cH Confederation of Indian Industry Since 1895 i In Pursuit of ‘GREEN’ Excellence India’s Best Practices on Environment ManagementIn Pursuit of ‘Green’ Excellence India’s Best Practices on Environment Management Volume - 1Message India is poised to become a developed country by 2020. The current level of high GDP growth needs to be maintained for making the developed India a reality. The achievement of higher growth with optimal use of resources and better emission & discharge standards is need of the hour. With prudent resource usage, businesses not only gain competitive advantage but also turn out to be Ecologically Sustainable Business Models. To foster the Ecologically Sustainable Business Growth, CII has launched the “Mission on Sustainable Growth”. The core Purpose of this mission is to “promote and champion conservation of natural resources in industry, without compromising on high and accelerated growth”. { strongly believe that to meet the objective of the mission, it is necessary to have a neutral platform for sharing knowledge and skills across the country on best practices. Tam happy to mention that Cll — Godrej GBC Environment & Recycling Council has brought out an excellent publication on environmental best practices. This book is an important milestone, to showcase some of the best practices implemented by various industries. This compendium will be an important resource & guide book for all stakeholders and can be eas replicated My congratulations to Mr. Pradeep Bhargava, Chairman, Environment & Recycling Council and Mr. LS Ganapati, Chairman, Cll Environmental Best Practices Award 2011 for their efforts and contribution. Tam sure that this best practices book would go a long way in facilitating quicker adoption of environmental best practices in Indian Industry. OFT One Jamshyd N. Godrej Chairman, Cll Sohrabji Godrej Green Business Centre & Chairman and Managing Director, Godrej & Boyce Mfg Co. LtdForeword ‘The awareness on environment management among the Indian corporate & academic institutions is increasing over the years The environment friendly initiatives are fast becoming a competitive and strategic issue for several organizations. Materia conservation and recycling / reuse are of prime importance. Environment & Recycling Council of Cll-Godrej GBC constitutes eminent and committed personnel from Indian Industries who have insight knowledge and understanding in this area, The broad objective of the Councils to; facilitate Indian Industry in adopting best Environmental & Recycling practices. Across the country, there are some outstanding examples of truly pioneering work on Environment Management, adopte by various sectors with proven and extremely impressive results. These need to be mutually shared and get benefited. Th interesting fact is, majority of these best practices can be replicated at a reasonable cost, with the benefits far outstripping th investments. a Environment Management. - We would like to express our gratitude to Indian industry for their contributions, guidance and support in shaping thi initiative. Nae Pradeep Bhargava Chairman, Environment and Recycling Council, Cll- Godrej GBC & Managing Director, Cummins Generator Technologies India LidPreface Environmentis the basis for existence of all living beings and they are mutually interdependent. But due to accelerated growth of socio economic development of the world, the problem of environment degradation has become a serious concern. Therefore, it is necessary to find out sustainable paths and methods of development to protect the ecology, reduce consumption of water, energy & raw materials and reduce waste generation as well as prevention of pollution, Itis the need of the hour that over & above skills, all pertinent technologies for better environment protection should be transparent and available to all. Cll-Godrej GBC in its endeavor to encourage, support and applaud the efforts of the industry in conserving natural resources and pollution prevention is organizing the first edition of CI Environmental Best Practices Award on 28th and 29 January 2011 at Hyderabad. CII - Godrej GBC is extremely delighted to release a collection of environmental best practices, based on the case studies submitted by the short listed companies in the award. The objective of this publication is to disseminate success stories to a larger section of stakeholders. The publication has captured the technical & financial aspects of various projects implemented on environment management and has excellent replication potential in various industrial sectors. Itis of paramount importance that environmental issues become part of our innate desire to obtain the best that comes from within each one of us. It must involve, our lives at work, gatherings of social nature and at home so that we create all round awakening on the subject. My