DCM Shriram Ltd. UNIT: SHRIRAM ALKALI & CHEMICALS 749, GIDC, Jhagadia - Bharuch-Gujarat, India

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1 DCM Shriram Ltd. UNIT: SHRIRAM ALKALI & CHEMICALS 749, GIDC, Jhagadia BharuchGujarat, India Brief profile Industrial Estate developed by Gujarat Industrial Development Corporation (GIDC) Bharuch Location : GIDC Jhagadia, Distt.Bharuch, Gujarat, India Operating Since March1996 Technology : Membrane Cell Based ChlorAlkali Plant Plant/Facility : = MTPA Caustic Soda, = 122 MW Coal based Power Plant : 24 MW HFO based Power Plant (for emergency) : Stateoftheart Distributed Control System Shriram Alkali & Chemicals : Designed & Built to National/international standards (Asahi Kasei Corporation, Japan) 1

2 Process Flow Diagram POWER PLANT DECHLORINATION SALT SATURATION PRIMARY BRINE PURIFICATION SECONDARY BRINE PURIFICATION ANODIC CHAMBER ELECTROLYSIS CONCENTRATION CAUSTIC FLAKING OF CAUSTIC SODA LYE (48%) SODA LYE (30%) CATHODIC CHAMBER BOTTLING HYDROGEN CHLORINE WASHING & COOLING HYDROCHLORIC LIQUEFACTION ACID & COMPRESSION STORAGE VAPORIZATION TO CONSUMER THROUGH PIPELINE FILLING IN TONNERS TO CONSUMER THRU PIPELINE DESPATCH SODIUM HYPOCHLORITE Our Way of SAC Safety, Environment and Hygiene is at top most priority: IMS Certificaton Systematic Approach Monitoring and Control Mechanism Continual Improvement Inhouse Development Energy Conservation Loss Identification & Minimization Optimizations of Process Parameter Training & Awareness Involvement Of Every Employee Encouragement From Management Team Work 4 2

3 Roll of Honour 2017 Gold Award in Chemical Sector for outstanding achievement in safety management by Genentech safety award 2017, ( 15th December, 2017) 2017 Energy saving under the perform, Achieve & trade Chlor & Alkali sector by Bureau of Energy Efficiency, New Delhi. (14th December2017) 2016 Silver category in Chemical sectors Genentech Environment Award nd prize in National Energy Conservation Award in Chlor Alkali Sector by Ministry of Power, Government of India Sword of Honor by British Safety Council, UK for best safety management system Sir Shriram Award for best managed ChlorAlkali Plant by Alkali Manufacturer Association of India Gujarat State Safety award for achieving accident free million man hours worked Award for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Gov of India for Prashansa Patra in recognition for developing & implementing effective Management Systems Occupational safety and health for the assessment period of three years 2002 to 2004 by NSC. Award for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Government of India Platinum award ( Greentech in chemical sector for outstanding achievement in Environment Management Roll of Honour nd prize in National Energy Conservation Award in Chlor Alkali Sector by Ministry of Power, Government of India Award for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Government of India Certificate of appreciation for achieving accident free million man hours in the year 2003 by Gujarat Safety Council Platinum award ( Greentech in chemical sector for outstanding achievement in Environment Management National award for prevention of pollution and Rajiv Gandhi Environmental award for clean Technology for from Ministry of Environment and Forest nd rank out of 34 ChlorAlkali plants in overall environmental rating of the Indian causticchlorine sector by Center for Science & Environment,NewDelhi under their green rating project. 1 st prize in National Energy Conservation Award in Chlor Alkali Sector by Ministry of Power,Government of India. Award for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Gov of India for

4 2001 Roll of Honour National Energy Conservation Award in ChlorAlkali Sector by Ministry of Power, Govt. of India for consecutive third year Award for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Government of India for consecutive second year. Corporate Environment Award by Tata Energy Research Institute in recognition of corporate leadership efforts towards environment management and sustainable initiatives in the category of company with turnover below Rs 100 Cr National Energy Conservation Award in ChlorAlkali Sector by Ministry of Power, Govt. of India for consecutive second year Two awards for unique & innovative efforts in Energy conservation by PCRA, Ministry of Petroleum & Natural Gas, Government of India ICMA certificate of merit for excellence in energy conservation and management Project Waste Management & Recycling ( Reduction in generation of Brine Sludge by using Washery Salt in place of natural sea salt to avoid impurities ) 8 4

