Environment protection initiatives at Watson Pharma- Ambernath

19.03.2016

AMMOR – December 2014By Nitin Ambavane

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INDEX

1. Effluent treatment plant – success story

2. Online monitoring system

3. Environment protection initiatives

4. Conservation of natural resources

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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

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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

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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

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ETP VIEW

MEE & ETP Ultra filtration/ RO block

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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

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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

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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”

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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:

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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.

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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

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COMPONENTS: SPECTROLYSER, PH SENSOR, FLOW METER

Flow meter

pH meter &

Spectrolyser

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ONLINE ANALYZER & DATA PROCESSOR

Data processor

Modem/ USB

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DATA PROCESSOR

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DATA MONITORING

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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

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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

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ENVIRONMENT PROTECTION INITIATIVES

Control of VOCs:

Vent condensers provided to storage tanks where ever required.

Vent condenser

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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

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ENVIRONMENT PROTECTION INITIATIVES

Soil contamination:

Secondary containment to tanks, tanker unloading area, pumps etc.

Use of spill containment pallets

Dyke & sec. Containment

Spill pallet

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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

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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

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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

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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

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Celebration of “World environment day”

Competitions organized viz. Quiz, Energy Conservations idea & Env. pledge, tree Plantation

THANK YOU