sincere thank to all those who have contributed in release of this publication. This publication will undergo changes in subsequent years to capture the latest case studies. ob Fs L.S. Ganapati Chairman, CIl-Environmental Best Practices Award 2011 ClI-Sohrabji Godrej Green Business CentreHow to use the Book Best Practices book is a compendium of 31 best Environmental Projects across our country. Each of the following pages show cases one such Best practice in simple, clear terms. It outlines the objective of the project, results achieved and salient features of the project. Abestpractice cannot be a best practice if itis not shared with, and adopted by others. Against each Environment Best practice, you will see the name and contact of the Environment champions who made it possible. Each of our Environment champions is committed to sharing all information, and answering all your Queries about his/her Environment Best Practice. Please do reach out to them to learn more about the best practices which you are planning to adopt. Finally, if you are aware of good work done on environment management in your organization, or others ~ we are keen to hear from you. Please send us candidates for Environment Best Practices as per the template used in the published case studies, to Mr K S Venkatagiri, Prinicipal Counsellor, Cll-Sohrabji Godrej Green Business Centre at k.s.venkatagiri@cii.in. If selected, we will definitely publish them in the second edition of Best Practices book.Content Installation of Gas turbine with Dry low NOx (DLN-2) Burners Company Ltd, Tanjore jon of Telescopic Chute at Clinker Stock Pile amodhar Cement Works Use of Alternate Fuel and Raw material (AFR) from diffeedt industry wastes ACC Ltd, Kymore Cement Works Coprocessing of Paint sudge and Oil soaked coton waste in cement kiln Generation Ltd., Vemagiti reduce furnace oil consumption ies Ltd., Kumarapatnam 1 Fuel finery, Vizag Reduction of flue gas CO, emissions releasing from Lime Kiln stacks in to atmosphere by diverting the same for ‘manufacturing Precipitated Calcium Carbonate(PCC) Division, Bhadrachalam Co-Processing Of Hazardous Wastes in Cement Kiln Jubilant Life Sciences Ltd, NanjangudFoundry Resin Mixed Waste sand recycled by Sand reclamation plant to reduce sand consumption by 90% Lakshmi Machine Works Ltd., Coimbatore Screening Plant For Recovering Cement Grade Limestone From Marl Mixed Limestone Madras cements Ltd., Alathiy ion, Zaheerabad 7 by Sintering bag house fuk & Manganese ore nes Nava Bharat Venture Replacement of venturi type wet scrubber with Fuidized Bed Nye ~ Tray type wet scrubber for reducing dust concentration jue gas Nava Barat Ventures Ltd, Sugar Division, Samatkot ‘Take Back and Recycling Program (Planet Ke Rakhwale) Nokia India Pvt Ltd, Gurgaon Cyanide reduction in Acrylonitrile (ACN) plant Reliance Industries Ltd., Vadodara ProductiveManagement of Waste Residue stream in Purified Terepthalic Acid (PTA) plant Reliance Industries Ltd, Hazira Use of Plastics in Tar road Reliance Industries Ltd, Hazira Flue gas desulfurization for reduction of SO, from flue gas with sea water scrubbing Reliance Infrastructure Ltd., Dahanu Thermal Power Station, Dahanu Conservation of wood in glass packing Saint Gobain Glass India Ltd,, Sriperumbudur int and Papers Ltd., Kagithapuram Utilize the Effluent Treated Sludge (ETP) as a part of raw material in making pavement tiles ‘Tata Motors Ltd., Pantnagar Installation of High Efficiency and Low Odour Chemical Recovery Boiler The Andhra Pradesh Paper Mill Ltd,, Rajahmundry Elimination of Trichloroethylene(TCE) and conservation of solvent Titan Industries Ltd., Watch Division, Hosur 37 39 41instailation of Gas turbine with Dry Low NOx (DLN-2) burners ~ Aban Power Company Ltd, TanjoreOBJECTIVE RESULTS HOW ACHIEVED ‘To minimize NOx emissions caused due to combustion process in gas turbines . . .4 Raw water’savings of 175000 m° /year Air pollution limited to 25ppm Effluent generation minimized Annual savings considering DM water: Rs 100 Million Earlier conventional combustors were used which requires water or steam injection to control NOx emissions The NOx level attained was 45ppm Installed DLN-2 combustors which requires no water or steam. requirement to. control NOX levels Every 8000 hours of operation, gas turbine combustors were inspected and DLN tuning was carried out Natural gas temperature was maintained above 65°C for DLN combustion Investment: Rs 160 MillionInstallation of Telescopic chute at clinker stock pile - ACC Limited, Damodhar cement wo! PS ChakrabortyOBJECTIVE RESULTS HOW ACHIEVED | To reduce the fugitive dust emissions during unloading of the clinker .4 Reduced “the fugitive emission from 22864 pig/m* to 2122 g/m? Annual cost savings of Rs.19 Million Earlier clinker was unloaded through wagon tippler to the stock pile which resulted in high fugitive dust