Environment protection initiatives at Watson Pharma- Ambernath. AMMOR December 2014

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1 Environment protection initiatives at Watson Pharma- Ambernath AMMOR December 2014 By Nitin Ambavane

2 INDEX 1. Effluent treatment plant success story 2. Online monitoring system 3. Environment protection initiatives 4. Conservation of natural resources 2

3 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 New ETP should impart smooth treatment for at least next 10 Years 4. Construction activities started in April New plant was commissioned in February

4 ETP- WORKING OUT DESIGN PARAMETERS Lean Stream IDENTIFICATION OF STREAM CHARACTERISATION SEGREGATION 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 % safety margin on hydraulic load % safety margin on chemical load. Lean Stream High COD /High TDS stream High COD /High TDS stream Design Parameters for ETP Biological Treatment COD BOD TDS Flow Design Parameter MEE Plant 4

5 DESIGNING OF NEW ETP Stream Flow in COD values in KL/day mg/lit Lean process streams 90 3,750 Domestic streams High COD strength stream ,000 MEE condensate due to High COD Stream 20 15,000 Reject from RO TVR condensate MEE capacity 42 NA Total effluent quantity for design of ETP 169 4,496 5

6 ETP- flow chart Equalization Tank Low COD Equalization Tank Primary Clarifier Condensate High COD Equalization Tank Primary Treatment Striper Multi Effect Evaporator Agitated Thin Film Dryer Residue for disposal Moving Bed Bio reactor I Secondary Clarifier - I Moving Bed Bio reactor II Secondary Clarifier - II Sand Filter I-01 Activated Carbon filter- 03 Ultra filtration & Reverse Osmosis Disinfection Treated Water for Recycling Sand Filter II-01 Activated Carbon Filter - II

7 ETP VIEW MEE & ETP Ultra filtration/ RO block 7

8 TREATED WATER RECYCLING No Month Water recycled CuM 1 October November December January February

9 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 c. Final guidelines issued by CPCB on covering total 22 types of industries 9

10 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 10

11 REAL TIME DATA MONITORING SYSTEM Categories of Industries required to install 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 11

12 REAL TIME DATA MONITORING SYSTEM CPCB Guidelines: a. All the systems used for real time data monitoring should have certified instruments/ 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 each station 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 calibration spectras for different industrial matrices with provision of accumulating further calibration matrices. 12

13 REAL TIME DATA MONITORING SYSTEM Benefits: 1. System provides continuous data for long period of time without skilled staff to perform analysis 2. All major steps in traditional analysis like sample collection, preservation, transportation, calibration, reagent addition, analysis procedures are eliminated. 3. In case of sudden disturbance in the system compared to conventional system online analyzer provides timely information for taking corrective/ preventive steps. 4. Helps industry to monitor performance of their ETP from remote location 13

14 COMPONENTS: SPECTROLYSER, PH SENSOR, FLOW METER Flow meter ph meter & Spectrolyser 14

15 ONLINE ANALYZER & DATA PROCESSOR Data processor Modem/ USB 15

16 DATA PROCESSOR 16

17 DATA MONITORING 17

18 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 exhaust ventilators connected to scrubber Drum docking station 18

19 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 can Disposal can 19

20 ENVIRONMENT PROTECTION INITIATIVES Control of VOCs: Vent condensers provided to storage tanks where ever required. Vent condenser 20

21 ENVIRONMENT PROTECTION INITIATIVES Powder and dust emission control: PTS LEV Use of powder transfer system for charging of chemicals Local exhaust ventilators connected to dust collector No spillage no waste 21

22 ENVIRONMENT PROTECTION INITIATIVES Soil contamination: Secondary containment to tanks, tanker unloading area, pumps etc. Use of spill containment pallets Spill pallet Dyke & sec. Containment 22

23 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 23

24 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 24

25 CONSERVATION OF NATURAL RESOURCES Rain water harvesting: Roof top water from buildings is collected through separate pipelines and carried to cooling tower. Water consumption monitoring: Water meter at each building Recycling of treated effluent Cooling tower sump 25

26 CONSERVATION OF NATURAL RESOURCES 2 Energy reduction projects completed in 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 Cooling tower fan automation Utiltiy modification for centralised operation done for Plant 1,2, 3 & R&D utility Cooling tower fan auto start stop operation through temperature controller 800 KWH / Day KWH / Day

27 Celebration of World environment day Competitions organized viz. Quiz, Energy Conservations idea & Env. pledge, tree Plantation 27

28 THANK YOU

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