CLEANER PRODUCTION TECHNOLOGIES FOR POLLUTION PREVENTION B.Madhusudhana Rao, M.E.,LL.B.; Senior Environmental Engineer A

1. CLEANER PRODUCTION TECHNOLOGIES FOR POLLUTION PREVENTION B.Madhusudhana Rao, M.E.,LL.B.;Senior Environmental EngineerAPPCB, HYDERABAD

2. TECHNOLOGY COST

3. LIMITATION ON EOP • Present approach for Pollution Control is end of pipe (EOP) treatment • Encounter limitation on EOP treatment • EOP treatment mostly changes the physical form of pollutants without • eliminating them totally • It is cost intensive, with hardly any benefits to the entrepreneur • It encourages existing technologies or processes to continue without • upgradation

4. ENVIRONMENT PROTECTION SHOULD BE PROMOTED WITHOUT SACRIFICING PRODUCTIVITY

5. PRODUCTIVITY AND ENVIRONMENT • EVOLUTION OF CONCEPT OF GREEN PRODUCTIVITY • ENVIRONMENTAL ENHANCEMENTS & PRODUCTIVITY. AT THE SAME TIME REDUCED COSTS, HIGHER PROFITS & REDUCED LEVEL OF POLLUTANTS, QUALITY OF LIFE. • POLLUTION PREVENTION IS THE KEY

6. WHAT IS GREEN PRODUCTIVITY Green Productivity (GP) is a strategy for enhancing productivity and environmental performance for overall socio-economic development. It is the application of appropriate productivity and environmental management tools, techniques, technologies to reduce the environmental impact of organization’s activities, goods and services.

7. Relationship between Productivity & Environment

8. GREEN PRODUCTIVITY • 25 DEMONSTRATION AND OTHER PROJECTS UNDERTAKEN HAS ESTABLISHED GP AS AN EFFECTIVE APPROACH • GP-- AN UNIQUE INTEGRATED APPROACH THAT COMBINES PRODUCTIVITY AND ENVIRONMENT. • IT IS A MICRO-MACRO AND PREVENTIVE APPROACH FOR ENHANCING RESOURCES, PRODUCTIVITY AND WASTE UTILIZATION • SYSTEMATIC METHODOLOGY & PROJECT BASED

9. SUSTAINABILITY IS THE VISION AND GOAL OF GP

10. RAW MATERIAL PRODUCTION PROCESS PRODUCT GASEOUS LIQUID SOLID WASTES TREATMENT &/DISPOSAL CONVENTIONAL PRACTICES PRODUCT RAW MATERIAL PRODUCTION PROCESS BY- PRODUCT RECYCLE/ REUSE GASEOUS LIQUID SOLID REMAINDER LESS WASTES TREATMENT &/DISPOSAL GP PRACTICES Conventional Versus GP Practices

11. Environment (Sustainable Development) Quality (Voice of Customer ) Profitability (Factor Inputs) TRIPLE FOCUS OF GP

12. Green Productivity also referred to as • - Pollution Prevention • - Source reduction • - Eco - efficiency • -Waste Minimisation • Green Productivity is a new and creative way of thinking about products and processes that make them. • It is achieved by the continuous application of strategies to minimise the generation of wastes and emissions. • Green Productivity means applying an integrated, preventative environmental strategy to processes, products, and services to increase efficiency and reduce risks to humans and the environment. Cleaner production saves money for companies while reducing wastes and harm to the environment

13. BACK GROUND Andhra Pradesh, today is among the leading states in the production of Bulk Drug manufacturing units and are mainly concentrated around Hyderabad city in the districts of Ranga Reddy & Medak. At present 120 Bulk Drug and Pharma units are in operation in AP. 90% of the Bulk Drug manufacturing units are in small or medium scale sector.

14. Most of the Drugs and Pharma are manufactured by chemical synthesis. Hence their manufacturing processes and unit operations are similar, though the products in each industry are different. Bulk Drug manufacturing units generate a variety of wastes including Hazardous Wastes. Typical waste streams include mother liquors, spent solvents, equipment wash waters, spilled materials, off-spec products and used processing aids. The effluent streams generally contain toxic substances like poly aromatic hydrocarbons and heavy metals.

15. Minimising the generation of these wastes at the source or recycling of these wastes will benefit Bulk Drug manufacturers by increasing product yields, reducing raw material needs, reducing disposal costs and liabilities associated with Hazardous Wastes. Some case studies are available to show that there is tremendous potential for waste minimisation in these industries.