emissions due to material falling from a height Installed a retractable chute (Telescopic chute) at the belt conveyor discharge point. This automatically adjusts vertical distance between the material hip and the chute discharge mouth thus avoiding high emissions From the top hood of the telescopic chute there is a dust pick up point which is connected with a fabric bag filter having the capacity of 10000 m? Investment cost for installing the chute: Rs 0.2 Million Investment cost for bag filter: Rs.25 Million- ACC Ltd, Kymore Cement Works a TMI Hitesh Goyal hitesh.goyal@acclimited.com Ph: +91 98934 05191To utilise hazardous waste as alternate fuel in cement kiln Safe disposal of hazardous waste Avoiding lahdfill Reduction in GHG emissions HOW ACHIEVED Developed Policy framework to promote the use of alternative fuels & raw materials ‘Waste identification of other industries across the state and examine its feasibility for co-processing in the kiln and captive power plant Discussion with industry and getting assurance for their support Installation of machinery and equipment for AFR feeding ‘Testing of hazardous waste samples to assess the scope of their usage as AFR Information through articles/seminars/presentations to encourage greater acceptance of co processing as a preferred form of waste disposal as compared to incineration ‘The results of the flue gases emissions tested by the Central Pollution Control Board (CPCB) approved.Co-processing of paint sludge and oil soaked cotton waste in cement kiln - Ashok Leyland Lid, it It Hosur | P Udaysppan | Pus.cih2@eshokleylencicom Pas =91 $8944 48060OBJECTIVE | Use of hazardous waste as an alternate fuel in cement kiln RESULTS + Saving of 390 Mf of coal by disposing equivalent amount of paint sludge. . # © Avoiding landfill / incineration « Reduction in GHG emissions HOW ACHIEVED © Earlier paint sludge generated from the paint shop was stored inside the plant premises * Detailed feasibility study wasconducted tousetheheating value (calorific value ) to use as fuel with cement manufacturers. © Applied through State pollution control board for Authorization © The dry paint sludge was processed for making it to uniform size (of below 20 mm size) and it is packed for transporting to cement kilnding of o: ading of online environmental parameters of the factory to - Asian Paints Ltd, (Penta Division). Cuddalore, Tamilnadu.HOW ACHIEVED Make environmental performance of the plant transparent to the monitoring authorities and maintain clean records Cleanmage built up over a period of time with respect to environmental performance Direct access to the Top Management on the environment related parameters of the process plant A moral pressure to ensure perfect functioning of the Environmental Management Systems (EMS) of the plant, which in turn immensely benefits the Company Installed a Data Acquisition System (DAS) at the factory Uploading of the data to the Server located at the Pollution Control Board (PCB ) through Static IP Internet connection Software compatible to PCB server was installed at the factory Das Continuous monitoring and calculation of the pollutant loads in kg/day basis Investment: 0.30 MillionGreening of old Lime Sludge Hillocks, a waste generated in chemical recovery process of Pulp & Paper Industry - Bilt Graphic Paper Products Ltd, BallarpurOBJECTIVE RESULTS | . HOW ACHIEVED Effectively manage the old lime sludge hillocks Greenery wes developed in about 25 acres of land Fresh watersaving of 250 m'/day forirrigation of the vegetation due to use of treated effluent for the irrigation Old lime sludge contains about 88% calcium carbonate and 8-9% silica Fertile soil layer of about 6-7 inches was laid to plant the saplings Made 2 x 2x 1.5 feet about 30,000 pits in about 25 acres of sludge hillocks, on the sludge top and slopes and filled with fertile black soil Planted saplings of Karanjee, Eucalyptus, Casia, Kadu Neem, Glaricida, Gulmohar etc into these pits Provided about 2 km long pipe line for irrigating these hillocks with treated effluent Investment cost for developing greenery: Rs 3.5 MillionElectric Arc Furnace (EAF) Slag utilization for tiles manufacturing - Essar Steel Ltd, Hazira Road bed EAF Slag Tile from Slag Achintya Das chintyo.des@essorcom Ph +91 98791 00025 |OBJECTIVE RESULTS HOW ACHIEVED To effectively utilize the slag generated in steel industry Utilisation of about 480 tons of slag to manufacture about 42,000 sq.tn tiles/week Achieved Rs. 60 Million/annum by selling slag based tiles Earlier, the waste slag from the process was disposed for landfills & road construction Developed Technology for Tile manufacturing from EAF Slag in consultation with Central Glass and Ceramic Research Institute (CGCRI), Kolkata ‘The EAF slag can be effectively utilized in manufacturing Vitrified ceramic tiles for Buildings, Pavement block (15 