incentives at the plant level seem to work the best. However, there are opportunities for improving machines and other devices that many different factories and industries use.

Industrial Boilers and Motors

Industrial boilers burn coal, oil and other fossil fuels or very often gases that are by products of the production process, to generate hot water or steam used in a variety of ways. Chemical plants, for example, use the heat to change one substance into another. Paper mills will use it to pulp wood, which creates the raw material for paper. Because boilers are common to so many industrial processes, boosting their efficiency will sharply reduce emissions.

Similarly, electric motors are widely used in industrial applications, so increasing their efficiency will also reduce pollution. Motors that have been used most commonly in the past have efficiencies ranging from 60 to 90 percent, but versions are now available to reach 95 percent.

5. Control Techniques
Industrial activities are so different, one from the other, it is impossible to arrive at any single solutionor even any single set of solutionsto the variety of pollution challenges that they present. There are many approaches that can be adopted, but generic

Better

Boilers-

One

specific

way

of

improving the efficiency of boilers deserves special mention because is can be used so widely, but isnt in the U.S.

Cogeneration of heat and power-In the vast majority of cases, the largest single improvement in efficiency and reduction in air pollution that can be made at an industrial facility and is through the adoption generation, of or cogenerationalso known as combined heat power, distributed recycled energywhich is the simultaneous production of two or more forms of energy from a single fuel source. Most often, fuel is burned to generate electricity and the leftover heat, which otherwise would simply be released into the air, is used to make chemicals, process food or the like. Cogeneration facilities can extract 80 to 85 percent of the energy in fuel, significantly reducing the air pollution compared to facilities where electricity and heat are produced separately. The engine used to generate electricity canvary from large diesels to giant turbines, but the approach is the same: make the electricity and use the heat that would otherwise be wasted. The heat can also be used to provide air conditioning, using absorption chillers in which heat is used to run a compressor instead of electricity, in which case it is called trigeneration. Whatever the name, cogeneration is used widely in Europe, but is the exception not the rule in the United States. Most of the nations CHP stations are small facilities, operated on college campuses, military bases or offices, hospitals and other commercial facilities.

Increasing

boiler

efficiency-Increasing

boiler efficiency, thus reducing air pollution, can be accomplished in a variety of ways: 1.Proper maintenance, which can include a wide range of options, such as blowing soot from surfaces, tune ups, and reducing excess air. 2.Reducing the need for steam and, thus use of the boiler, by eliminating leaks, insulating pipes, recovering heat. These can boost system efficiency by 5 to 40 percent, and costs are usually recovered in one to two years. 3. Improving the operating system by, for example, installing devices that allow loads to be automatically controlled, which also saves money by reducing fuel consumption. 4. Switching from coal or oil to natural gas, this reduces operating costs and extends the plants lifetime by eliminating corrosion and other damage from pollution-rich fuels.

Electric Motor System

Motors produce air pollution indirectly using electricity, so the emission reductions that result from improving efficiency will depend on the type of fuel used by the generator. The amount of electricity consumed by these motors can be huge. In California, for example, one-third of the electricity is used to move water. Standard motors operate with an efficiency of 60 to 70 percent for small devices of a few kilowatts, to 92 percent for large motors of 100 or more kilowatts. High-

efficiency motors operate in the range of 83 to more than 95 percent.

industrial

sectors

that

are

the

largest

consumers of energy and sources of air pollution: cement kilns, steel making and oil refineries.

Some of the opportunities lie in improving the efficiency with which the output of a motor is used, not in the motor itself. One analysis of an industrial pumping system, for example, found that only 49 percent of the energy output of the electric motor was actually converted into work to move the liquid. Optimizing system design rather than simply choosing components can lead to improvements of 60 percent using existing technology. One study found that replacing traditional power-transmission V belts with modern flat belts could improve efficiency from 85 to 98 percent. Adjustable-speed electronic drives that better match mechanical load reduce electricity demand.1

Cement Kilns

Cement production consumes vast amounts of energy and raw materials, so what comes out of the smoke stack is not pretty. The pollutant emitted in largest quantity is carbon dioxide. Cement accounts for roughly 22 percent of the carbon dioxide emitted by the worlds industries. This is for two reasons: First, the raw material for cement is limestone, or calcium carbonateseashells deposited millions of years ago. One of the first steps in cement production is to decarbonize it, or drive off the carbon dioxide that it contains by burning. Older kilns do this in a huge rotating kiln in which the mass of materials is so wet that the process takes roughly 30 minutes and large amounts of energy.

