industrialsafety.ppt

7/29/2019 INDUSTRIALSAFETY.ppt

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INDUSTRIAL HAZARDS AND SAFETY

Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D

Department of PharmaceuticsKLE University College of Pharmacy

BELGAUM-590010, Karnataka, India

Cell No: 00919742431000

E-mail : [email protected]

24 August 2012 1KLE College of Pharmacy, Nipani


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CONTENTS Introduction

Types of hazards

Recommendations and Suggestions

Industrial effluent testing and treatment

Discussion on industrial accident case

studies

Questions

References



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Industrial hazards:

It can be defined as any condition produced byindustries that may cause injury or death to

personal or loss of product or property.

INTRODUCTION



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HAZARDS

Physical

Chemical

Biological

Mechanical

Electrical

Pollution



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PhysicalHazards

Heat& Cold



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Heat and Cold

Burns

Heat stroke

Heat cramps

Foot sore

Immersion foot

Frost bite

Preventive Measures

A reasonable temp. of 20-250C must be maintained



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24 August 2012 KLE College of Pharmacy, Nipani 7

PhysicalHazards

Heat

andCold

Noise


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Auditory

Non auditory effects

Preventive measures

a. At source:

Source of noise can be enclosed with an insulation

material or concrete wall.

Proper maintenance of machinery

b. By distance

c. Personal protection against noise.


Noise have two type of effects


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Equipment noise sources ,level & potential control solutions

Equipment Sound level indBA at 3 feet

Possible noise controltreatments

Air coolers 87-94 Aerodynamic fun blades,

revolutions/min pitch,

pressure dropCompressors 90-120 Install mufflers on intake,&

exhaust, enclosure the

machine with casing,

vibration isolation & lagging

of piping system

Electric motors 90-110 Acoustically lined fun

covers, enclosure 7 motor

mutes24 August 2012 9KLE College of Pharmacy, Nipani


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Heater &furnaces 95-110 Acoustic plenums, intake mufflers,lined & damped ducts

Valves


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Physical

hazards

Heat &Cold

NoiseRadiation


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Radiation

Radiation are divided into two groups

Natural Man made

Cosmic rays Medical /dental x-rays isotopes

Environmental (radioactive

elements e.g. uranium)

Occupational exposure

Internal (potassium,) Nuclear radioactive fallout

Approx 0.1 rad/yr Miscellaneous

Use of radio active substances

by different industries



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Somatic Genetic

i. Preventive measures

ii. Radiation source should be housed in a buildingthat shields any surrounding area.

iii. Radiation badges should be worn.

iv. Periodical medical examination.

v. Proper use of lead shields & lead rubber aprons.


Effect of hazards


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PhysicalHazards

Heat &

Cold

Noise

Radiation

Fire &Explosion


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Causes

Smoking in the factory

Defective heating equipment, electrical equipment &

wiring.

Explosive gas leakage.

Inadequate protection of electric motors

Sparking of electric wires & equipment

Protection & preventionTypes of fire


Fire & explosion hazards


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Preventive measures Prohibition of smoking in manufacturing areas.

Oxygen present in the inflammable atmosphere maybe by dilution with gases such as nitrogen, co

2

,steamor combination of these.

Hazardous operation should be isolated

Eliminating the ignition sources

Using fire resistant material in construction

Suitable emergency exits

Adequate venting




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Automatic sprinklers Equipment should design to meet the specifications &

code of recognized authorities, such as ISA, API

&ASME

The design & construction of pressure vessels &

storage tanks should follow API & ASME codes.

Inspection




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Chemical Hazards

Local

Dermatitis

Eczema

Ulcers

Cancer

Inhalation

Gas Poisoning

Ingestion

Living tissue may be destroyed by chemical reactions such as

Dehydration

Digestion

Oxidation



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Source, effect & precautions of chemical hazards

Type/ source of

chemical contaminant

Effect/ organ

affected

Precautions to be taken

Acridines,

phenothiazines

Dermatitis Cleanliness, removal of people

from the areas as soon as first

sign of skin reaction is observed.

Solvents like

chloroform, benzene

Handle with care

Vegetable drugs like

capsicum &podophyllum

Dust evolves,

affects eye

Goggles are to be worn

Long term use of filter

without cleaning

Dust explosion Regular cleaning



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Source, effect & precautions of chemical hazards

Improper use ofcleaning agents

contamination Follow establishedcleaning procedures

Working with radio

pharmaceuticals

Hazards due to

emitted radiation

Wearing lead coat,

maintaining pressure

of working areaslightly less than

atmospheric pressure

Underground tanks Difficulty inmonitoring

interior & exterior

Minimal use ofunderground tanks



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Tolerance levels for toxic chemicals set by federal

regulations have to be followed.