to 20mm thickness) for Roads, Public places, Boundary walls etc. and Industrial floor tiles (10 to 20 mm thickness) The physico chemical characteristics of the waste was analysed and also compared with conventional tile for its reproducibility EAF slag lumpsneeds tobe properly ground below 150 micron to use in the manufacturing process Capital investment (Plant & Machinery): Rs. 120 MillionEnvironmental mitigation with New Advance Technology and contribution towards Sustainable Development of Indian Electrical Grid - GMR Vemagiri Power Generation Ltd, Vemagiri Magatapalli Roja Sekhor rolosekhor:masOBJECTIVE Reduction of Southern Grid Base line Emission By adopting New Advance Technology & best Environmental Practices wt RESULTS NOx Lévels Reduction up to 90% of convectional thermal Power generation Combustion Process Avoided DM water or steam consumption for maintaining NOx level NOx level less than 25 ppm HOW ACHIEVED Installed new advance class Dry Low Nox Combustors The dry low NOx control system regulates the distribution of fuel delivered to a multi nozzle combustor Self assessment of plant Performance & targeted areas for opportunities for improvemental Use of Biogas in Lime Kiln to reduce Furnace Oil consumptionOBJECTIVE -RESULTS HOW ACHIEVED Reduce furnace oil consumption in lime kiln by substituting with biogas generated from waste water a Reducéd 450 MT/year of furnace oil in lime kiln ‘Total biogas used is 16,67,514 m3 / Year Reduced GHG emissions of 52000 MT CO /annum COD reduction upto 90% Annual cost savings of Rs.12.5 Million Rayon grade pulp process generated waste water stream called Pre Hydrolysate (PH) liquor which has high COD Earlier the PH liquor was treated in open lagoons Installed Biogas Plant to treat the PH Liquor and produce Biogas The Biogas generated contained 60-65% methane and 35-40% CO,, The calorific value is nearly 5000Keal Biogas generated was used in lime kiln which replaced 8-9% of the furnace oil used as fuel and also used to replace Light Diesel Oil in Hot Air Generators (HAG) Biogas in lime kiln along with furnace oil produce high purity lime required for Rayon Grade Pulping Investment for Biogas plant : Rs. 1.5 millionSweetening of refinery fuel gas for internal fuel ~ Hindustan Petroleum Corporation Limited, Visakh Refinery, Vi Pure solid SulphurOBJECTIVE RESULTS HOW ACHIEVED ‘Treat the fuel gas( HS ) effectively and limit the sulphur dioxide ‘emissions from the refinery a © Refinery:90, emissions were maintained at 8.6 TPD (the stipulated norms of 11.5 TPD by APPCB) post commissioning, + Thesulphur obtained is more than 99% pure and bright yellow in color * Earlier, the gas was treated in Sulphur Recovery Units(SRU) using LOCAT technology * LOCAT system is a liquid oxidation process which removes H2S from gas stream by converting it to elemental sulphur Installed a FGAAU (Fuel gas Amine Absorber Unit) and integrated with the existing Diesel Hydro-desulphurization unit (DHDS)-Sulphur Recovery Unit (SRU), based on claus technology * Lean Amine absorbs the hydrogen sulphide from the sour fuel gas and becomes Rich Amine (rich in H2S) * The Amine Acid Gas rich in hydrogen sulphide from the Amine Regeneration Unit (ARU) is treated in the DHDS-SRU to produce sulphur * Project Investment cost : Rs 200 MillionRe-use of anode flakes through conversion to low grade Lead bearing compound and Manganese Sulphate solution - Hindusthan Zinc Ltd - Zine Smelter, Vizag Apamita Das ‘opomita.das@vedanta.coin hz 09394535908,) | OBJECTIVE RESULTS HOW ACHIEVED Promote re-use é& recycling of wastes and conserve natural resources 4 About 216 MT/Year of Lead was recovered About 0.777 MT/Year of Silver was recovered. Recovered 862.5 m’/Year of Manganese as MnSO, solution Annual cost savings: Rs. 19 Million Anode Flakes (1035 MT/annum) generated from Lead-Silver anodes are used in electro winning process Earlier these anode flakes are disposed to landfill and they contain metals like Lead, Silver and Manganese which have economic value Developed a R&D scheme to treat the waste anode flakes and extract the recoverable value added products, such as, ‘Manganese as Manganese Sulphate solution & Lead as low grade Lead bearing compound Leaching of Anode Flakes with Sulphur-Di-Oxide (SO,) gas for extraction of the Lead bearing compound and Manganese Sulphate solution Investment: Rs 2.5 Million Payback: 18 monthsImplementation of Carbon Dioxide Recovery (CDR) Unit ~ Indian Farmers Fertilizer Co-operative Ltd. (IFFCO) Aonla Unit CDR UnitOBJECTIVE To recover CO, from flue gas of Primary Reformer in Ammonia Plant to meet the CO, shortage for conversion of complete Ammonia production to Urea for improving plant productivity oe * Recovered 253000 MT of CO, from flue gases in last 3 years. * Produced 337300 MT of additional Urea by the recovered CO, in last 3 years Reduction in CO, emission