LANXESS India –Integrated Water Management - Nagda Site

Devendra Dhami

Sr. Manager - HSEQ

April 23, 2014

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Agenda

Introduction to LANXESS‒ Introduction to LANXESS and its global presence

‒ Overview of LANXESS in India

‒ Positioning of Nagda site in LANXESS business

Waste Water Management at LANXESS

Nagda site

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LANXESS – a leading specialty chemicals company with global leadership in synthetic rubber

Background� Name: combination of French word “lancer” (to set in motion)

and “success”

� Manufactures and markets advanced rubber polymers,

plastics, intermediates and specialty chemicals

� Listed on Stock Exchange and part of DAX indices, Germany

Global success story

� 52 production sites worldwide (2 in India)*

� ~17,500 employees* in 31 countries

� Global sales of € 8.3 bn *

� EBITDA*** of € 735 mn *

Young company with strong roots

� More than 100 years of history in India

� Consolidation of parts of previous Bayer polymers and

chemicals businesses into new entity in 2004

� Inception of LANXESS as independent company in Feb 2004

* As on December 2013

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� Material Protection Products

� Inorganic Pigments

� Functional Chemicals

� Leather

� Rhein Chemie

� Rubber Chemicals

� Liquid Purification

Technologies

� Advanced Industrial

Intermediates

� Saltigo

� Butyl Rubber

� Performance Butadiene

Rubbers

� Keltan Elastomers

� High Performance

Elastomers

� High Performance Materials

Business Portfolio – 3 Strong Business Segments and 14 Business Units

Performance ChemicalsAdvanced IntermediatesPerformance Polymers

Leading supplier of Synthetic Rubber, High-tech Plastics, Specialty Chemicals

and Advanced Industrial Intermediates in India and globally

Globally No. 1- 3 Europe No. 1- 2 No. 1- 4 in niches

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LANXESS with more than 100 years of history in India

� LANXESS established in India since

February 20, 2004

� A leading supplier of specialty

chemicals and advanced polymers to

customers in India and global markets

� Organizational set-up

– All 14 LANXESS business units are

represented locally

– 2 production sites: domestic sales

and exports

– 3 sales offices and country-wide

dealer and indent agent networkSales officeProduction site

Note: Dealer and indent agent network all over the country

Jhagadia (RUC, LPT, MPP, RCH, HPM)

Delhi

Nagda (AII)

Thane - LANXESS India Private Limited HQ

Chennai

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LANXESS India site at Nagda, Madhya Pradesh

Introduction

� Located at Birlagram, about 55km

from Ujjain

� Substantial investments in

sustainability since acquisition of

the site assets in 2009*

� Production of Advanced

Intermediates (AII business units)

� The largest contributor to the

LANXESS India business

*Acquisition of chemical businesses and production assets belonging to Gwalior Chemical Industries Ltd.

Facilities continuously

modernized since acquisition

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Aerial view of Nagda site

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Business Unit Portfolio – Advanced Industrial Intermediates (AII)

� 3 business lines of BU - AII

� Nagda site belongs to BL- BIA

� Production volume of approx. 3,00,000

metric tons/year

� Major products include Benzyl

Chloride, Benzyl Alcohol,

Benzaldehyde, Thionyl Chloride,

Benzyl Acetate and Cinnamaldehyde

Picture/Artwork size:

Height = 6.28 cm

Width = 14.69 cm

� Serving wide range of domestic and

export customers with more than 50%

exports

� Catering to various application

segments like agrochemicals,

pharmaceuticals, dyestuff, flavors and

fragrances, coatings

Aromatic Network

Polyols and Oxidation

Products

Benzyl Products and

Inorganic Acids

N

A

G

D

A

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Agenda

Introduction to LANXESS

Waste Water Management At LANXESS

Nagda Site‒ Global philosophy on Sustainable Development

‒ Sewage Treatment Plant

‒ RO Section

‒ Forward Integration of Waste Water Management at Nagda:

Implementation of Waste Water Post Treatment plant

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Sustainability at LANXESS

Overview

� Future success is closely linked to the future of

customers, communities and environment thus

sustainability is a responsibility shared by all

� Systematic steps taken for sustainable and profitable

growth – involves an integrated approach considering

ecological, societal as well as economic factors

– Includes all HSEQ related aspects

– Continuous improvement of products and processes

at all levels

– Investment in bio-based fuel / raw material

– CSR in the vicinity of operation areas

– Commitment to global sustainability indices

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Nagda Plant – Role Model for Sustainable development in India and Globally

Picture/Artwork size:

Height = 5.28 cm

Width = 7.09 cm

Picture/Artwork size:

Height = 5.28 cm

Width = 7.09 cm

Picture/Artwork size:

Height = 5.28 cm

Width = 7.09 cm

Picture/Artwork size:

Height = 5.28 cm

Width = 7.09 cm

Picture/Artwork size:

Height = 5.28 cm

Width = 7.09 cm

Effluent Treatment

Plant

Waste Water Post

Treatment Plant

Occupational Health

Center

Co-gen (bio-based)

Plant

Sewage Water

Treatment Plant

Incinerator

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Benjamin Franklin

“When the well is dry, we know the

worth of water”

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Background

LANXESS water requirement (formerly GCIL*) met through Grasim

Industries till 2007

Plant situated at the bank of river Chambal

Surrounded by industries (e.g. Grasim Industries Ltd.) having very

high water consumption

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2

3

Type of water Quantity ( m3/day) Purpose

Fresh water 36 Drinking

Raw water 800 Cooling Tower

Steam generation 450 Plant steam

Water requirement (2007)

*Gwalior Chemical Industries Ltd.

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Alternatives Explored

Using sewage water was a workable option

Use of ground water from bore well, not feasible due to quality

concerns

Water from nearby villages by tankers would mean adding to the

problem of scarcity

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2

3

Final alternative selected

� Obtain clearance from Grasim for use of their sewage water (otherwise drained to river)

� Install sewage water treatment plant with capacity of 3,000 m3/day and use water for Cooling Tower

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Sewage Treatment Plant

Overview

� First of its kind in MP

used to treat and recycle

domestic sewage water

from nearby colony

� Capacity of treating

3,000 cum/day of

sewage water

� Award received from

Indian Chemical Council

in 2009 for innovative

approach to recycle and

harness domestic

sewage water for

industrial useLANXESS harnessing grey water

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Aerial View Of Sewage Treatment Plant

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Schematic Diagram Of Sewage Treatment Plant

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Taking Next Step – Setting up a Reverse Osmosis (RO) plant

� Treated sewage from the sewage treatment plant is used for cooling tower

makeup

� Fresh water was still being used for Boiler feed water

� Treated Sewage was available after meeting the cooling water demand

� Further treatment can help to enhance the quality of water to be later used

as boiler feed water

� To achieve this, RO plant has been installed

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RO plant

Boiler feed waterSewage treated water

Short title EShort title E

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RO plant – Enhancing the Quality of recovered water

� Treated sewage from the sewage

treatment plant is fed to the RO

plant

� Permeate is used as boiler feed

water

� Condensate from stream traps is

recovered and economized in

various processes

� Some portion of condensate is

recycled as boiler feed water

through condensate polishing unit

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Front View of RO & DM plant

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Schematic Diagram of RO plant

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62,791

283,225

410,935

468,342

511,778

679,383

0

100,000

200,000

300,000

400,000

500,000

600,000

700,000

800,000

2008 2009 2010 2011 2012 2013

Water recycled through STP and RO Fresh water consumption

Recycled Sewage Water Quantity and Quality

All quantities are in m3 / annum

Reduction in Fresh Water Consumption

Parameters of

recycled water

�pH = 7.5

�COD = 40 ppm

�TDS = 800 ppm

�Chlorides = 300 ppm

�Hardness = 300 ppm

(CaCO3)

�TSS = 80 ppm

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Benefits accrued from STP and RO operations

Benefits

� Judicious utilization of the water

� Conservation of natural resources

� Reduction of river water pollution

� Reduction of CO2 emission by about 400 tons/year

� Sludge from clarifier is used as natural manure

� Cost savings with continuous plant running even during dry months

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Forward Integration towards Sustainability