Strict observation of operations of all safety

regulations


PREVENTIVE MEASURES


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Biological hazards

Disease due to biological hazards

Brucellosis (dairy industry)Byssinosis (textile industry)Bagassosis (sugar-cane)Loco motor disorder

Preventive measuresPeriodic health check upPersonal protectionThe manufacturer should also provide

First aid facilitiesInitial examinationFacility for vaccinationRoutine sanitation programme



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Mechanical hazards

Accidents usually take place by the combination of unsafe

condition & carelessness.

Most of industrial accidents are due to

Faulty inspection

Inability of employee

Poor discipline

Lack of concentration

Unsafe practice

Mental & physical unfitness for job

Faulty equipment or improper working condition

Improper training regarding the safety aspects



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In order to prevent mechanical accidents factories act

lay down certain requirements

For cranes

End buffers

Indicating lamps

Signals

Proof loading

upto20 tons 25% in excess20 to 50 tons 5 tons in excess

above 50 tons 10% in excess


Mechanical hazards


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Preventive

measures

Building

planning


Mechanical hazards


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Building planning

Floors must be of unskid/non-slippery type.

Enough space for employees to work.

Passages between working places.

Proper arrangements of temperature control; like fans,A.C., heaters.



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Preventive

measures

Building

planning

Safe

material

handling


Building planning


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Careless handling of heavy materials and componentsshould be avoided.

Full use of mechanical material handling equipment.

All material handling equipments should be repaired

and maintained properly.

Containers employed to transport liquids should not

be defective or leaking.

Safe material handling



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Protection of head by using hard hats/helmets.

Protection of ears by using earmufffs and plugs.

Protection of face by using face marks, face

shields.

Personal protective devices



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Electrical hazards

Shocks

Sparking Fire

Wiring faults

Preventive measures

Proper maintenance of wiring & equipment

High voltage equipment should be properly enclosed

Good house keeping

Water should not be used for dousing electric fire

Worker should avoid working in electric circuits orequipment in wet clothing or shoes.



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Pollution hazards Types

a. Air pollutionb. Water pollution

c. Thermal pollution

d. Sound pollution

Air pollution

Sources

Automobiles

Industries

Domestic


P ti


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i. Those suitable for removing particulate matter

a. Ventilation Exhaust ventilation

Plenum ventilation

b. Air purifying equipment

ii. Those associated with removing gaseous pollutants

Water pollution

1. Types of water pollutants

Physical Chemical

Physiological

Biological24 August 2012 32KLE College of Pharmacy, Nipani

Preventive measures

Pre enti e meas res


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2. Problems of water pollution

3. Preventive measurea. Control of water pollution

i. Physical treatment

Storage

Filtration

ii. Chemical treatment

iii. Biological treatment

b. Treatment of industrial wastePrimary treatment

Secondary treatment

Tertiary treatment24 August 2012 33KLE College of Pharmacy, Nipani

Preventive measures

Preventive measures


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c. Thermal pollution Effects

Damage to aquatic environment

Reduction in assimilative capacity of organic waste

Various off stream cooling systems

i. Wet cooling towers

ii. Dry cooling towers

iii. Cooling ponds

iv. Spray ponds24 August 2012 34KLE College of Pharmacy, Nipani

Preventive measures


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Recommendations & suggestions

Proper treatment & disposal methods for effluents

should be adopted

An awareness program

Measures for increase efficiency of the water use



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Classification of signs according to use

(1) Danger signs.

The DANGER header is used when there is a hazardous

situation which has a high probability of death or severe

injury. It should not be considered for property damageunless personal injury risk is present.


) i i (i)


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2) Caution signs. (i)

The CAUTION header is used to indicate a hazardous

situation which may result in minor or moderate

injury. However, Caution should not be used whenthere is a possibility of death or serious injury.



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(3) Safety instruction signs

General Safety Signs (SAFETY FIRST, BE

CAREFUL, THINK) should indicate general

instructions relative to safe work practices,

reminders of proper safety procedures, and thelocation of safety equipment.



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(4) Biological hazard signs.

The biological hazard warning shall be used to

signify the actual or potential presence of a

biohazard and to identify equipment, containers,

rooms, materials, experimental animals, orcombinations thereof, which contain, or are

contaminated with, viable hazardous agents.



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Pictograph

Pictograph means a pictorial representation used to

identify a hazardous condition or to convey a safety

instruction



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Signal Word

Signal wordmeans that portion of a tag's inscription

that contains the word or words that are intended to

capture the employee's immediate attention.