by 84300 MT per annum Installed a Carbon Dioxide Recovery (CDR) unit The process of CO, recovery from the flue gas at various conditions is a proven technology Project implemented in time period of 21 months Meeting the requirement of CO, for additional Urea production, at a cheaper price using waste flue gases in an eco-friendly way Investment : Rs. 590 MillionCold Plasma Odour Control Abatement System - ITC Limited, BangaloreOBJECTIVE RESULTS HOW ACHIEVED Control of odour generated by implementing Cold Plasma Odour Control System 4 Reduced* odour level from 1127 OU/m? to 384 OU/m? (QU=Odour Unit) Water Savings of 14,600 m’/yeai Cost savings for water is Rs 0.6 Million/year Removes 85% of the odour released from the process Identified areas of odour generation in the plant and the odour levels has been measured Evaluated different odour abatement systems like scrubbing, adsorption, biofilteration, high speed oxidation and cold plasma system Installed Cold Plasma odour control system which provides 85-90% efficiency for odour elimination ‘The system uses minimal water and no chemicals for operation with low maintainence requirements Reactions occur inside the plasma module chamber and odour bearing compounds are converted to odour free compounds Investment Made: Rs. 40 Million.Reduction of flue gas CO, emissions from Lime Kiln stacks by divertin| the same for manufacturing Precipitated Calcium Carbonate (PCC) - ITC Ltd Paper Board & Speciality Paper Division, Bh A Das| OBJECTIVE id RESULTS q HOW ACHIEVED s Reduction of flue gas CO, emissions Reduction in emission of 30240 MT of CO, / annum by divertingit for PCC manufacturing Annual cost savings of Rs. 165 Million The flue gas extracted from the limekiln stack is cooled in a ‘wet scrubber (gas quencher). A continuous blow down and make-up water system is used for the process. ‘The cooled gas is transferred through pipe work to the PCC plant under vacuum conditions and compressed using a gas compressor. Investment made for + Civil & Buildings : Rs. 80 Million + Plant & Machinery : Rs, 250 Million Payback:24 months 31A case study on co-processing of hazardous wastes in Cen Kiln ife Sciences Ltd, NanjangudOBJECTIVE RESULTS HOW ACHIEVED Utilize High calorific Hazardous waste as Alternative Fuels and Raw materials in (cement) kilns in place of fossil fuels and primary raw materials Annual Savings Achieved: Rs.284 Million (compared with captive incineration cost of Rs.27/kg and packing & transportation Rs.3/kg) Avoided 950 MT/annum of hazardous waste for disposal to landfill / incinerator Earlier the waste generated was incinerated ‘Tied up with ACC cement Ltd to utilize waste material having organic content and calorific value of more than 2500 kcal in their kiln Representative waste samples were collected and sample analysis carried out to estimate the impacts of the physical and chemical properties on cement quality Thermal characteristics of the kiln system were assessed and the point of feeding of the wastes into the kiln system was established The feed rate of the wastes is established during the trial run where the material feed to the kiln is optimized and the emissions are monitored ‘Trial runs are carried out in presence of PCB members and got approved for coprocessing the waste generated at ACC Ltd— dry Resin mixed waste sand recycled by Sand reclamation o reduce sand consumption by 90% chine Works Ltd, Coimbatore aS ow R, Nandagopal nandegopelir@!OBJECTIVE RESULTS HOW ACHIEVED To solve the resin mixed waste sand disposal problem and reduce the environmental pollution ot Reduction in hazardous waste disposal and conserving natural resources Thermally reclaimed sand is superior than fresh sand and purchase of fresh sand upto 80% was reduced. Cost saving Rs 2200 /- per ton of sand Annual savings: Rs. 7.5 Million Earlier resin mixed sand waste was landfilled due to which ground water was polluted Installed gas fired thermal sand reclamation plant ‘The waste sand processed was 35 MT/day Investment cost for equipment :Rs 30 Million Pay back : 29 monthsScreening Plant for recovering Cement Grade Limestone from Marl Mixed Limestone - Madras Cements Ltd, AlathiyurOBJECTIVE Recover cement grade limestone from marl mixed limestone RESULTS | «= Recov¢red 2,92,500 MT/year of limestone from screening plant * Net high grade limestone savings due to screening is | 40800 MT/year + Production capacity increased from 720 TPH to 840 TPH Annual savings of Rs 44.74 Million achieved HOW ACHIEVED Earlier high silica (23%) in the limestone due to the presence | of marl content was rejected as waste Installed a mechanical screening plant to separate marl from limestone. | The total carbonate (TCO,) is up graded from 65-70 to 75-85 with a 60-65% recovery from the feed quantity Mines life is also increased by conserving the limestone. Investment cost of the plant : Rs 