CII ENVIRONMENTAL BEST PRACTICES AWARD 2018 WASTE IS WEALTH

Transcription

1 CII ENVIRONMENTAL BEST PRACTICES AWARD 2018 WASTE IS WEALTH Sandeep Kakade Vivek Gore Shrikant Patil (Waste Management Team)

2 Waste Management BCIN Commitment Minimize waste in our operations through careful and efficient use of processes, materials and ensure disposal of waste safely and sensibly Page 2

3 BCIN - Types of Wastes Reduce Reuse Recycle Page 3

4 Trigger of the Project & Target Setting Type of waste UOM Achived Short term Mid term Long term Kg Hazardous waste Reduction % Baseline 10.16% 13.17% 16.00% 20.00% Non-Hazardous waste Kg Reduction % Baseline 20.12% 3.92% 19.17% 27.25% BCIN 2020 waste management target Short Term & long Term Goals (w.r.t. Baseline Year 2015) Yearly Goals & CAPEX / OPEX (Top Management Approval) Individual Team Tasks Execution & Project Tracking Project/Task closure (Presentation to GreenCo Core Team/Manag ement) Page 4

5 Trigger of the Project & Target Setting Approach Followed for Projects Planning GreenCo Forum meetings Waste Mgmt. Summits Industrial Visits Project/Description Can this be eliminated? Alternat e Process? Reduce consum ption? Use of Oil soaked Cotton New technolog y Chemical sludge from waste water treatment Wastes & residues (Paint Sludge) Shot blasting waste Grinding waste Rubber/Plastic Scrap Biogas plant for canteen food waste Trigger of these two projects: BCIN Green Targets Achieving zero waste to landfill status Focus on recycling principles BCINs contribution on Swachh Bharat Page 5

6 Uniqueness of the Project Brick making from Hazardous wastes Waste generation Washing machine made from waste barrel to reuse oily cotton waste Washing machine made from waste barrel Use of Brick for civil work Adding of waste with cement mixture Reuse Oil cotton Waste generation Brick drying Brick formation Cotton waste drying Washing of Oily cotton waste a) Pollution Control Board consent to operate received b) In-house set-up for brick making c) Small waste generating companies send waste to CHWTSDF for disposal, which leads to land filling d) We are using same wastes in brick making, which eliminates land filling a) In-house development of washing machine from waste items b) Pollution Control Board consent to operate received which similar industries do not get c) Quality of washed cotton is good (Test Results) Page 6

7 Milestones of Project Accomplishment Brick making from Hazardous wastes Legal Authorization from Pollution control board Strength of Bricks Washing machine made from waste barrel to reuse oily cotton waste Legal Authorization from Pollution control board Capacity of Washing machine Sr. No Activity Reuse of Oil soaked Cotton after washing Reuse Chemical sludge in brick making Reuse Wastes & residues in brick making Reuse Shot blasting waste in brick making Reuse Grinding waste in brick making Recycle Paper waste for making notepads Projects Planning & Action plan Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. Application of Bricks Design of Washing machine 8 9 Reuse of canteen food waste for Biogas plant Reuse of empty oil barrels for seating arrangement Plan Actual Training & Guideline Quality of washed cottons Training & Guideline Brick Making Initial planned date : 09/06/2017 Date of completion : 15/06/2017 Date of commencement: 18/06/2017 Washing machine Initial planned date : 05/07/2017 Date of completion : 18/07/2017 Date of commencement: 20/07/2017 Page 7

8 Project Applications Washing Machine Application Approved MPCB Consent Brick Applications Video Page 8

9 List all Tangible & Intangible Benefits Tangible Eliminated disposal of 5500 kg of waste in landfills Saved hazardous waste disposal charges INR 2,20,000/- per annum Project cost only INR 8000 (Bearing, coupling, + man-hours ) Payback of project was less than one month. Reduction in total 400 km of hazardous waste transport and associated risks 300 Kg of CO2/year emissions saved Intangible Moving towards zero landfill Waste disposal handling reduction of 20 man-days/yr. Reduced cost of raw material required for civil work Improved Team motivation/morale Page 9