16. Reactants Solvent A TYPICAL FLOW SHEET OF BULK DRUG Process Emissions Reactors Solvent losses Alkali/ Acid Spent Solvent Distillation Recovered Solvent Separation Distillation Residue Filtration Water Effluents to ETP Activated Carbon Spent Carbon Purification Effluents to ETP Water Vapour Dryer Product

17. HIERARCHY OF Green Productivity Waste avoidance Waste reduction Waste reuse Waste recycling Waste treatment Waste disposal

18. ADMINISTRATIVE COMPONENTS OF EFFECTIVE Green Productivity • Top Management Commitment • Establishment of Clear Objectives • Accurate Waste Accounting • Accurate Cost Accounting • Personnel involvement • Continuing efforts towards waste minimisation • Encouragement of technology transfer

19. Technical components of • Green Productivity • Process modification (Technology changes) • Improved House keeping and work practices (Improved Operating and • House keeping practices) • Equipment modification / Change in Raw Materials • Recovery and Recycling of materials (On - site reuse) • Product changes • Solvent recovery • Waste Audit

20. Process modification (Technology changes) • Change equipment, layout, or piping to improve material flows and • efficiency • Use better automation and process control equipment to avoid making poor • quality or off-spec products • Improve process conditions such as flow rates, temperatures, pressures, • and residence times to improve product yields and reduce waste quantities • Use processing agents or aids, such as catalysts, more optimally • Install countercurrent rinsing equipment • Change to mechanical stripping/cleaning devices to avoid solvent use • Install more efficient motors and speed controls on pump motors to reduce • energy consumption

21. Improved House keeping and work practices (Improved Operating and House keeping practices) • Reduce loss of raw materials, products, and energy due to leaks and spills • Place equipment so as to minimize spills, losses, and contamination during transport of parts or materials • Use drip pans and splash guards • Schedule production in ways that help reduce the need to clean equipment • Minimize batch size to reduce clean-out waste • Improve management of inventory of raw materials and products to avoid spoilage of expired shelf life • Improve maintenance scheduling to avoid shutdown losses • Turn off electricity when not in use • Avoid combining different types of waste streams

22. Equipment modification / Change in • Raw Materials • Reduce or eliminate use of hazardous raw materials such as heavy metal pigments, dyes and chlorinated solvents • Use higher quality or purer raw materials to avoid introducing contaminants into the process. • Use recycled materials to create markets for these products

23. Recovery and Recycling of materials • (On - site reuse) • Recycle cooling and process waters, solvents, and other materials within the factory or plant • Recover heat energy wherever possible • Find less critical uses for off-spec raw materials • Create useful by-products from "waste" materials

24. Product Changes • Reformulate products to reduce their environmental impact when used by consumers • Increase product lifetimes • Make recycling easier by eliminating un-recyclable parts or components in products • Design products so that they can be disassembled and recycled easily • Eliminate unnecessary packaging

25. Benefits • Savings in raw material and manufacturing overheads. • Savings in treatment and disposal of the wastes • Increase in company’s profits due to efficient operation. • Reduced chances of company liability • By minimising environmental problems at on-site and off-site treatment, • Storage and disposal facilities. • - By increasing worker safety • Better public image for the company • Improved employee morale, team work and productivity. • Reduced Environmental impacts. • A competitive edge over the other companies

26. INITIATIVES OF A.P.P.C.B FOR POLLUTION PREVENTION / GREEN PRODUCTIVITY • Hyderabad waste minimisation strategy developed and adopted in August, 1998 • The strategy is initially developed for areas in and around Hyderabad in 3 districts and is being extended for other areas • Cleaner production cell Established in August, 1998 • Cleaner production cell is independent and meant for helping the industry

27. ACTIVITIES OF CP CELL • Conducting demonstration waste audits • Providing information bulletins and guidelines • Providing technical advise on recycling of waste through waste exchange service • Organising environmental awards • Developing database on cleaner production technologies

28. INCENTIVES FOR CLEANER PRODUCTION • Non-Financial • CFO for three years • Awarding appreciation certificates • Nomination of Industry representatives • Financial • From Water Cess funds to assist R & D to prevent wasteful production • and for resources recovery projects.

29. WASTE GENERATORS QUANTITIES (T/Y) USERS CHEMICAL AND PHARMACEUTICALS Iron sludge 6500 Fertiliser units Spent Carbon 1100 Cement Industries Gypsum 7000 Paint industries Spent solvents 500 Solvent recovery units Sodium sulphate 1500 Paper industries Waste oils and lubricants 2100 Waste oil reprocessing units DYE INTERMEDIATE Iron sludge 11000 Cement Industries Spent sulphuric acid (55%) 9000 Fertiliser Gypsum 900 Cement Industries PAINT INDUSTRIES Spent solvents 300 Solvents recovery & Paint industry