An energy-efficient motor costs more to buy, with a price typically 15 to 30 percent above that of a standard motor. But over a typical 10-year operating life, a motor can easily consume electricity valued at over 57 times its initial purchase price. So, for example, with the purchase of a $1,600 less-efficient motor, a buyer may be committing much larger electricity bills. In the case of the $1,600 motor, paying a bit more up front say, $400will reduce electricity consumption by 3 percent, saving $2,760. Purchasing new or replacement energyefficient motors makes good economic sense. Now for a closer look at three specific

Second, producing the heat for baking burns huge quantities of fuel, usually whatever is the cheapest, which means its usually the dirtiest as well. The owners will burn whatever they get their hands on, everything from coal and used tires to hazardous wastes and city trash. As a result, for every ton of Portland cement produced, roughly one ton of carbon dioxide is emitted, as well as other

pollutants such as black carbon, dioxins, mercury and the like. Because so much of carbon dioxide comes from decarbonizing the essential ingredient of cement, it might seem likely that cutting emissions would be tough. Not so. Emissions can also be sharply reduced by substituting other materials for limestone to produce so-called blended cements. Substitute materials include blast furnace slag from steel mills and fly ash from coal-fired power plants. Blended cement sets a bit more slowly, but produces a stronger and longer-lasting concrete. In some nations (e.g., The Netherlands), all concrete is made from blended cement. Individual states determine how much pollution is emitted from cement kilns because they are the principal customers. The state highway department sets specifications for concrete used to build highways, and their counterparts who build schools, courthouses and the like do the same for them, and those who write the building codes determine what architects and contractors do. Requiring blended cement might not be as simple as snapping fingers, but it is certainly no herculean task. Other pollution can be cut by switching from a wet kiln to the more efficient, and hence cleaner, dry process. Then theres the question of fuel: kiln operators are willing to use any fuel that will sustain a flame, but that neednt be the case. The kilns could just as easily burn natural gas instead of coal, used tires or hazardous waste. For that matter, burning isnt required at all,

just heat. That can be provided by the suns energy or electricity.

Dust in Cement Plant and CHP

Several mechanical equipments are used in cement manufacturing plant to control / collect dust. These are: Dust collector - A dust collector (bag house) is a typically low strength enclosure that separates dust from a gas stream by passing the gas through a media filter. The dust is collected on either the inside or the outside of the filter. A pulse of air or mechanical vibration removes the layer of dust from the filter. This type of filter is typically efficient when particle sizes are in the 0.01 to 20 micron range. Cyclone - Dust laden gas enters the chamber from a tangential direction at the outer wall of the device, forming a vortex as it swirls within the chamber. The larger articulates, because of their greater inertia, move outward and are forced against the chamber wall. Slowed by friction with the wall surface, they then slide down the wall into a conical dust hopper at the bottom of the cyclone. The cleaned air swirls upward in a narrower spiral through an inner cylinder and emerges from an outlet at the top. Accumulated particulate dust is deposited into a hopper, dust bin or screw conveyor at the base of the collector

Electrostatic

Precipitator

- In

an

Coking: coke oven emissions are highly toxic is to assure that the oven doors are tightly closed. But an even better option is to make steel without coke, using a process now employed in South Africa and South Korea.

electrostatic precipitator, particles suspended in the air stream are given an electric charge as they enter the unit and are then removed by the influence of an electric field. A high DC voltage (as much as 100,000 volts) is applied to the discharge electrodes to charge the particles, which then are attracted to oppositely charged collection electrodes, on which they become trapped. An electrostatic precipitator can remove particulates as small as 1 m (0.00004 inch) with an efficiency exceeding 99 percent.

Casting: Continuous casting in which the steel is rolled immediately, thus avoiding the energy and pollution from reheating, is employed widely in other countries, especially Japan.