39.5 Million Payback period: 11 months29928 wer DipuyoU ED, _(_oisra [ ssousng | \ BuBeuew, x y YSN “UOISTAIG] SAOWONY ‘pry BIpUTyEY 2 wIpUIyLYY - juouoseueyy ureyd Ajddng usoinOBJECTIVE Training and educating suppliers, contractors on green practices as a business requirement and make it part of strategy RESULTS 2 Reduced-wWood packaging waste from 2208 MT to 554 MT in | two years * Reduced 74 % of wood & 45 % of card board box used for | packaging «487 MT/ annum of CO, emissions have been reduced due to transport optimization HOW ACHIEVED | * Organizing yearly training sessions, workshops, exhibitions for suppliers to make them understand the plant requirements with respect to environment standards, © Promoting reusable packaging & reducing use of corrugated boxes and wooden boxes © Promoting milk runs to minimize CO, emissions + Milk-run isa tested and proven method of optimizing, vendor's vehicle movement for delivering goods © Reduction in logistics costs by utilization of full load of | containers 39MC aanowomy “pry expat Jong ayeurayye 001d Jo asnay wz opohoay ‘oonpay mu *OBJECTIVE ‘Use of hazardous waste as an alternate fuel in cement kiln ‘© Reduetion in waste disposal expenses of Rs 28 Million / annum Avoiding disposal of 300 MT / annum of hazardous waste to landfill / incineration Saving of 200 MT of coal / annum Reducing Green House Gas emissions (approx. 270 MT/ annum of CO, gas reduced) as waste is not being incinerated. HOW ACHIEVED Hazardous waste is a by product of the Paint shop operation in the plant The chemical composition and the calorific value of the waste were determined The samples were offered to various cement industries for trials Grasim, Tadipatri agreed to undertake the trials and found that the results were promising to use the waste material as fuel Meeting AP Pollution Control Board norms Ateam from Grasim visited the plant to work out the modalities The method of transporting the waste was decided upon and the costs involved.210980 (rr2a0i te Wee. oDy B1puDYyr0UJ00g 4 Wuolg Suu03}5 805) Bd “PIT 1d soumqua, remeyg Bary - | SOUL 9IQ dsouKsuLyl 2 oun y | (UA-IS) esauesueyl OorIg Jo uonoNporgOBJECTIVE RESULTS HOW ACHIEVED Recover Manganese (Mn) present in the fume and ore fines to conserve the consumption of prime ore * Reusing the following waste materials for sintering + Fume Collected from Bag fillers - 4500 MT/annum + Manganese Ore fines = 25500 MT/annum + Coke fines = 3300 MT/annum + Dolomite fines - 1200 MT/annum 30000 MT/annum of sinter is produced on an average conserving the prime ore consumption Annual cost savings of Rs.100 Million Earlier the waste fume from the filter baghouse and Mn ore fines were dumped in an open land Laboratory experiments were carried out to sinter the fume along with ore fines and coke fines Constructed sintering plant with in-house technology Fume collected in the bag filters, screened Mn ore fines(-6mm), dolomite fines, coke fines & waste oil are the waste materials used as input Sinter cake formed after processing are sent to the furnace for Si-Mn production Fume with high MnO content resulted in high strength sinters Investment for construction of Sintering Plant: Rs. 10 Million Payback period: one monthJOY[BWLS “UOISIAIG IWSNg ‘pomuT] sanjua, JereY BARN - Joqqnios 39M addy Avy — 9AN pog pozIpM yA YUM Jaqqnios jam adAq Linjua, Jo yuauraoe[dayOBJECTIVE RESULTS HOW ACHIEVED Reduce dust concentration in flue gas Reduced dust concentration from 110mg/Nm? to 60mg/Nm’* which isbelow the CPCB standard 150 mg/Nm* Reduced CO, emissions by 1400 MT/annum Annual cost savings of Rs. 2.23 Million Earlier Venturi type wet scrubbers were used to reduce dust concentration in flue gases Installed Fluidized Bed Nye ~ Tray type wet scrubber which is an improved version of Sieve Tray scrubber and more efficient than others Dust particles are accelerated to impinge the water layer, which is created by the pressure drop of flue gas The direct impingement on a wetted target dynamically precipitates & traps particles in the scrubbing liquid Generally suitable for biomass fired boilers. Investment: Rs. 11.99 Million Payback: 64 monthsUWORSIND ‘PIT 1A PIPUT BLYON - (g/eeayyey oy Jouer]g) ureBo1g SurpoAoay pue yorg-oyeOBJECTIVE RESULTS HOW ACHIEVED Educating mobile phone consumers on the importance of recycling, v4 Over 606,000 pieces of old phones and accessories weighing over 18 MT are collected for recycling Ifevery mobile phone user across the world recycled, it could prevent nearly 240,000 tonnes of raw materials from being mined 40000 trees have already been planted working with NGO's Planned a sustained and phased program which includes infrastructure set-up by installing secure bins at Care centres branded retail stores, adopting reverse logistics and tie up with responsible recycler Pilot campaign in four Major cities resulted in collection