� Reduce environmental footprint – reduce dependence on conventional water

sources

� Prevent contamination of river Chambal, the primary source of water for villagers

downstream

Second project to harness waste water after STP (ICC Award 2009)

in which water utilization and conservation efforts maximized with

state-of-the-art ZLD concept

Drivers for zero liquid discharge (ZLD)

� Decision to study possibility of recycling entire treated waste water at site resulted in

the Waste Water Post Treatment Plant project

� Development process involved water quality surveys, water composition analysis

from different sources and additional measures for water pre-conditioning (incl. trials

and pilot runs)

� Finally zeroed in on concept involving reverse osmosis process followed by

evaporation step

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Forward Integration of Water Management

Schematic diagram

SludgeCooling tower bleed

Sewage

water

Evaporation/

Crystallization

Filter/

Centrifuge

Disposable

salt

Lime or soda

softening

(option)RO2

RO1

Boiler feed

water

RO

existing

Ion Exch.

existing

ETP-effluent

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Waste Water Post Treatment Plant – Stepping it up with Zero Liquid Discharge Concept

Overview

� Treatment of discharge from

ETP in a PTRO (Plate Type

Reverse Osmosis) unit and

Evaporator plant so that no

liquid effluents are discharged

from the site at all

� Water recovered is re-used for

production processes

� Investment of nearly INR 35

crore

Benchmark for the whole Indian

chemical industry

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Overall Process Flow Diagram – RO system

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Selection of Reverse Osmosis System

� PTRO system selection has been done based on the detailed analysis,

several lab trials and pilot runs on waster water

� The study was carried out using water samples from different sources

having different composition

� Frequent fouling consideration

� Plate type module selection

– Can handle high COD /BOD effluent directly

– Easily upgradable

– High quality product water

– Longer membrane life

– Reliable PLC based fail safe units

– No Chemical pretreatment required hence no sludge generation

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Performance of PTRO system

Operational parameter quantity

Parameters PTRO-I PTRO -II

Feed Permeate Feed Permeate

Flow 430 360 400 286

Recovery 84% 72%

pH 6.8 6.6 6.9 6.7

TDS 1,500 130 2,500 160

Chlorides 690 55 2,700 45

COD 150 10 210 12

� Cleaning frequency and method of cleaning

� CIP: Once in a month with Membrane Cleaning agent

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Evaporation System

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Sections of Waste Water Post Treatment Plant

Pretreatment Section

Heat ExchangerVapor Compressors

Crystallizer

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Evaporator Section

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� Wastewater is pumped to the crystallizer through a heat exchanger

� A stream from the recirculating loop is sent to a centrifuge to separate remaining water from crystals

� Vapor is fed to a Mechanical Compressor through a mist eliminator, and sent back to heat the incoming feed

� The recirculating brine enters the crystallizer vapor body; a small amount of brine evaporates

� As water evaporates from brine, crystals form

condensate product

feed

Crystallizer – Flow Schematic

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Feed and Product Quality

� Feed (Brine) - 3.5% TDS (35000 ppm)

� Product (Distillate) – less than 25 ppm TDS

� Byproduct (mixed salt) – less than 20% wt/wt moisture

Feed, Product and Salt Quality

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2701

2154

0

500

1000

1500

2000

2500

3000

Before WWPT After WWPT

20%

Reduction in total water intake at site

All quantities are in m3 / day

Impact of WWPT on Water Consumption

Water Intake at site

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� Sustainable solutions implemented

� Continued plant operation even during summer (water shortage)

� Conservation of water resources/ Reducing water footprint

� Recognition within LANXESS globally

� Recently recognized by ICC through ICC HSE Excellence Award 2012

� Recognition within the community

Advantages of initiatives for water conservation

Summary

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Emphasis on Green Zone development – around 7,000 saplings planted around site

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LANXESS’ commitment recognized by Indian Chemical Council

Received ICC HSE Excellence Award 2012, which bears

testimony to world class HSEQ initiatives at LANXESS sites

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