62 ....................................................................................................................................................................................................................................................................................................................................................................................................................................................................... Environment initiatives in action Performance highlights Unit IV Environment-friendly batch execution Unit III Before After Effluent testing laboratory Unit II • Recycling 100% hazardous waste since FY 2020 • 0% waste sent to landfill since FY 2020 • 7% Reduction in ZLD energy consumption • 11% Reduction in operational cost of ZLD system • 24% reduction in freshwater consumption due to recycling of RO permeate in cooling towers • 12% increase in recycling of hazardous waste through coprocessing and alternate reuse A product in Unit III comprising stages A to E had concerns identified in the last 3 stages: • Excess Water consumption • Excess discharge of effluents • Solvent vapour exposure during drying to the operator and to the environment • Ergonomic concern to the operator during unloading crude material as the crude gets solidified at higher temperature (4000C) Environment-friendly changes made to three stages of the process: • Reduction of water consumption by 44% thereby • Reduction of effluent discharges • Complete elimination of n-Heptane solvent • Vapour losses were prevented due to the replacement of hot air dryer with a vacuum tray dryer under Nitrogen blanketing • Ergonomic issue resolved by the usage of Acetonitrile to liquefy crude material ETP lab strategy • Pre-stage analysis of waste water nature and properties • Analysis helps sustainable operation of effluents • Helps in removing the physical, Chemical and Biological constituents • Helps in maintaining environmental pollution control The Unit 4 facility has a Zero Liquid Discharge facility (ZLD). The ETP consists of Stripper, Multiple Effect Evaporator (MEE), Agitated Thin Film Drier (ATFD), and Reverse Osmosis (RO) plant. A state-of-the-art effluent testing laboratory was set up in Unit 2, which supports detailed waste characterization. The data on waste characterization is shared with manufacturing facilities during technology transfer. This helps in planning for disposal methodology from the inception of commercial manufacturing. Used chemicals inventory management is another aspect of concern in laboratories. A centralized reagent laboratory has been developed to manage used chemical inventory. The chemical reagents are evaluated and segregated by the R&D team. Based on the need, these chemicals stored in the reagent library are issued. This practice has led to responsible usage of the chemicals, which would have otherwise been disposed of. In our efforts to prevent the release of VOC emissions into the atmosphere, we addressed this concern by introducing heat exchangers in the vent lines of vacuum pumps. By incorporating eco-friendly methodologies in one of the products, we considerably reduced the quantity of water consumption and effluents. We addressed the exposure to solvent vapours and resolved the ergonomic issues faced by operating personnel in the production block.
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