of over 68000 pieces weighing over 3 tons of old phones and accessories in 45 days ‘Consumer research & Development Set-up of an environmental community, and nation-wide campaign Planting a tree for every phone dropped for recycling and also handing out a set of pens made of recycled plastics to consumersCyanide Reduction in Acrylonitrile (ACN) production plant ies Ltd., VatOBJECTIVE RESULTS . HOW ACHIEVED . Reduction of Hydrogen Cyanide (HCN) generated in Acrylonitrile (ACN) production process Reductidn in risk of HCN Emissions to atmosphere by 4 MT/year Reduction of ACN emissions to atmosphere by 51.840 MT/ annum, Anual revenue generation : Rs. 2.7 Million Hydrogen Cyanide is removed from the system as additional product in gaseous phase ‘The water separated out from Acetonitrile Stripping operation, is recycled as solvent in Acrylonitrile Absorber column as “Lean water” Stripper column modification was carried out to reduce HCN concentration in lean water by 50% The entire modified technology was developed in house by using process engineering tools such as stead state stimulation . Investment : INR 4.5 Million Payback period: 18 monthsBIIZB} “pouuury s aouRTay - d (proy oreudoroy, poytimg) Lf Ul { o4SBA\ JO JuaWIOSeURIY dATIONpOIg Ld Ut NA N oAl iOBJECTIVE RESULTS . HOW ACHIEVED . Reduce the waste catalyst residue generation and recover valuable chemicals during the manufacturing of Purified Terepthalic Acid (PTA) ’ Reduced Cobalt Acetate consumption from 0.515 Kg/MT to 0.161 Kg/MT of PTA by improving recovery Reduced Manganese Acetate consumption from 0.541 Kg/MT to 0.194 Kg/MT of PTA Reduced Fuel gas consumption from 2.954 sm'/MT to 2.050 sm°/MT of PTA Annual cost savings of Rs. 280 Million Earlier the catalyst residue (containing cobalt and manganese metals) was incinerated and the incinerator ash was sent to vendor for recovery of metals Installed chemical recovery unit (CRU) for recovery of metals in their salt form from the mother liquor and are recycled back to the process Six sigma methodology was adopted to optimize the process parameters for cobalt recovery Developed statistical model to monitor the performance of the operating parameters which resulted in improved Cobalt recovery from 73 % to 90% Installed flakers in the plant for ease of handling in transportation of catalyst residue to vendor facility 51Sh. S. Narayanan roreyenan@rilcom +91 99989 67735OBJECTIVE RESULTS HOW ACHIEVED Use of plastic waste generated for tar road construction 1.5Mf of waste plastics are used for 1 Km stretch road at Surat Cost savings of Rs.20000/MT for waste plastics used per Km Elastomers like natural rubber, crumb rubber, SBR, and Plastomeric substances like Polyethylene, Ethylene Vinyl Acetate, Ethylene Butyl Acrylates were mixed with Bitumen to modify its binding properties Mixture of Bitumen and waste plastics was prepared and plastic waste(Rs. 4-5 / Kg) of 5 to 8 % has been used in place of Bitumen (Rs. 20-25 / Kg) Partnered with Surat Municipal Corporation in the project and consulted ICPE (Indian Centre for Plastics in the Environment) for best results ‘Trial runs at Hazira for km stretch were successful and replicated to 10km stretch road at Vadodara and the overall methodology was approved by CPCB (Central Pollution Control Board)6zreez-82sz0 Ad puowespuales !puoN oupusloy 2eqqn.9g aD4 huvyeg ‘woHeIS Jamog [euLay], nueYyeC] ‘pry eumonyseruy souR!ay - SUIQQNINS 10]8M\ BIS YUM sed ong woy “Og Jo UoHONpol oJ UOezLINJ[NS-op sed onyPOLL O06 16+ Na wos yo qo8-.uIDs@eu UDSDAIUMIN S Inpnquiniadig ‘py eIpuy sse[H uregoy utes - Suryoed sse[3 Ul poom Jo uoeArlosuodOBJECTIVE ‘To optimize the consumption of wood for packaging, RESULTS Reduction irt consumption of wood 2.7 Cubic Foot of wood/ton of glass is saved Savings in packing cost : Rs.1000 / Ton of glass HOW ACHIEVED Designed a special type of metal ‘A’ frame with self inclination and rubber lining to transport the glass without wood packing The Metal Frames designed in house underwent stringent testing standards for load and strength involving Structural Engineering Research center (SERC) ‘Thorough study and survey has been done at the customer end to facilitate easy unloading and unpacking, Several training, programs were conducted at customer end for safe handling of glass without wood packing ‘A frames are used for 7 times and reverse logistics has been adopted Cost of Packing with Wood : 1600 Rs/ton of glass Packing in A frame : 600 Rs/ton of glassayupt Aanoses 2us00> dung ug dung ueindepisey ‘pry siedeg 2 julig sMoN NpeujTUEy - ouryoeut 19ded ut yno [10g Joye dSNed JO AIOAOIOYOBJECTIVE RESULTS HOW ACHIEVED ‘To recover valuable chemicals and avoid pollutant load to End of Pipe . . Recovered éaustic: 280 MT/annum(for 2010-2011) Reduction in effluent discharge volume : 1400 m’/ boil out Sodium reduction as Na in final effluent: 86 MT/annum