Content: In most of the tanneries, water and chemicals are added manually in the tanning drum and pH of the float / leather is adjusted. Addition of correct amount of process recipe are necessary for better processing of the hides and minimizing wastage of utility, thereby controlling pollution load in effluent. However, fugitive-emission from process and drains accumulate ammonia, hydrogen-sulphide and volatile organic compounds which contribute bad odor in tannery as well as in wastewater-treatment premises causing problems to occupational health & safety of workers. Both local and supervisory control stations are employed to monitor and accurately manage the unit operations. The objective of this work is to produce consistent quality of leathers and to provide a healthy environment through automatic dosing and odor abatement system. Therefore the entire process control operation is integrated to operate through PLCs with following five modules: i) Water addition module ii) Chemical preparation and dosing system iii) pH monitoring and float recycle system iv) Drum rotation module v) Odor reduction module. In the integrated system, critical and bulk chemicals are stored in bulk storage tanks and are drawn into the load cell (LC) as per process sequence or recipe for feeding into the drums through auxiliary tanks. The float-recycle system helps to remix & heat the float where a pH electrode is housed to monitor pH online. The pH monitoring system adjusts addition of critical chemicals that indicates automatic end point. The contaminated air inside the tannery is sucked and passed through blower and then through bio-filter. The filtration process is based on the principle that VOCs (in the order of 50-200 ppm) and odors can be biologically treated by naturally occurring microbes. The control parameters monitored are: moisture in the bed and uniformity of media (contaminated air or process liquor). The humidity and temperature of inlet media is controlled and contact time with microbes is 10-30 secs. Moisture is controlled to maintain microbial population. A lead in laboratory scale has been developed to measure process variables (PV) considering their spatial distribution in two dimensions. Spatial distribution of process variables inside hides (across cross section) may provide accurate measurement of through reconstruction of image and data driven models using artificial intelligence tools. Computational intelligence is developed for updation of model parameters as that can be used for direct estimation of PV Take-Away: 1. Cleaner production is provided through automation of dosing & pH monitoring using PLC in indegeneous way 2. Pollution Load in exit stream and odor-gas emmision are minimized 3. Artificial Intelligence and data analytics techniques are used in Leather making

>Magister Scientiae - MSc / To address the urgent need for safe potable water in South Africa’s rural areas, sustainable systems for water disinfection at the village-scale of operation are required.In this thesis, the development of a small-scale water chlorination system that runs on salt and solar panels is described. The system combines a membrane-based hypochlorite generator, or “membrane electrolyser”, with an automated hypochlorite dosing system.The system was designed to (i) coordinate hypochlorite production and dosing automatically in a flow-through system, and (ii) fit inline with low pressure pipelines from overhead storage tanks or raised water sources. Low cost materials were used for construction, and water-powered mechanisms were devised to control both brine supply to the electrolyser and regulation of water flow. The capacity of the system was based on the maximum daily output of the electrolyser at ~20 g of sodium hypochlorite. This was sufficient chlorinate up to 10 kL of water per day using less than 80 g of salt and less than 0.1 kW.h of electricity. The cost of the system was estimated at ~R10 000 and therefore potentially affordable for communities up to 100 people, e.g. small farms and villages.Testing of the system was carried out at a farm site in Worcester (Western Cape) using remote monitoring of current levels in the electrolyser. Operation of the system over a two month test period, dosing at ~4 mg/L, produced consistent chlorination measured as(FAC). Community participation in maintenance of the brine supply was managed and chlorinated water was made available to the community after a brief social survey was conducted. Community awareness of chlorination was minimal. No significant history of diarrhoea was reported. However, the community regularly boiled their tap water in response to turbidity increase in summer.The system was affected by turbidity increase in the local water, which caused a drop in electrolyser current and chlorine production due to particle blockage of the membrane in the electrolyser. However, turbidity at acceptable levels for chlorination was found to have no detrimental effect on the system’s performance. The system showed promise for rural implementation providing low turbidity was maintained. Therefore,groundwater sites, and surface waters with appropriate clarification systems are recommended for the system’s installation. Further testing of the system will be required to establish its long term viability in the hands of a rural community.