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Tag

Tagmeans a device usually made of card, paper, pasteboard,

plastic or other material used to identify a hazardous

condition.



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Danger Tags

Danger tags shall be used in major hazard situations

where an immediate hazard presents a threat of death

or serious injury to employees. Danger tags shall be

used only in these situations.



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Caution Tags

Caution tags shall be used in minor hazard situationswhere a non-immediate or potential hazard or unsafe

practice presents a lesser threat of employee injury.

Caution tags shall be used only in these situations.



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Warning Tags

Warning tags may be used to represent a hazard levelbetween "Caution" and "Danger," instead of the

required "Caution" tag, provided that they have a

signal word of "Warning," an appropriate major

message



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Biological Hazard Tags

The symbol design for biological hazard tags shallconform to the design shown below:



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Color Coding-Danger Tag

"DANGER" -- Red, or predominantly red, with

lettering or symbols in a contrasting color.



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Color Coding-Caution Tag

"CAUTION" -- Yellow, or predominantly yellow, with




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Color Coding-Warning Tag

"WARNING" -- Orange, or predominantly orange, with




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Biological Hazard Tag

BIOLOGICAL HAZARD -- Fluorescent orange ororange-red, or predominantly so, with lettering or

symbols in a contrasting color.



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Industrial effluent testing and treatment

Effluent is an outflowing of water from a natural bodyof water, or from a man-made structure.

Water pollution or waste water discharge from theindustrial facilities.

REASON OF TESTING

To find out-Pollution load

-Presence of toxic ingredients

-Color, turbidity, odour and quality of water

-pH and acidity / alkalinity-Suspended solids and dissolved solids

-Phenolic compoundsand oily materials



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GUIDELINES FOR TESTING EFFLUENTS

Samples may be collected at specific intervals andfinally can be mixed before analysis.

Containers made up of glass, polythene or any suitable

plastic material may be used.

Samples may also be refrigerated to avoid loss of

volatile matter

Samples could be preserved after adjusting the pH

O2, CO2, CO may be estimated



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Effluents may be expressed as mg/ltr, ppm, %/ltr, andmcg/ltr

Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes

content should be reported

TESTING OF WASTE WATER (EFFLUENT)

TEST TREATMENT METHOD

pH

Acidic

Basic

Lime or NAOH

H2SO4


THE RESULTS OF TESTING ARE REPORTED

AS FOLLOWS:



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Suspended Solids Sedimentation

Oil and grease -grease taps

-skimming

Cyanide

Chlorinated & complex with pyridinepyroxolene

-Colourimetrically

-alkaline chlorination-oxidation with ozone

-oxidation with H2O2

Phosphates

-Convert to ammonium molybdatephosphates

-extracted with benzene/ isobutyl alcohol

mixture

-organic phase treated with tin chloride (blue)

Colourimetrically

-ppt with chalk or lime

-coagulation with alum


AS FOLLOWS:



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Mercury

-treated with nitric acid and potassiumdichromate soln- treared with tin chloride

Vapour determined by spectrophotometry

-Coagulation

-chelation with

trimercaptotriazine

Phenolic compounds

Steam distillation-acidify (pH


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BIOLOGICAL OXYGEN DEMAND

It is the amounts of oxygen required by micro organisms to

bio chemically oxidize carbonaceous organic matter at 200Cin 5 days.

10 mg/litre or less

Excess makes water toxic

MEASUREMENT

Special designed bottle with flared cap

Incubated at 20 0C for 5 day measuring DO Microorganism added if required



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Dissol oxy in ppm (mg/ltr) = N(V) (8) (1000)

V1V = Volume of sodium thio sulphate required.

N = Normality

V 1= Volume of sample taken.

CHEMICAL OXYGEN DEMAND Oxygen equivalent of organic matter present in waste water

that is susceptible to oxidation

Waste water sample is refluxed with a known excess of pot.dichromate in a 50% sulphuric acid solution in presence ofsilver sulphate and mercuric sulphate


CHEMICAL OXYGEN DEMAND


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The organic matter of the sample is oxidised to water, carbon

dioxide and ammonia The excess of dichromate remaining untreated in the solution

is titrated against standard ferrous ammonium sulphate

COD(mg/l) = (V1-V2) x N x 8 x100

XWhere,

V1 = Volume of ferrous ammonium sulphate solution

consumed in blank

V2 = Volume of ferrous ammonium sulphate solution

consumed for test solution

X= Volume of sample taken

N= Normality of ferrous ammonium sulphate solution24 August 2012 58KLE College of Pharmacy, Nipani

Limit for Discharge into Systems


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Limit for Discharge into Systems