5 Waste minimization (Non Hazardous Waste Brine sludge) Brief description of the project with schematic representation Our unit is a membrane based chlor alkali plant manufacturing Caustic, Chlorine, Hydrogen, Hydrochloric Acid and Sodium Hypo Chlorite Raw salt is used as raw material for caustic production. The impurities like Calcium, Magnesium, Sulfate etc. contained in the salt which are present in sea water are removed by chemical reaction as Brine sludge in the brine purification process The underflows from the clarifier (Brine sludge) is pumped to RVDF (Rotary Vacuum Drum Filter) to recover brine from the sludge. Dry sludge discharge from the RVDF is collected in specially designed trolley placed below it and transferred to Secured Landfill disposal facility developed within our factory premises. 9 Schematic diagram of Brine Purification process Salt Salt Silo Salt Saturator Return Brine NaOH, Barium Carbonate, Soda Ash Reactor Brine RVDF Brine Sludge Clarifier SLF (Secure Land Fill Site Anthracite filter Alpha Cellulose Polish Filter Sodium Sulphite Ion Exchange Resin Column Filter Brine Electrolyser 10 5

6 Brine sludge disposal Brine Sludge is disposed off in a secured landfill facility inside the works. The secured landfill facility has impervious construction as per the requirements of Municipal Solid Waste Rules. Designed by National productivity Council and approved by GPCB authorised auditors. 11 Major Thrust/reason behind initiating the project The first trigger for the idea is that nonavailability of space within the complex for the brine sludge disposal. As we reduced brine sludge generation at source, finally we could use SLFs for longer period of operation thus less space is required in our secured land fill (SLF) site. Reduction of solid waste generation at source reduces the environmental load & subsequently reduces production cost. Chemicals used for the brine purification is reduced & ultimately reduction in brine purification cost and increased efficiency of the product. By reduction in the brine purification chemicals consumption, Less chemical procurement is done & ultimately saving of transportation fuel & reduction in the green house gases emissions. Since brine sludge generation is reduced & ultimately reduction in vehicle movement for solid waste disposal occurs, which is indirectly helping in reduction of green house gases emissions. 12 6

7 Uniqueness of the project Generation of brine sludge depends on impurities contained in natural salt like, calcium, magnesium, sulphate and insolubles, etc., which are removed through chemical precipitation during brine purification process in the form of brine sludge (solid waste), which contains inorganic salts of calcium carbonate, magnesium hydroxide & barium sulphate. We partnered with the potential salt suppliers in Gujarat and established exclusive salt washeries to source 100% of our requirement. Thus, our project is unique as we reduced waste generation at source by sourcing and using the salt with less impurities as raw materials. This gave an edge in saving of the treatment chemicals like, BaCO3, Na2CO3, NaOH, Flocculants, alphacellulose, HCl, etc. and more over saving in water consumption and effluent generation. Sr. No. Before Project (Kg per MT of product) Earlier generaion After Project (Kg per MT of product) FY FY FY # Benchmark for Brine sludge generation in Chloro alkali industry is kg per MT of caustic production. 13 # Year wise brine sludge reduction details after implementation is as under: Sr. No. Brine sludge reduction at source after project against the best Against our earlier generation FY MT 1806 MT FY MT 3016 MT FY MT 6142 MT Total 1417 MT MT # Salt Impurities: Before Project After Project FY15 FY16 FY17 FY18 Ca ++ Mg ++ SO 4 Ca ++ Mg ++ SO 4 Ca ++ Mg ++ SO 4 Ca ++ Mg ++ SO

8 Chemicals consumption and Sludge generation Salt BaCO Soda Ash Sludge generation/ T of caustic soda production Sludge generation/ T of caustic soda production Cost Economics & the environmental benefits Project Cost Intangible Benefits Tangible Benefits Savings Saving Pay Back (INR Lakhs) (in UoM ) (INR Lakhs) (Years) Unit is using washery washed salt instead of unwashery salt. The rate of washary washed salt is appx Rs. 150 higher than normal Salt industrial saving in chemicals for regeneration increase in efficiency of plant equipments less effect on human health due to less exposure of the sludge handling MT of Brine sludge reduced against our earlier standards in last three year. Saving in land, transportation, sludge handling costs, etc Rs 188 lakhs year 16 8

9 Benchmark for Brine sludge generation in Chloro alkali industry is kg per MT of caustic production as per the data available with Alkali Manufacturers Association, India. We have surpassed the national benchmark and achieved the 44kg per MT of Caustic production. Aim of the project is reduction of solid waste generation at source & reduces the environmental load & subsequently reduces production cost. This can be easily replicated across chloralkali plants. In fact, we have communicated our best practices to Alkali Manufacturers Association of India and some of the industries are trying to implement the project 17 Thank you "LETS GO GREEN TO GET OUR GLOBE CLEAN 18 9

10 QHSE MANAGEMENT SYSTEMS AT SAC Complex Certified for : Quality Management System under ISO 9001:2015 Environment Management System under ISO 14001:2015 Occupational Health and Safety Management System under OHSAS 18001:2007 Health and Safety Management System as per British Safety Council s protocol has been achieving 5 Star rating continuously since 2010 Periodical surveillance and recertification audits are carried out by the certification agencies as per schedule. 10