NAMES:

BERNARD GANZWA (H0810105R) HARVEY GUMBO (H0910030U) LAVINIA CHIKOMO (H0910017H)

PROGRAMME: COURSE: AND

CPSE (PART 4) ENVIRONMENTAL POLLUTION PROTECTION

LECTURER: PRACTICAL:

DOCTOR PHIRI 2

Introduction This practical report was prepared after a plant tour visit which the authors attended on the 01/11/12 at the Cernol Chemical Zimbabwe. The purpose of the site visit was mainly to carry out survey on the environmental aspects on the plant. Different environmental aspects were covered and there are highlighted in this report. This report basically covers the company profile, Companys operations, waste management system and details, the environmental impacts assessment of the plant. Company profile Cernol was established in March 1960 as a subsidiary of Chemical Services a company based in South Africa. The company known as Cernol Chemicals (Zimbabwe) (Private) Limited in December 1980 and prior to that its name had been changed from Chemical Services to Chemserve in October 1973. The company was localized in 1982 after a management buyout from Chemical Services South Africa. SMM acquired the entire issued capital of Cernol in July 2002 from the management. The company has a manufacturing plant in Harare and distribution centers in Bulawayo and Mutare. The company is engaged in the manufacture, importation and distribution of various chemical products used in the water and metal treatment industries, dairy, hospital and

healthcare, commercial and industrial laundry, food and beverage, hospitality, mining and heavy industrial manufacturing industries. Operations The company is engaged in four different operations as outlined below: Production Engineering Quality assurance and control Product research and development

Production Cernol is involved in the manufacturing and distribution of various chemicals direct from source for various sectors of the economy including food and beverage, mining, personal care and candle manufacturing industries. Under food and beverages the company produces both alkaline and acidic liquid and powdered detergents for CIP and manual vessel cleaning as well as bottle washing additives and liquid and gel type conveyor lubricants. It also manufactures a very wide range of sanitizers and disinfectants for equipment, hands and fogging. In mining and heavy industrial manufacturing, Cernol manufactures chemicals utilized in the heavy industry for cleaning, protecting stainless steel surfaces and removing of rust and scale form ferrous surfaces. These are Magnus waterless Hand cleaner, Magnus 92 PR, CTC P, Chloracid 93, Alichena and Solvene 222. It also manufactures a Magnus toilet deodorizer and all purposes oil for use in lathes that is Chmespec solub oil. Cernol manufactures chemicals for cleaning and disinfecting kitchen utensils, toilets, cold rooms, pantries, floors and walls this is under hospital & housekeeping. Also the company manufactures chemicals used in water treatment, diary, transport and many other sectors. At the plant there is the production side were all the manufacturing of products are carried and this side is divided into three major areas the raw material receiving bay, the processing bay and the warehouse. The production manager oversees the department. Engineering

The department is sometimes called the workshop, the department involves the maintenance of the machinery used at the plant and it is also its mandate to attended to all break down. Quality assurance and control The primary responsibilities of the Quality Assurance Department are to assure that the delivered product meets workmanship standards imposed for standard or hi-reliability products and/or special customer requirements. This is accomplished through a program of process controls and gate inspections designed so that all devices are properly tested and sampled prior to shipment. Real time feedback, concerning control/inspection data, keeps all relevant personnel fully informed on the quality level of product going through final test operations. Product research and development The work of research and development involves developing new products and improving current ones through various forms of research. New products and improvements to current products are needed to meet the requirements of customers, taking into consideration changes in consumer demand, seasonal sales changes, and the availability of new materials and technology. The marketing department collects information about changes in consumer demand and the requirements of customers. The research and development department must also be aware of new materials, technology and products that affect the customers requirements and possibly the future of their customers needs. Waste generation All the processes involved in the production of chemical products bring about the release of different types of waste into the environment. There are three main types of waste which are produced at cernol chemical Zimbabwe; these are solid waste, liquid waste and gaseous waste. Solid Waste Solid waste is generated mainly from the packages which are used at the plant. The main packaging material which is used at the plant is plastic containers, sacs and plastics bag. Also there are other form of solid waste which is produced this includes scrap metal from the equipment fabrication and papers from the administration department. Liquid waste

This waste is generate from the processing of chemicals since all the process are mainly wet processes and all the waste stream from the process are discharged into the environment. Gaseous waste At cernol chemicals there is little gaseous waste production. The only gaseous waste produced is produced from the boilers. Environmental assessment The adverse environmental relating to Cernol chemical company with reference to the Zimbabwean regulations identified are as follows: Air Pollution Water pollution Noise pollution

The mitigating measures put in place for the above environmental impacts at the plant are as follows: Air Pollution Mitigation Measures In the effort to prevent air pollution the cernol chemical company has mainly concentrated in the production of its products through the wet process which do not brings about major quantities of gases being released into the atmosphere. The equipment used at the plant has fume hoods which prevent dust raw materials from escaping to the environment. The boilers used only release steam to the environment which is not harmful. Water Contamination Mitigation Measure All the liquid waste produced at the plant is discharged to the municipal sewer lines, but before being discharged there is a mini effluent treatment tank which treats the effluent to required levels before being discharged to the sewer line. The company also engages the research department in coming up with substitution of raw materials which reduce toxic waste. Mitigation Measure against Noise Mitigation measure to reduce noise around the vicinity of the site is geared towards ensuring that surrounding and people working in offices around the site are not

adversely affected by noise due to the activities at the construction sites. The following measures are deemed to mitigate the impact of noise to the surrounding environment.

Fitting proper mufflers to vehicles and production equipment to minimize noise pollution. Sensitization and discussion with residential and office workers around the sites about the working hours and the impact of noise. The use of hearing protection gears by workers when exposed to noise levels above 85 dB(A)

Legislative of Zimbabwe which govern Cernol Company Cernol chemical is a company which is registered in Zimbabwe and it abides to the rules and regulations of environmental protection. There are two pieces of legislation which governs cernol chemical in their operations namely: The Urban Councils act (chapter 29:15) The Environmental Management Act (chapter 20:27)

The statutory instrument 7 subsection 56 states that it is an offence for any individual or organization to dispose toxic substance to the environment hence the cernol chemical operates in accordance to this regulation. Also there is a section in the urban council act which regulates the disposal of waste to sewer lines such that the council conducts compliance audits once a month on the company to assess the quality of waste which being produced. Recommendations The company should further look into regulation of other waste parameter than pH only. There should try also regulate the BOD, COD, nutrients in the waste they produce The Council and EMA should enforce the rules and regulation of protection of the environment serious at the company Proper ventilation of the production area is required

Conclusion From an environmental point of view the cernol chemical company is striving to protect the environment in all its operations although they need to improve on one or two

aspects for the nation at large to achieve the millennium development goals especially goal number 7 which ensures environmental sustainability. The company is currently facing lower production capacity and there havent fully recovered from the economy melt down which was experienced a few years ago.