Sr. No. Parameters Tolerance limits1 pH 5.59.02 Oil and grease 103 Total suspended solid, mg/l 1004 BOD, mg/l 305 COD, mg/l 506 Mercury 0.017 Arsenic, mg/l 0.208 Cyanide, mg/l 0.109 Sulphides, mg/l 2.0010 Phosphates, mg/l 5.0024 August 2012 59KLE College of Pharmacy, Nipani

Waste Water Treatment


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Waste Water Treatment

Waste Water Pretreatment

Attempted to render the effluent suitable for further

treatment

Equalization

Concentrated waste is diluted if necessary

-by mechanical mixing

-by aeration mixing

Neutralization Removal of Grease and Oils



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Primary Treatment of Waste Water

Removal of large floating or suspended particle byphysical and chemical treatment

Screening

Large particles are removed

Coarse screen of metal bars or heavy wires spaced 25-50mm apart

Finer materials are separated by screening through 0.8-6mm meshes

Grit Chambers

Removal of particles by centrifugal action and frictionagainst tank walls

Diffused air used for mixing pattern



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It is used

To prevent any damage to equipment

To avoid settling in pipe bends




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Chemical Reaction

Involves agglomeration of tiny particles into largeparticles

Flocculation

-by mechanical stirring and by chemical flocculants

Precipitation

-Large amount of suspended solid formed

Coagulation

-Formation of large and quick settling flocs by

a) Reduction of charges and repulsive force

b) Adsorption on long chain molecular structure




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Secondary Treatment of Waste Water

It is a biological process

C, H, and O sources are available

Nitrogen should be 5% of the BOD

Phosphorus should be 20% of mass of nitrogen

Environmental conditions are provided

Advantages

Continuous waste treatment is favored

Low cost system

Disadvantages

Prior prediction of biological degradability is not possible

Solubility limits biodegradability



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Activated Sludge Process Microbial Floc is suspended in tank

Air is continuously supplied

Biological degradation of waste into CO2

and H2O

Bacterial flora grows and remains suspended in the form

of floc called as activatedsludge

20% of sludge is recycled

6 to 24 hours aeration is required




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Advantages-Removal of soluble organic substance, colloidal

matter, particulate matter, inorganic substance

-Produce high quality effluent

Disadvantage

-Maintenance cost is high

-Growth of anaerobic bacteria fungi etc



Activated Sludge Process


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Activated Sludge Process


Trickling filtration process


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Microorganisms are attached to fixed bed

It acts as a filter

Bed is maintained at height of 2.5 meter

Gelatinous film is formed

Effluent is sprayed over the surface

Slots at the bottom for air inlet

Aerobic metabolism occur on the surface

Anaerobic metabolism occur at the bottom


Trickling filtration process

Trickling Filtration Process


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Advantages

Produce effluent of consistent quality

Aerobic and anaerobic digestion are achieved

More economical

Sludge can be removed quickly

Disadvantage

Cost for ventilation duct for air supply is high

Efficiency decreases in the winter




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Oxidation Ponds Depth should be 1 to 2 meters.

Bottom and sides are lined with polyethylene, cement.

Oxygen released by algae, carbon dioxide generate from

biodegradative Aerobic oxidation producing carbon dioxide and water.

Advantage:

Operation is simple and economical.

Disadvantages:

Required disinfections

Use for wastes having low BOD.24 August 2012 71KLE College of Pharmacy, Nipani



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Tertiary Treatment Of Waste Water

Meant for polishing the effluents. Bacteria are removed by keeping in maturation

ponds.

Chlorinated, if still contain bacteria.

Methods are more expensive than biologicaltreatment.

Coagulation :

Reaction take place upon addition of the

coagulants.-Metal salts

-Organic Polymers

In water, form insoluble product with impurities.



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Coprecipitation :

Ions in solution phase precipitate with the carriermolecule by

-Adsorption Process

-Inclusion Process Filtration

Most common type in addition to disinfection.

Practiced prior to the chlorination.

Should be done after coagulation.

May be made up of sand, activated charcoal.




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Adsorption Involves treatment with activated carbon.

Useful for removal of pesticides



REFRENCES


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REFRENCES

Pharmaceutical Production and Management By C. V. S. Subrahmanyam

www.geocities.com

www.britannica.com

http://nptel:iipm.ac.in

www.waste_management_world.com

Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel

The Theory & Practical of Industrial Pharmacy By Leon Lachman, HerbertA. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House.

www.osha.gov

http://www.geocities.com/http://www.britannica.com/http://www.waste_management_world.com/http://www.waste_management_world.com/http://www.britannica.com/http://www.britannica.com/http://www.geocities.com/


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THANK YOU

Cell No: 00919742431000

E-mail : [email protected]

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