DOING THINGS BETTER

Ashish Dagade

8th Dec-13

Green Initiatives at UPL

Ashish Dagade UPL1

Outline

Initiatives Outside UPL

Infrastructure

Pathway

Implemented Projects

Ashish Dagade UPL2

Initiatives outside UPL

Group companies

BEIL (Bharuch Enviro Infrastructure Ltd),

Ankleshwar, Gujarat (solid & hazardous waste

management)

Enviro Technology Ltd (ETL) Ankleshwar,

Gujarat (common effluent treatment plant)

UPL Environmental Engineers Ltd

(consultancy & turnkey projects)

Ashish Dagade UPL3

Infrastructure

High level of Awareness at Top level & drive

by top management

Well equipped PI & Microbiology lab

Expertise teams of Process engineers, Process

Chemists, Energy & Microbiology

scale up & technical guidance by expertise

from ICT, IIT

Ashish Dagade UPL4

Focuses on

Process optimization

Yield improvement & Efficiency enhancement

Identify & implement Advanced Technologies to

manufacturing eg converting batch processes to

more efficient continuous processes

• Equipment selection to fit Manufacturing needs

• Process automation

Ashish Dagade UPL 5

• Focus on

• Identify & implement best energy practices

• Optimization of energy utilization

• Implement energy saving projects

• Reduction in specific consumption

• Energy from alternate source / alternate fuel

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• Focus on

• Waste Reduction at source

• Recovering value added products from waste streams

• Recovering products/intermediates from waste

• Converting non-degradable waste into Bio-

degradable form

• Cracking refractory COD

• Energy recovery from waste streams

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Raw Materials SolventsFuel

Energy

Generation

ProductsWaste

solvents

Wastes

Process

Power

Energy Cell MAXPRO GREEN CELL

Recovery

Intermediate

RecoveryBy product

recovery

In manufacturing sites

Idea Generation

POC at Lab

scale

Scheme &

Capex

Commissioning

Evaluation by

relevant team

Project

implementation

Realization

Pathway

Capex approval

Pesticide product manufacturing

A solvent (Methanol) is replaced with Water in theprocessing.

This initiative has eliminated 1000TPA of Methanol usage

Improvement in quality by 3% and

Improvement in Yield by 3%

Ashish Dagade UPL 10

Pesticide manufacturing

Methyl Chloride is generated inmanufacturing – most of the units eithervent it or incinerate it

UPL have installed a Methyl ChlorideRecovery Plant

Recovered Methyl Chloride is saleable by-product and generates revenue

MeCl convert in to By-Product (PoultryFeed)

Ashish Dagade UPL 11

Pesticide Intermediate manufacturing

A solvent Hexane is completely eliminated from theprocess step to make it neat reaction.

This initiative has eliminated almost 500TPA of Hexaneusage

Eliminated 50TPA of Hexane losses to atmosphere

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• Copper hydroxide from waste from

10kLD effluent

• Technology – precipitation followed

by resin absorption

• Conversion of the streams in highly

bio-degradable form

• Elimination of evaporation of

3000kL per year

• 100TPA recovery of Cu(OH)2

• Annual benefits of Rs 100 LPA

Ashish Dagade UPL 13

Before

After

Two steps of Intermediates for Pesticide

• 300TPA waste streams was sent for incineration

• Developed process to recover intermediates

• Recovered intermediates recycled in process

• Eliminated incineration of 300TPA waste

• Resulted into yield improvement by 3-5% and

• Annual benefits Rs 150 Lacs

Ashish Dagade UPL 14

Non-bio degradable streams into degradable form

• Pretreatment to streams (eg hydrolysis, stripping, ion

exhange, etc)

• Culture enrichment & development for specific wastes

• Bio-Augmentation

• Successful implementation of three streams• Elimination of evaporation of 50kLD of effluent

• Steam saving of 50TPD

• Annual benefits Rs 450 Lacs

Ashish Dagade UPL 15

Measures by energy cell

Chemical free treatment for cooling tower eliminating annual usage of 1ton treatment chemicals per site

Condensing economizer for fuel norm reduction in boiler

Condensate recovery system with CCDS system.

Efficient refrigeration system to get Lowest Kw/TR.

Replacement CFC refrigerants by Ammonia gas

Bio Gas plant for canteen and bio waste.

Use of solar water heaters for all canteen & bathrooms

Ashish Dagade UPL 16

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Ashish Dagade

UPL18