Approach towards zero discharge tanning: role of concentration on the development of eco-friendly liming–reliming processes

Abstract

Beam house processes 1 Beam house processes generally mean liming–reliming processes, which employ beam. 1 in leather processing are known for their uncleanness. More than 60% of the total pollution is emerging from the liming–reliming processes. The use of lime and sodium sulphide is purely empirical without quantification. Lime has a potential to drive swelling in a gradual manner due to its low solubility; however, the use of lime is currently creating a lot of environmental concern. Huge amounts of lime sludge and total solids formation are the main drawbacks of lime. Sulphide plays a detrimental role in effluent treatment plants. This is mainly due to the application of lime, sulphide, water and other chemicals without any rationalization. An approach has been made to apply the beam-house chemicals with optimal requirement. This is based on the fact that swelling requires only 20 to 40% water (based on raw skin weight before soaking) for conventional opening up. This would, in principle, make possible the use of only one tenth of the chemicals conventionally used in liming–reliming processes maintaining the same concentration gradient. The process employs 40% water, 0.35% sodium sulphide and 1% lime for liming and 40% water and 1% lime for reliming, with conventional process time in a drum. Commercial post-reliming processes and operations were adopted. A control experiment was run parallel using conventional liming–reliming processes. It has been found that the dehairing is complete and the extent of opening up of fibre bundles is comparable to that of the control. This has been substantiated through scanning electron microscopic, stratigraphic chrome distribution analysis and softness measurements. Performance of the leathers is shown to be on par with conventionally opened up leathers through physical and hand evaluation. Especially, softness of the leathers is numerically proven to be comparable with that of control. The process also enjoys reduction in chemical oxygen demand and total solids load on environment by 85 and 12%, respectively compared to the conventional process. The total dry sludge from the liming–reliming processes is brought down from 152 to 6 kg for processing 1 ton of raw skins, which has been demonstrated for the first time.