Waterless Chrome Tanning Technology (Wctt)

Technology Outline

• Use of water during chrome tanning is very important for attaining uniform diffusion, distribution and hydrolysis of chromium
• Waterless chrome tanning that eliminates the use of water, salt, sulfuric acid and basification salts during the chrome tanning process is well known
• There is a need for the development of a product for facilitating chrome tanning without water for widespread manufacturing and application

Salient Features/ Highlights/ Advantages

• A product composition for pre-treatment during waterless chrome tanning process
• Complete elimination of salt and sulphuric acid
• Complete elimination of inorganic acids
• Reduction of Total dissolved solids in wastewater
• No discharge of chrome containing wastewater
• Wet blue leathers on par with the conventionally tanned leathers

Commercialization Status/ Techno - Economics:

• Status of commercialization : This technology has been already commercialized
• Licensed to 124 clients in PAN India
• Major Raw Materials to be utlilized: Existing raw materials in the tanneries can be employed
• Validation level: Product developed and validated at pilot scale Commercial level validation on goat skins and cow hides carried out at a tannery in Rani pet
• Handholding support: Training, Demonstration, Technology Document, Trouble Shooting, Technology Implementation
• Techno-Economics :
• Min. Economic size - Small and Medium scale tanneries; Optimum investment- Existing tanneries without any new investment, the technology can be adopted; Appreciate payback period/ROI

Preservation-Cum-Unhairing (Pcu) Process

Technology Outline

• Use of salt in preservation generates large amount of contaminated salt and enormous total dissolved solids (TDS) in wastewater
• Toxic sodium sulphide is employed for conventional unhairing of hides/skins
• A single compound performing dual functions viz. preservation and unhairing at neutral pH and ambient conditions has been developed

Salient Features/ Highlights/ Advantages

• One step process for preservation and unhairing
• Complete elimination of salt from preservation process
• Reduction of TDS in wastewater
• Treated skins/ hides can be stored for 6 months at ambient conditions without dehydration
• Reduction in sulphide up to 70% is possible for complete removal of hair

Commercialization Status/ Techno - Economics:

• Status of commercialization : This technology is ready for commercialization
• Major Row Materials to be utlilized: The developed organic formulation con be manufactured using indigenous row materials. While for other leather processing requirements, existing row materials con be employed
• Validation level: Validated at Lob and Pilot scale
• Hondholding support: Training, Demonstration, Technology Document, Trouble Shooting, Technology Implementation
• Techno-Economics :
• Min. Economic size - Small and Medium scale tanneries; Optimum investment- without any new investment, the technology can be adopted; Appromiote payback period/ROI - 12 Months

Odor Abatement System for Tanneries

Technology Outline

An indigenous eco-friendly integrated technology for removal of odor from tannery using biofilter is designed. Odourous gas generated from the process is passed through vent and duct and is treated in the biofilter with a removal efficiency of about 90%. A prototype is fabricated based on the design and the technology has been implemented in a commercial tannery

Salient Technical Features including Competing Features

Temperature of operation = 30-41 C, Moisture = 100% saturated gas as feed; Care & feeding: A balanced macro nutrient; Acidity= near pH 7; Flowrate: upto max 300 CFM & maximum of 200 ppm odorous gases; Filter loading = 30 CFM/Ft2; Microbial strain -CLRI; Removal efficiency = 90 % VOC, 90% NH3 & 95% H2S. Provides- occupational safety; Abates air pollution/ emission. Uses online gas sensors & monitoring system; Automatic nutrient dosing system; Eco-friendly & indigenous technology; First time in the country; Possible expansion to Poultry, Tobacco, Dairy, Fish industries.

Business Case and Translation Status

The technology has been implemented in a commercial tannery with capacity 1000 hides /day at SA Abdul Azeez & Co, Erode as a demonstration unit and is running successfully

Business Case and Translation Status

• Tech Prototype is available at CSIR-CLRI for demonstration.
• A commercial level technology is Designed & Commissioned at SA Abdul Aziz Tannery, BP Agaram Road, Erode, TN.
• The product is ready for commercialization

Eo Based Zero Wastewater Discharge Process

Technology Outline

The waste streams from different unit processes are segregated. Gross solids are removed through screening. The sectional streams are then subjected to electro-oxidation for removing the organic pollutants using specially developed electrodes. Treated wastewater, which is free from organic pollutants, can be reused appropriately in the processes of leather manufacturing to achieve zero wastewater discharge. The residual chemicals present in the treated wastewater in many waste streams are reutilized in the process.

Salient Technical Features including Competing Features

• No wastewater Discharge; No sludge from treatment;
• No emission from hazardous gases; Less space requirement; Simple to operate;
• Reduction in Water input; Reduction in chemical offer;

Commercialization Status/ Techno - Economics:

• Status of commercialization : This technology has been already commercialized
• Licensed to three clients
• Major Raw Materials to be utlilized: Raw materials required for preparation of the equipment are available indigenously.
• Validation level: The technology has been standardized at pilot scale. It has been demonstrated at commercial scale ten units in India and four units in Ethiopia. The technology has been transferred to four leather manufacturing units. The technology is also suitable to textile and slaughterhouse wastewater.
• Handholding support: Training, Demonstration, Technology Document, Trouble Shooting, Technology Implementation
• Techno-Economics :
• For a unit manufacturing Leather from 2 tons of raw hide/ skin; Optimum investment- Rs. l O lakh/ton of raw hide; Approximate pay back period/ Return on Investment is about 2 years.

Dry Tanning (Dispersing Agent)

Technology Outline

Multiple benefits relating to in-process abatement of effluent problem, curtailing process steps, huge water conservation, time economy and cost saving

Salient Features/ Highlights/ Advantages

• New composition for waterless chrome tanning
• Time saving to the extent of about 30%
• Delimed skins treated without addition of any water or any other liquid medium
• Reduces number of unit operations
• No requirement of any additional infrastructure
• Reduces the requirement of conventional chrome tanning agent by about 50%
• Potential saving of 15 Million Liters of water per day when adopted by the entire country

Commercialization Status/ Techno - Economics:

• Status of commercialization : This technology has been already commercialized
• Licensed to one client
• Validation level: Validated at Pilot scale
Handholding support: Training, Demonstration, Technology Document, Trouble Shooting, Technology Implementation

Rapid Fibre Opening By Cocktail Of Enzymes

Technology Outline

Rapid opening up offibre matrix to facilitate improved tanning.

Salient Features/ Highlights/ Advantages

• Harmful lime replaced with benign enzymes
• Fibre opening achieved in 30 minutes compared to 72 hours conventional process
• 0.5 % (v/w) used in the place of 10% (w/w) lime
• Paradigm shift in leather making ensuring time saving & pollution abatement
• More suited for "Make in India for Global use11 theme

Commercialization Status/ Techno - Economics:

• Status of commercialization : This technology is ready for commercialization
• Validation level: Lab scale enzyme production and Commercial scale application trails completed
• Handholding support: Training, Demonstration, Technology Document, Trouble Shooting, Technology Implementation
• Techno-Economics :
• ROI - 100% in 2- 3 years