environment protection initiatives at watson pharma- … conference/day 1... · environment...
TRANSCRIPT
Environment protection initiatives at Watson Pharma- Ambernath
19.03.2016
AMMOR – December 2014By Nitin Ambavane
2
INDEX
1. Effluent treatment plant – success story
2. Online monitoring system
3. Environment protection initiatives
4. Conservation of natural resources
3
EFFLUENT MANAGEMENT SYSTEM- SUCCESS STORY
Effluent treatment plant:
1. Problems faced in past:
a. Change in characteristics of effluent due to change in campaigns
b. Shock loads
c. Hydraulic capacity of plant
2. Need to upgrade ETP for future production plan realized in year 2012
3. New ETP should impart smooth treatment for at least next 10 Years
4. Construction activities started in April- 2013
5. New plant was commissioned in February- 2014
4
ETP- WORKING OUT DESIGN PARAMETERSIDENTIFICATION OF STREAM
↓CHARACTERISATION
↓SEGREGATION
↓
Lean Stream High COD /High TDS stream
↓DESIGN PARAMETERS WORKING
↓1. Production plan for 5 Years 2. Product Time Cycle.3. Per Day load of effluent.4. Worst case products with respect to pollution.5. Maximum Production per Year.6. 20 % safety margin on hydraulic load.7. 20 % safety margin on chemical load.
↓
Lean Stream High COD /High TDS stream
↓ ↓Design Parameters for ETP
Biological TreatmentCODBODTDSFlow
Design ParameterMEE Plant
5
DESIGNING OF NEW ETP
Stream Flow in
KL/day
COD values in
mg/lit
Lean process streams 90 3,750
Domestic streams
High COD strength stream 20 120,000
MEE condensate due to High COD
Stream
20 15,000
Reject from RO 22 500
TVR condensate 13 25
MEE capacity 42 NA
Total effluent quantity for design of
ETP
169 4,496
ETP- flow chart
Condensate
Activated
Carbon filter-
03
Sand Filter
– I-01
Ultra filtration
& Reverse
Osmosis
Moving Bed
Bio reactor – II
Secondary
Clarifier - I
Primary
Treatment
Multi Effect
Evaporator
Equalization
Tank
Primary Clarifier
Secondary
Clarifier - IIMoving Bed
Bio reactor – I
Equalization
Tank
Equalization
Tank
Low
COD
Sand Filter
– II-01
Treated
Water for
Recycling
Residue
for
disposal
High CODStriper
Agitated
Thin
Film
Dryer
Disinfection
Activated
Carbon
Filter - II
7
ETP VIEW
MEE & ETP Ultra filtration/ RO block
8
TREATED WATER RECYCLING
No Month Water recycled CuM
1 October-2015 469
2 November- 2015 461
3 December- 2015 543
4 January-2016 713
5 February- 2016 575
9
REAL TIME DATA MONITORING SYSTEM
Historical background:
a. Directions issued by CPCB in February 2014 and subsequent communication from MPCB to industries
b. Initially 17 types of highly polluting industries, CETPs, CHWTSDFs and
BMW incinerators need to comply by 31.03.2015
c. Final guidelines issued by CPCB on 7.11.2014 covering total 22 types of
industries
10
REAL TIME DATA MONITORING SYSTEM
Genesis of problem:
a. Pollution in the river ganga and its Tributaries
b. Need for compliance monitoring to be strengthened
c. Routine monitoring is difficult hence industry to be self disciplined and should do self monitoring and compliant and should transmit data to CPCB/SPCB on continuous basis
d. Online emission and effluent monitoring systems to be installed and operated by the developers and industries on “ Polluter pays principle”
11
REAL TIME DATA MONITORING SYSTEM
No. Type Of Industry Sub type Parameters to be monitored
1 Aluminum pH, BOD,COD TSS, Flow
2 Cement No real time monitoring is required for effluent
3 Distillery pH, BOD,COD TSS, Flow
4 Dye and Dye intermediate pH, BOD,COD TSS, Chromium, Flow
5 Chlor alkali pH, TSS
6 Fertilizer Urea plant pH, Ammonical nitrogen, Flow
DAP pH, Flow
Phosphoric acid and SSP pH, Fluoride, Flow
7 Iron and Steel pH, Phenol, Cyanide
8 Oil refinery pH, BOD,COD TSS, Flow
9 Petrochemical pH, BOD,COD TSS, Flow
10 Pesticide pH, BOD,COD TSS, chromium, Arsenic, Flow
11 Pharmaceuticals pH, BOD,COD TSS, chromium, Arsenic, Flow
12 Power plants pH, SS, Temperature
13 Pulp and paper pH, BOD,COD TSS, Flow, AOx
14 Sugar pH, BOD,COD TSS, Flow
15 Tannery pH, BOD,COD TSS, Chromium, Flow
16 Zinc pH, TSS, Flow
17 Copper pH, TSS, Flow
18 Textile and bleaching pH, COD, TSS, Flow
19 Dairy pH, BOD,COD TSS, Flow
20 Slaughter house pH, BOD,COD TSS, Flow
21 Other Engg. units like electroplating pH, COD, TSS, Ni, Cr, Flow
22 Other units of soft drinks & food pH, BOD,COD TSS, Flow
Categories of Industries required to install real time data monitoring system:
12
REAL TIME DATA MONITORING SYSTEM
CPCB Guidelines:
a. All the systems used for real time data monitoring should have certifiedinstruments/ analyzers/ equipment (each model individually certified)from institutions like TUV, MCERT, USEPA as notified by CPCB
b. Data from installed location should seamlessly be transmitted to CPCB/SPCB by placing server by individual vendor at CPCB/ SPCB
c. No human intervention should be there in the system
d. Should have provision for multi server data transmission from eachstation without intermediate PC or plant server
e. For each parameter there should be provision for independent analysis,validation, calibration and data transmission.