10 Replication Potential of Projects Replication Potential across All below mentioned Sectors Automobile Engineering & Projects GreenCo Forum BCIN Promotion Channels Vendor Meet & Recognitio n for Green Initiatives & Training to Vendors Refineries & Petrochemicals Tyre & Textile In-house Magazine Replication Potential s / Best Practices sharing to Neighboring Industry Fertilizers, Glass Iron, Steel, Non Ferrous metals Corporate Sustainabili ty Report Best Practices sharing within BC Units Page 10

11 Replication Potential of Projects Page 11

12 Challenges Faced and Brief on Countering Technical Administrative Design of Washing machine Capacity of Washing machine Strength of Bricks Quality of washed cottons Washing solution Treatment of drained water from washing machine Legal Authorization from Pollution control board Application of Bricks for civil work Training & Guideline Handling of oily & washed cottons Reports and forms for reused hazardous wastes Tools used for problem solving Tool Box Talk RCA- 5 WHY Analysis Brainstorming Fishbone Diagram Pareto Analysis Maintenance related Drum balancing of washing machine Vibration of washing machine Rusting of washing machine Water leakages from washing machine Page 12

13 Achieving National & International Benchmarks Performance in terms of waste with National benchmarks The only compressor manufacturing company with GreenCo GOLD & following Green initiatives in India We are a project based industry; Customized Compressor systems as per customer needs; product mix with batch type production Small waste generating companies send waste to CHWTSDF for disposal, which leads to land filling We are using same wastes in brick making, which eliminates land filling Performance in terms of waste with International benchmarks Sr. No. Manufacturer Category Description Reference 1 Burckhardt Compression (India) Pvt. Ltd. Specific waste generation Kg 14,584 13,103 12,663 Production Hrs. 6,48,688 6,57,512 6,98,520 Kg/Prod. Hrs Time office data 3 Burckhardt Compression AG (Switzerland) Specific waste generation Kg 33,377 36,524 39,227 Production Hrs. NA 11,79,150 13,09,998 Kg/Prod. Hrs NA Time office data Page 13

14 Priority Plans Sr. No Activity Effluent reaction cum sludge dewatering tank making for liquid waste Effluent pre-equalization tank with oil & grease trap tobe make Procurement of oil and paint in smaller containers Battery restoration & reuse Reuse of empty oil barrels for different uses like material storage etc. Priority plans Apr. May. Jun. Jul. Aug. Sep. Oct. Nov. Dec. Jan. Feb. Mar. Plan Actual Page 14

15 Road Map for Sustaining Benchmark Action Plan & resource allocation S = Shot term (18-19) M = Mid Term (19-20) L = Long term (20-21) Sr. No. 1 2 Project Effluent reaction cum sludge dewatering tank making for liquid waste Effluent pre-equalization tank with oil & grease trap to be make Benefit Budject Target plan Approach Material Waste type Kgs Lacks S M L Recycle Sludge HW Recycle Sludge HW 3 Procurement of oil and paint in smaller containers Recycle Liquid HW 4 Battery restoration & reuse Reuse Solid HW 5 Reuse of empty oil barrels for different uses like material storage etc Recycle Solid HW Total Page 15

16 Best Practices Project / best practices Reuse of Oil soaked Cotton after washing Reuse Chemical sludge in brick making Reuse Wastes & residues in brick making Reuse Shot blasting waste in brick making Reuse Grinding waste in brick making Recycle Plastic waste for making bio-diesel Recycle Paper waste for making notepads Reuse of canteen food waste for Biogas plant Recycling of E-waste Recycling of Scrap Batteries Reuse of empty oil barrels in sitting arrangement Reuse of wooden waste in packing plywood Approach Plan Term Reduce Reuse Recycle Page 16

17 Best Practices Training & awareness to all employees Waste segregation with color codes at shop floor Dedicated team for handling waste Daily tool box talk & quarterly training to team Measurement & monitoring of each waste Maintain Form-3 for waste generation Dedicated closed waste storage area with color code Instruction board displayed at storage Hazardous wastes given to only authorized recycler/chwtsdf Monthly review & analysis on set targets Page 17

18 Major Learnings Zero Landfilling We can achieve zero land filling by reduce / reuse / recycle. Without depending up on Recycler / CHWTSDF Zero Investment We can implement projects with Low or No investments. Immediate payback period Zero Resource We can implement projects with available resources Tapping people within the organization with required skills Page 18

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