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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
Ashish Dagade UPL 6
• 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
Ashish Dagade UPL 7
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
Ashish Dagade UPL 12
• 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
17
Ashish Dagade
UPL18