Standard Operating Procedure (SOP) for Demineralization Plants

The Standard Operating Procedure for Demineralization Plant is a document that outlines a set of step-by-step instructions to ensure a safe and efficient process for utilising a particular material or resource. It guides the personnel involved in the process and outlines the safety precautions, quality control measures, and environmental compliance requirements that must be followed. The SOP for utilisation serves as a reference document that ensures consistency in the utilisation process and helps to minimise errors and deviations. It also records the steps taken and the data collected during the utilisation process, which can be used for tracking purposes or in the case of audits.

SOP for Demineralization Plant Utilization

SOP for Demineralization Plant Utilization is as follows:

1. The used ion exchange resin produced by the Demineralization (DM) plant must be stored in covered drums on site to prevent rainwater from getting in.
2. The amount of used ion exchange resin must be at most 1% of the coal used in the boiler.
3. The transfer of used ion exchange resin from the storage area must be done using a mechanical conveyor system to mix it uniformly with coal at a ratio of 1:99 (used ion exchange resin: coal).
4. Proper mechanised mixing units must be used to achieve a uniform mixture of coal and used ion exchange resin.
5. A conveyor system must transfer the mixture of used ion exchange resin and coal to the boiler.
6. The boiler must maintain a temperature of at least 850°C.
7. Using used ion exchange resin is not permitted during unstable or breakdown conditions in the boiler.
8. The hot flue gases must be treated using an Electrostatic Precipitator (ESP) or Bag dust collectors connected to a stack with a prescribed height by the State Pollution Control Board (SPCB).
9. All personnel involved in the plant operation must wear proper personal protective equipment such as masks, safety gloves, goggles, and safety shoes suitable for power plant operation.
10. The unit must obtain authorisation from the relevant State Pollution Control Board under the Hazardous and Other Wastes (Management & Transboundary Movement) Rules, 2016^[1], for generating, storing, and utilising used ion exchange resin.
11. The unit must provide quarterly and annual information on the amount of used ion exchange resin generated, consumed, and utilised and the resources conserved (including the type and quantity) to the relevant SPCB.
12. A logbook must be maintained with information on the source, quantity, quality, and date-wise utilisation of used ion exchange resin, including analysis reports on emission monitoring and effluent discharge, where applicable.
13. The unit must keep records of hazardous waste utilised and disposed of following Form 3 and file annual returns in Form 4, as required by Rule 20 (1) and (2) of the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016, with the relevant SPCB.
14. Suppose any environmental damage occurs due to improper handling of hazardous waste, including accidental spillage during its generation, storage, processing, transportation, or disposal. In that case, the unit responsible must take immediate response measures and carry out an environmental site assessment. They must also remediate contaminated soil, groundwater, sediment, etc., according to the “Guidelines on Implementing Liabilities for Environmental Damages due to Handling & Disposal of Hazardous Wastes and Penalty” published by the Central Pollution Control Board (CPCB).
15. When utilising and handling hazardous waste, the unit must follow the requirements outlined in the Public Liability Insurance Act of 1991, if applicable.

Required Permits and Approvals

The permits and approvals required for the SOP of Demineralization Plant are as follows:

• Authorisation from the relevant State Pollution Control Board (SPCB) under the Hazardous and Other Wastes (Management & Transboundary Movement) Rules, 2016, for the generation, storage, and utilisation of used ion exchange resin.
• Quarterly and annual reporting to the relevant SPCB on the amount of used ion exchange resin generated, consumed, and utilised and the resources conserved.
• Record keeping of hazardous waste utilised and disposed of following Form 3 and filing of annual returns in Form 4, as required by Rule 20 (1) and (2) of the Hazardous and Other Wastes (Management and Transboundary Movement) Rules, 2016, with the relevant SPCB.

Documents Required

The documents required for SOP for Demineralization Plant are as follows:

• A detailed project report outlining the technical and financial aspects of the project.
• A business plan outlining the marketing, sales, and distribution strategies for the products generated by the DM Plant.
• Environmental clearance certificate from the relevant regulatory authority.
• Land documents, including ownership, lease, or rental agreement.
• Building and site plans approved by the local authorities.
• A safety plan and hazard analysis outlining the safety measures and risk mitigation strategies for the DM Plant.
• Permit or authorisation from the relevant regulatory authority to generate, store, and utilise hazardous waste, including used ion exchange resin.
• Registration with the relevant state pollution control board.
• Proof of compliance with relevant safety and environmental standards.
• Approval from the relevant authorities for installing the Electrostatic Precipitator (ESP) or Bag dust collectors and stack with prescribed height.
• Certification for the use of proper personal protective equipment (PPE) for the personnel involved in the plant operation.
• Documentation of the mechanical conveyor system and mixing units to be used to transfer the used ion exchange resin from the storage area and to achieve a uniform mixture of coal and used ion exchange resin.
• Records of quarterly and annual information on the amount of used ion exchange resin generated, consumed, and utilized, as well as the resources conserved, are to be submitted to the relevant state pollution control board.

Conclusion

SOP for Demineralization Plant Utilisation is a set of guidelines that ensure the safe and efficient utilisation of used ion exchange resin generated by the DM Plant. The SOP outlines the procedures for storing, transferring, and utilising the used ion exchange resin while also emphasising the importance of environmental compliance, worker safety, and proper record keeping. It is necessary to hire an expert to set up and operate a DM Plant and follow the SOP because of the complex technical and regulatory requirements. The expert can provide the necessary technical knowledge and experience to design, install, and operate the DM Plant safely and efficiently, ensuring compliance with regulatory requirements and environmental standards. The expert can also provide training and guidance to the personnel involved in the DM Plant’s operation, minimising the risks associated with handling hazardous waste and ensuring safe and efficient utilisation of the used ion exchange resin.

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