Caustic boil out is carried out in Paper Machines for system cleaning and to remove scales, deposits & slime. Earlier, the Spent Caustic is drained to Effluent channel for end of pipe treatment. Constructed a sump pit to collect the spent caustic effluent. ‘Then pumped to a storage tank in Soda Recovery plant (SRP). Project cost: Rs 2 Million Pay back : 9 monthsOSv8S 96126 16> Md wor S10 OUD IO1B) eBeN Ue “PY SION ere], - s9[f] WOWAARg SuLyeUL UL [eLIO}eUL ed B se (LA) oSpnyg poyeory, juon_FY oy} ozOBJECTIVE RESULTS HOW ACHIEVED To Reduce the Impact on Environment by Re-Utilizing the ETP Sludge as a raw material in making pavement tiles eee Eliminated GHG emissions of 201.6 TCO? by re-using 120 MT of ETP sludge per annum Net cost savings of Rs 3.6 Million/annum. + Rs.2.28 Million saved by not disposing ETP sludge + Rs 1.32 Million saved by not purchasing new tiles Earlier ETP Sludge was disposed to authorized recyclers ETP sledge was tested at 3rd party chemical laboratory for its chemical and physical analysis for heavy metal, grease, oil ete Developed the process for re-utilization of ETP sludge in making pavement tiles Laboratory test was conducted at G.B. Patnagar University for microbial growth, disintegration, COD of the manufactured tiles The strength of the tile found was 10 - 12 N/sq.mm_ No additional investment done on making tiles Immediate payback 1Kg of ETP sludge gives a new tile 61OBJECTIVE Maximizing overall chemical recovery efficiency and elimination | of odour from recovery boilers | ’ RESULTS | —«_ Steam savingé of 0.90 T/T of Black Liquor Solids Firing. * Black Liquor Solids Firing: 1000 T/Day * Annual Cost Savings of Rs. 145 HOW ACHIEVED «Earlier three recovery boilers designed for firing concentrated Black Liquor of 50% solids and steam generation of 2.5 T/T of BL solids * Installed one High Efficiency 1300 TPD Chemical Recovery Boiler * Single drum Boiler capable to fire Black Liquor of 75% Solids, * Increased steam generation of 3.4 T/T of BL solids there by increase in self power generation + High Efficiency ESPs with reduced stack emission of less than 50 mg/Nm' minimized air pollution ‘* Elimination of odour by avoiding direct contact evaporators ‘* Chain less soot blowers are provided for improved operational | convenience and reduced maintenance |e Total investment is around Rs.800 Millionwawdinbs Buuosp 023 NSO] ‘TOISTAT TINA * JUOAOS JO UOTJBAIOSUOO puk (DL) sUsTAUJOOIOTYOUY, Jo uoeUTUNTTA,OBJECTIVE | _ Elimination of Trichloroethylene (TCE) by alternate eco friendly solvent and optimize the new solvent consumption RESULTS. © Reduced solvent consumption from 120 MT to 26 MT © Annual cost savings of Rs. 6.25 Million for solvent consumption HOW ACHIEVED * Earlier Hazardous chemical, TCE was used for cleaning of machine components to remove oil, grease and dust particles © Eliminated TCE completely from the manufacturing process by substituting it with Aqueous based solvent (Galvex) and Hydrocarbon based solvent (ISOPAR) | | Installed High efficieny Eco - Cleaning equipment with all safety controls and provided it with online solvent recycling system * Reduced cleaning cycle time from 20 minutes to 6 minutes to improve the production in the process * Solvent consumption reduced by more than 78% (from 120MT in 2006-07 to 26MT in 2009-10) and reduction in operating | cost Investment cost for Equipment: Rs. 30 Million,About CII The Confederation of Indian Industry ( sustain an environment conducive to the growth of industry in India, partnering industry and government alike through ad CTlis anon-government, not-for-proft, industry led andindustry 1) works to createand ry and consultative processes. managed organisation, playing a proactive role in India’s development process. Founded over 115 years ago, it is India’s premier business association, with a direct membership of over 8100 organisations from the private as well as public sectors, including SMEs and MNCs, and an indirect membership of over 90,000 companies from around 400 national and regional sectoral Cll- Sohrabji Godrej Green Business Centre Survey No 64, Kothaguda Post Near HITEC City, Hyderabad - 500 084 Tel: 491 40 44185111, Ext 101 Fax: 491 40 44185189, Email: encon@cii.in wwwgreenbusinesscentre.com About CII-Godrej GBC CII -Sohrabji Godrej Green Business Centre (CII - Godrej GBC), a division of Confederation of Indian Industry (Cll) is India’s premier developmental institution, ofering advisory services to the industry in the areas of Green Buildings, Energy Efciency, “3 Water Management, Renewable Energy, Green Business Incubation and Climate Change activities ‘The Centre sensitises key stakeholders to embrace green practices and facilitates market transformation, paving way for India to ‘become one of the global leaders in green businesses by 2015. KS Venkatagiri Principal Counss Ks.venkatagiri@cii.in