Cogeneration: Many of the gases produced during the production of steel can themselves be burned to generate electricity. Doing so increases pollution. efficiency and eliminates air

Steel Making

The iron and steel industry is the largest energy-consuming manufacturing industry in the world, accounting for 10 to 15 percent of the annual industrial energy consumption. Annual world steel production has increased from about 100 million tons in 1945 to about 770 million tons in 1990, and is expected to grow further, by about 1.7 percent a year, mainly because of an increase in steel consumption in developing countries. Air pollution, sometimes in prodigious amounts, is produced at several stages in making steel. Options for reducing pollution in each stage are: Process integration- So many streams of different fluids are constantly passing through a refinery, undergoing conversions Refining is most energy intensive industry and the source of immense amounts of air pollution Refinery pollution and energy consumption can both be reduced through a variety of measures. Oil Refineries

that are so complex and numerous that they inevitably reach a point where there is a pinch in the system that slows things down and cuts efficiency. To avoid these, analysts have developed a methodology to optimize the system called, not surprisingly pinch analysis. In recent years, it has been extended to virtually every aspect of refinery operation, in part because it has greater potential for increasing efficiency than any of the more traditional measures, such as cogeneration.

Textile industry is the source of air pollutants like Carbon dioxide, Aerosol fumes and gases, Toxic gases, Smoke and Dust. General control measure -Use of Electrostatic precipitator -Use of scrubber -Use of oxidizer -Height of chimneys: Chimneys height should not be less than 30 meters and release the pollutants not in the vicinity of living organism -Gravitational & inertial separator: These are working on gravitational and inertial concepts of collecting, filtering etc of the particulate matter. Eg. Settling chambers, dynamic separator and wet cyclones & multiple cyclones. - Filters: Woven or sintered metal beds of fibers, metal turning, fibrous mats & aggregate bed filter, paper filters and fabric filters are used for the filtration of particulate matter like dust, lint and fumes

Energy recovery-At various points in the refining process fluids are lost that could be captured and used either in the refining process itself or to generate electricity. Some of these are burned, or flared, as they are vented to the air. Capturing these and using them, either by re injecting them into the stream of refinery fluids or burning them for electricity generation, increases efficiency and reduces air pollution.

Heat recovery-In a modern refinery most processes operate at high temperatures and pressures alike. The crude oil that enters the process is loaded with contaminants that can and do foul pipes, furnaces and other components, reducing the efficiency with heat. By one estimate the economic value of these losses is roughly $2 billion a year.

Conclusion
There are many techniques which can be used to reduce the air pollution by industries. Every industry has a potential to reduce the emission. Developed countries are used these techniques and getting good results. May these techniques increase the overall cost and having a high payback period but it is essential to use these techniques in order to reduce the pollution, these technique will

Textile industries

give profit in the future In India these techniques must be use to make the environment pollution free. As in every other sector of the economy, ranging from herds of dairy cattle to fleets of cars, there is no lack of solutions in the industrial sector. They abound. But, just as in every other sector, those charged with making decisions are motivated only by making profit, as much as possible and as quickly as possible. They will not save us, so we must save ourselves.

5. "EPA: Air Pollutants". Epa.gov. 2006-0628. Retrieved 2010-08-29. 6SINTEF Trondheim, performance cement EMC". 6. www.e-textile.org Civil and Environmental "Mechanism for Engineering, Cement and Concrete, N-7465 Norway. of energetically modified

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1. Bonneville Power Administration, Energy-Efficient Selection Electric Jan., Motor 1993, Handbook,

2. Price, L. & Worrell, Global Energy Use, CO2 Emissions and the Potential for Reduction in the Cement Industry, Cement Energy Efficiency Workshop, Organized by IEA in cooperation with WBCSD, Paris, France, Sep.4-5, 2006,

3.

Air Pollution Caused by Industries |

eHow.com http://www.ehow.com/about_540 7184_air-pollution-causedindustries.html#ixzz1Jh4tke7oa 4. Zoidis, John D. (1999). "The Impact of Air Pollution on COPD". RT: for Decision Makers in Respiratory Care.