Water Pollution in Manufacturing Systems

Dr.S.P.Leo Kumar

Associate Professor
Department of Production Engineering
PSG College of Technology
Coimbatore
 Water Pollution
• Water pollution is the presence of some inorganic, biological,
radiological or physical foreign substance in the water that tends to
degrade its quality.

• Generally Water Never Pure in chemical sense.

• It contains impurities of various kinds dissolved as well as suspended.

• It includes dissolved gases (H2S, CO2, NH3, N2), dissolved minerals

(Ca, Mg, Na, salts), suspended matter (clay, silt sand) and microbes.

• Microbes are organisms that are too small to be seen include

bacteria,etc.
 Contd.,

• These are natural impurities derived from the atmosphere,

catchment areas and soil.

• If they are very low in amount, normally do not pollute water.

• While in small quantities may even have some positive effects in

improving the water quality.

• If their concentration increases substantially, it may have adverse

affect on the water quality and make water unfit for use.

• Such water is termed as polluted.

 Contd.,
• Water pollution is also caused by the presence of undesirable and
hazardous materials and pathogens beyond certain limits.

• Most of the pollution are due to anthropogenic activities like

discharge of sewage, effluents and wastes from domestic and
industrial establishments.

• Also particulate matter and metals and their compounds due to

mining and metallurgy, etc.
 Factors Affecting Water Quality

• Suspended and dissolved solids

• Biological substances

• pH

• Biological oxygen demand

• Chemical oxygen demand

• Industry wastage-Toxic substance, etc.

 Classification of Water Pollutants
Class of Pollutants Effects
Acidity/Alkalinity Water quality, aquatic life

BOD Water Quality, Oxygen levels

Metals Toxicity

Organic & Petrochemicals Water quality, Biological effects

Particulate matter Water quality, Aquatic biota

Patheogen Health hazard

Pesticides Toxicity, Aquatic biota

Sewage Water quality, Oxygen levels, Health

Trace Elements Aquatic biota, Health

 Water Quality Index
• Water Quality Index (WQI) is based on very important parameters that
can provide a simple indicator of water quality.

• The criteria to specify the water quality are combined to form WQI.

• Parameters include DO, fecal coliform, pH, BODs, temperature change,

total phosphorous, nitrate, turbidity and total dissolved solids.

• Note: (Fecal Coliform- Presence of Pathogens)

Contribution from Various Polluting Sources that Affect
Water Quality
 Summary

• Water gets polluted by various sources.

• It has harmful effect on the environment.

• Industrial activities becomes major source for water pollution.

 Metalworking Fluids

• Metalworking Fluids (MWF) is the name given to a range of oils

and other liquids that are used to cool and/or lubricate
workmaterial during manufacturing processes like machining,
milling, etc.

• Cutting fluids include oil, oil-water emulsion, gel, aerosol, air, etc.

• MWFs reduce the heat and friction between the cutting tool and
workpiece.

• It also helps prevent burning and smoking problem.

Contd.,
• To reduce friction between metal parts thereby increasing
their lifetime.

• Synonyms: machining fluid, cutting fluid, processing fluid,

lubricants, oil mist and coolant.
 Basic Requirements of MWFs

a. It should have good cooling and lubricating ability.

b. It should not cause corrosion.

c. It must not violate machine coatings.

d. It must be wholesome (low toxicity and biological irritation).

 Universal metalworking fluid does not exist.

 Hence different types are commonly used.

 Selection varies according to the type of machining operations

and working conditions.
 Properties and Composition

• Processing fluids are complex mixtures.

• According to thermo physical properties, the method of use

and oil content makes to distinguish four major categories:

• MWF Major Classifications:

Pure oil

Soluble oil

Semi-synthetic oil

Synthetic fluid
Typical Composition of the Four MWF
Contaminants and Issues Associated with MWF
 Four Major Concerns of MWFs

1. Particulates and bacteria are known to reduce the quality of

metalworking operations over time.

2. The contaminants eventually render the fluid ineffective for

metalworking operations, creating significant acquisition and
disposal costs.

3. Disposal of MWF places a significant burden on the

environment.

4. Biocides (chemicals) control the growth of MWFs can be a

significant health hazard.
 LIFE-Cycle Stage of MWFs

• Refining and production

• Transportation

• Preparation

• Use at the machine tool

• Recycling

• Treatment

• Oil recovery

• Disposal
 Contd.,
• In the life-cycle stage, the disposal stage has the largest impact on
the environment.

