LIFE 04 TCY/ET/45 ( ECOTAN ) Demonstration of clean technologies in tanning processes. Ecotan Summary

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1 Ecotan Summary

2 1. SUMMARY At present, the tanning sector plays an important role in the economies of the Mediterranean countries, as it supplies the leather related sectors (manufacturing of footwear, belts, bags, etc.) with the required raw materials needed for production. Furthermore, it makes use of the excess waste from slaughter houses (hides from animals that have been sacrificed for human consumption). In Egypt, the tanning industry is a sector with significant tradition, holding an important position in the domestic economy. The sector is made up of 10,000 employees working in nearly 360 companies, of which 320 can be found in Cairo, mainly in the district of Misr Al Kadima. Tanneries in Misr Al Kadima district (See Figure 1) are in close proximity to the Nile river and produce a significant amount of pollution in the city of Cairo. Causes are diverse, such as the faulty infrastructure in the area, the incorrect management of waste and wastewater, the inefficient use of raw materials, the use of obsolete technology and machinery and a lack of professionals duly trained and concerned about environmental issues. Figure 1. Tanneries area in Misr Al Kadima (Cairo) To improve the competitiveness, value-added and the profitability of the tanning sector in Egypt, both the environmental conditions of the Egyptian tanneries, and the production processes of Egyptian tanning methods need to be adjusted to be environmentally friendly with better health and safety conditions. The direct impact of this approach is the adaptation of the Egyptian tanneries to the environmental requirements and regulations that must be fulfilled in certain countries, which import leather from Egypt. With the object of increasing awareness about the needs and advantages of using friendly environmental methods in tanning processes in the Egyptian tanneries, the Center for Technology and Innovation in Spain (INESCOP) together with the Egyptian Ministry of Trade and Industry (MTI) carried out the European LIFE project titled Demonstration of Clean Technologies in the Tanning Process (ECOTAN), with partial funding support from the European Commission. The activities of the project covered a diagnosis of the environmental conditions of the Egyptian tanning industry in order to select the appropriate equipment and training according 2

3 to the features of that industry. The Technological part (hardware) was composed of the implementation of an environmental laboratory, a tanning pilot plant and a wastewater treatment pilot plant. On the other hand, the non technological activities (software part) focussed on the training of technical staff in the different kind of analysis and in the use of the pilot plants. Furthermore, within the project purposes it was highlighted the diffusion tasks addressed mainly to the Egyptian tanneries, but also to the surrounding countries. 2. RESULTS ACHIEVED The purpose of ECOTAN project was to promote the use of clean technologies within the Egyptian tanning industry, so that it contributes to strengthen and support environmental policies and practices, as well as serving other countries with similar environmental problems, by means of being a positive example. This project has provided the establishment of an environmental infrastructure in Egypt consisting of an environmental laboratory for analysis and testing, a pilot tanning drum and a Physical-Chemical Wastewater Treatment Pilot Plant. Such infrastructure is complemented through the Egyptian technicians working on Environmental laboratory analysis and the operation of both pilot plants. The main results achieved in the ECOTAN project have been: Knowledge of the current environmental situation of the Egyptian tanneries An analysis of the environmental situation in Egypt and the degree of understanding and adaptation of tanneries to the Egyptian legislations in force was carried out. The results have been collected in a book (See Figure 2) and shown the need to apply clean technologies in this sector, as well as the need to diffuse and educate the workers in this area. Figure 2. Book Study on the environmental situation of the Egyptian tanneries 3

4 Establishment of an environmental laboratory for analysis in Egyptian tanneries INESCOP has supported MTI in establishing an environmental laboratory, with all equipments that are capable of analysing diverse environmental parameters related to atmospheric emissions, sound contamination and wastewater analysis. MTI technicians trained by INESCOP's experts in Spain as well as in Egypt (See Figure 3) have carried out diverse environmental analysis in Egyptian tanneries obtaining the results that have complemented with the information previously gathered through the environmental questionnaire. Figure 3. Egyptian technicians training Currently, the environmental laboratory (See Figure 4) has a group of MTI technicians perfectly capable of offering environmental analyses services after the finalisation of the project. Figure 4. ECOTAN laboratory 4

5 Pilot drum to demonstrate clean tanning processes The leather tanning process is normally carried out in the known tanning drums where chemical reactions take place and all degradable materials are transformed. This process is the main cause for the production of wastewater in the tanneries, since huge amounts of water and chemical products are used and finally spilled into the sewage waters. LIFE-ECOTAN project has provided MTI with a pilot tanning drum (See Figure 5) that allows carrying out optimized tests on the traditional processes related to tanning in order to minimise the amount of pollution produced, to research, demonstrate and train Egyptian tanneries' workers on the new tanning technologies that are more environmentally friendly. Figure 5. Ecotan pilot tanning drum Physical-Chemical Wastewater Treatment pilot plant Currently, it is expected that the tanneries produce wastewater derived from the production processes. For this reason, it is advisable the use of preventative measures, in order to minimize pollution. In this context, the LIFE-ECOTAN project has provided MTI with a mobile physical-chemical wastewater treatment pilot plant, designed specifically for the treatment of wastewater in Egyptian tanneries, so as to demonstrate the efficiency of this technology among the tanneries and update workers with the use of this type of treatment. The demonstration of the physical-chemical wastewater treatment is the first step so that the Egyptian tanneries will be able to choose to incorporate these systems in their businesses, and permit that in the future they will supplement other techniques of wastewater treatment, for example, secondary or tertiary treatments. 5

6 3. TRANSFERABILITY AND CONCLUSIONS LIFE-ECOTAN project has been diffused among the Egyptian tanning sector by diverse means of promotional actions like the publication of various press notes, publication of technical articles in specialized magazines, conferences, seminars, open sessions, and through the distribution of a book that deals with the environmental situation of Egyptian tanneries, in addition to the creation of specific Web pages relating to the project, and the release of a video of the project. In this way, the Egyptian tanneries have been able to obtain diverse information about clean tanning technologies, the treatment of wastewater, and the relocation of the Egyptian tanneries to El Robeiki Leather Tanning City with the purpose of applying environmentally friendly production techniques. After the completion of the LIFE-ECOTAN project, and thanks to the infrastructure created and the numerous technical personnel from MTI, Egypt can continue to offer analytical and environmental advice services to the Egyptian tanneries, to evolve in the R&D environment and develop new projects that allow the evolutionary continuation to improve the environmental impacts of Egyptian tanneries. One of those projects is El Robeiki Leather Tanning City in Badr City, which aims to be the first city for leather and tanned products within the Middle East. This project includes the relocation of tanneries, a business and technology centre, the establishment of a joint plant for the treatment of wastewater and the creation of services such as warehouses, workshops, banks, a hospital, a firestation, restaurants, a department store, etc. (See Figure 6) Figure 6. Launching the "Stepping Stone of the Robeiki Leather City" The Minister of Trade and industry is middled by the Minister of Enviroment and the head of the Egyptian Chamber of Leather Taning 6

7 The MTI has completely established a 6000 m² Leather Tanning Technology Center (LTTC) in El Robeki Area where the environmental unit of the ECOTAN project after the end of the project will be located (See Figure 7). Figure 7. The Egyptian Leather Tanning Technology Center Ecotan at El Robeki Leather City where Ecotan project will be located This advanced infrastructure will make possible the improvement of technical and environmental management of tanneries and the modernization of the sector by means of technological transference. Moreover, it will promote innovation and make the Egyptian industry become more competitive in the international markets. For more information see: Ecotan project website Leather Tanning Technoly Center (Egypt) website: INESCOP website: 7