f. The instrument/ analyzer should have onboard library of calibrationspectras for different industrial matrices with provision of accumulatingfurther calibration matrices.
13
REAL TIME DATA MONITORING SYSTEM
Benefits:
1. System provides continuous data for long period of time without skilledstaff to perform analysis
2. All major steps in traditional analysis like sample collection,preservation, transportation, calibration, reagent addition, analysisprocedures are eliminated.
3. In case of sudden disturbance in the system compared to conventionalsystem online analyzer provides timely information for takingcorrective/ preventive steps.
4. Helps industry to monitor performance of their ETP from remotelocation
14
COMPONENTS: SPECTROLYSER, PH SENSOR, FLOW METER
Flow meter
pH meter &
Spectrolyser
15
ONLINE ANALYZER & DATA PROCESSOR
Data processor
Modem/ USB
16
DATA PROCESSOR
17
DATA MONITORING
18
ENVIRONMENT PROTECTION INITIATIVES
Liquid Handling:
Closed solvent transfer system from tank to reactor through DCS system
Drum docking station outside plant for moderate volumes.
Handling of corrosive chemicals under vacuum through glass pot
All reactor condenser vents attached to scrubber. Local exhaustventilators connected to scrubber
Drum docking station
19
ENVIRONMENT PROTECTION INITIATIVES
Small volume Liquid:
Small volume of solvent handled in safety cans.
For Laboratory waste- Closed Disposal cans are used
Use of conductive IBCs reduces drum handling
Segregation of laboratory wastes at source in SS closed containers for proper disposal.
Safety canDisposal can
20
ENVIRONMENT PROTECTION INITIATIVES
Control of VOCs:
Vent condensers provided to storage tanks where ever required.
Vent condenser
21
ENVIRONMENT PROTECTION INITIATIVES
Powder and dust emission control:
Use of powder transfer system forcharging of chemicals
Local exhaust ventilators connected todust collector
No spillage no wastePTS
LEV
22
ENVIRONMENT PROTECTION INITIATIVES
Soil contamination:
Secondary containment to tanks, tanker unloading area, pumps etc.
Use of spill containment pallets
Dyke & sec. Containment
Spill pallet
23
NEW PRODUCT DEVELOPMENT
While developing new process selection of RM and route of synthesis
depends on ….
E factor:
E = [kg raw materials- kg product]/[kg product]
E= Total mass of waste/ Total mass of product
Major elements considered during development viz..
1.Prevention instead of remediation
2.Atom efficiency
3.Less hazardous chemicals
4.Design safer chemical products
5.Safer solvents & auxiliaries
6.Energy efficient by design
24
RESEARCH AND DEVELOPMENT
Continued…
7. Renewable raw materials
8. Shorter synthesis
9. Catalytic methodologies
10. Design for degradation
11. Analysis for pollution prevention
12. Inherently safer chemistry
Hexanes Cyclohexane Acetone
Dioxanes Acetonitrile Ethanol
Pyridine THF Methanol
DMF Acetic acid Ethyl acetate
Benzene Ethylene glycol Heptane
Carbon Tetrachloride Toluene Isopropyl acetate
25
CONSERVATION OF NATURAL RESOURCES
Rain water harvesting:
Roof top water from buildings is collectedthrough separate pipelines and carried tocooling tower.
Water consumption monitoring:
Water meter at each building
Recycling of treated effluent
Cooling
tower sump
26
CONSERVATION OF NATURAL RESOURCES
2 Energy reduction projects completed in 2015.
Name of Project Description
Fuel saved,
e.g, electricity,
natural gas,
diesel
Estimated
Annual Energy
Savings, MWH
Annual Cost
Savings, US$
Investment
Made, US$
Pay Back Period,
years
Utility Integration -
Electricity Saving
Utiltiy modification
for centralised
operation done for
Plant 1,2, 3 & R&D
utility
800 KWH / Day 292 33692 61538 1.8
Cooling tower fan
automation
Cooling tower fan
auto start stop
operation through
temperature
controller
82 KWH / Day 29.93 460 230 0.5
27
Celebration of “World environment day”
Competitions organized viz. Quiz, Energy Conservations idea & Env. pledge, tree Plantation
THANK YOU