• MWF disposal results from a breakdown of the product by metal

residuals, microorganisms, leak oils, etc.

• MWF disposal can impact the environment due to

 Hazardous metal carry-off

 Hazardous chemical constituents

 Oxygen depletion

 Oil content and nutrient loading.

 1. Hazardous Metal Carry-Off

• MWF can become hazardous at the machine tool by carrying off

particulate containing inclusions of heavy metals such as lead,
chromium or cadmium.

• There is a trade-off between the benefit found in machining

workpiece and the environmental cost of disposing the waste
fluid once it becomes hazardous by chip contamination.

• Specifications of hazardous metals should be reexamined from

the context of disposal cost and environmental impact.
 2.Hazardous Chemical Constituents

• MWF may contain known hazardous ingredients that are

reported on accompanying Material Safety Data Sheet (MSDS).

• Generally, hazardous ingredients found on an MSDS may have

one or more of the following characteristics:

• Combustibility, flammability, oxidativity, instability, reactivity,

carcinogenicity, toxicity or corrosivity.

• MWFs with hazardous ingredients can be a hazard in the

environment if disposed of improperly.
 3.Biochemical Oxygen Demand
• As MWF enters a receiving water, the bacterial population will
begin breaking into metabolites, using up oxygen in the process.

• As the dissolved oxygen in the water is consumed, the fish and

plants that will have less oxygen for respiration.

• If Oxygen levels fall significantly, the organisms can no longer

survive and the ecology of the receiving water will be altered.

• Maximum permissible levels of BOD (measured over 5 days) in

sewered MWF are usually about 200 mg/l.

• Untreated MWFs may have BOD concentrations more than 20

times this limit.
 4. Oil and Grease

• Fat, oil, and grease (FOG) contaminants in MWFs come from

petroleum, mineral, animal or vegetable sources.

• FOG can lead to taste, odor and other aesthetic problems in water
at relatively low concentrations.

• At elevated concentrations, FOG is toxic to aquatic life.

• FOG can also have detrimental impacts on treatment processes for

BOD.
 Health Impact of MWFs

• MWFs brings certain drawbacks due to the production of aerosol,

which contaminate the working atmosphere and rise to serious
of health damage.

• Typical health problems to metalworking machine operators due

to spoilage of working environment.

• Their effect is greatly influenced by the amount of MWFs, the

pressure and the mode of fluid flow to the destination.
 Impact of MWFs
• Impact of MWFs is characterized by the following criteria:

a) Toxicity

b) Inhalation irritation

c) Carcinogenicity

d) Ocular irritation

e) Dermatological irritation

f) Flammability
 Health Impact Status

• MWFs are used in large quantities worldwide.

• In the year 2010, the consumption in Europe amount to 6,10,000

tonnes.

• It pose a risk to the staff and to the environment during their

subsequent disposal or processing as waste.

• Hence attention is paid to the cutting fluids and several review

articles dealt with this issue.

• Currently, entering the key words “metalworking fluids” brings up

more than 500,000 references that can be found.
 Components of Health Effects By MWFs

• Exposure of operating staff to MWFs, occurs by inhalation of

aerosols or by skin contact.

• Touching contaminated surfaces using parts and equipment, fluids

splashing, etc.

• Inhalation of MWF aerosols can cause irritation of the throat

(pain, burning throat), nose (congestion, and nosebleeds) and
lungs (cough, shortness of breath, increased mucus (cold)
production).
Contd.,

• MWF aerosol exposure is often associated with chronic

inflammation of the bronchi (bronchitis).

• Hypersensitive pneumonitis- Lungs inflammation (swelling)

problem due to inhalation of foreign substance, etc.
 Chronic Bronchitis
• It occurs when the lining of the bronchial tubes repeatedly becomes
irritated and inflamed.

• The continuous irritation and swelling can damage the airways and cause
a buildup of sticky mucus, making it difficult for air to move through the
lungs.
Hypersensitivity Pneumonitis
 Environmental Aspects of MWF Use

• Worldwide annual consumption of MWFs is estimated at more

than 200 Cr. Litres.

• Waste of used MWFs may be up to 10 times higher.

• It is due to the fact that most MWFs must be diluted before use.

• Used MWFs cause a high level of environmental contamination

due to the presence of a complex mixture of several chemicals.

• It increases the demand on their final treatment or disposal.

 Summary

• There are significant health and environmental effects

apartment from the usefulness.

• Important to minimize the usage and looking for alternative.