30. BULK DRUG AND DYE INTERMEDIATE INDUSTRIES BULK DRUG AND PHARMA INDUSTRIES

31. TEXTILE PROCESSING INDUSTRIES

32. PARABOILED RICE MILLS • MAJOR WM OPTIONS • Installation of High Efficiency Rice Husk based boiler • Installation of Failsafe electrical system • Replacing over capacity motors / electrical equipment with optimal capacity / power rating equipment • Direct unloading of paddy into hopper at paddy unloading section • Preventive maintenance example alignment of separator and control of air pollution • Conversation to High Tension Electricity supply • Control of Air Pollution by installing dust control enclosures • Preventive maintenance of separator • Installation of screw conveyor / feeder to introduce rice husk into boiler • Use of flue gas / solar energy for preheating boiler feed water • Improved heat exchanger system using copper fins • Optimisation of water consumption and reduced wastewater generation • Improvements in insulation of steam lines • Improved stead distribution system

33. PARABOILED RICE MILLS

34. PARABOILED RICE MILLS ENVIRONMENTAL INDICATORS

35. TANNERIES • MAJOR WM OPTIONS • Soaking • Better desalting – Machine • Segregation and Solar evaporation of wastewater • Liming • Less sulfide, Enzyme aided system • Deliming • CO2 Deliming • Reuse of Deliming wastewater for deliming or soaking • Pickling • Reuse of Pickling wastewater for a minimum of 10 recycles • Tanning • Chrome recovery and reuse • Wetfinishing • Screening of chemical products for degradability, treatability

36. TANNERIES ENVIRONMENTAL INDICATORSReducing water consumption

37. TANNERIES • ENVIRONMENTAL INDICATORS • Suspended solids by 58% • COD by 38% • COD by 38% • BOD by 37% • Chrome by 94% • Sulphides by 90% • Chlorides by 75% • Sulphates by 70%

38. FEASIBILITY STUDY ON ALTERNATE REUSE AND DESTRUCTION OF HAZARDOUS WASTES • ·300 industries located around Hyderabad identified to be generating HW • ·Estimates of APPCB indicate 59000TPA of HW generation • ·Bulk drug and dye intermediate manufacturing industry groups account for 60% of the • total wastes. • Wastes generated include spent carbon, ETP sludge, distillation residues, waste oils and • other organics which have high calorific value and wastes such as iron sludge and • inorganic salts like gypsum, sodium sulphate and sodium chloride • The feasibility study suggested that of the total waste of 59,000 tpa about 39,000 tpa • could be diverted to a number of beneficial uses after appropriate processing.

39. BENEFICIAL USES OF WASTE STREAMS

40. WASTE RECYCLING INDUSTRIES • S.NoNature of the WasteIndustry which is using the Waste • 1 Waste Oil from the industries M/s.Yenrol Lubex, Mallapur, R.R.Dist. • M/s.Super Lube Oils Pvt. Ltd., Nacharam, R.R.Dist. • M/s.Rivi Lubricants, Visakhapatnam. • 2 Iron Sludge, Gypsum, Dilute Sulphuric M/s. India Cements Ltd., Nalgonda. • Acid from bulk drug (like SMX) manufa M/s. ACC Cements Ltd., Nalgonda. • cturing industries and Dye intermediates • 3 Dilute Aluminimum Chloride (Green M/s. Vishnu Chromates Pvt. Ltd, • liquor) from Ibuprofen manufacturing Gaddapotharam, Medak Dist. • industries. • 4 Sodium Sulphate from bulk drugs (like M/s. Ballarpur industries, Warrangal. • SMX) manufacturing industries. M/s. A.P.Paper Mills Ltd. Rajahamundry,E.G.Dist. • 5 Caustic Lye from oil industries doing M/s.Swamy Soaps, Uppal, R.R.Dist. • chemical refining and bulk drug industries

41. S.NoNature of the WasteIndustry which is using the Waste 6 Recovered/Spent Hcl from Bulk drug M/s. Pennar industries ltd, Patancheru, manufacturing industries. Medak Dist. M/s.Surana Strips, Patancheru, Medak Dist. 7 Piperzin mls from CIPRO FLOXICIN M/s.Venlar Chemicals Pvt. Ltd. Nalgonda manfacturing industries. M/s. Surya Labs. Nalgonda M/s. S.R. Piperzin, Ghatkesar, R.R.Dist. 8 Zinc waste from Galvanizing industries M/s. Zem oxides, Nacharam, R.R.Dist. M/s. Siri industries, Bollaram, Medak Dist. 9 Lead Battery waste M/s.Nile Ltd., Nalgonda Dist. M/s. Aishwarya Metal Extractions, Medchal, R.R.Dist. 10 Effluents containing AlCl3 & “Recovery of pharma grade AlCl3, HCL HCL from M/s.Anu’s Laboratories and Ammonium Alum from the effluents” ltd., Mahaboobnagar Dist. By M/s.Anu’s Laboratories Ltd., Mahaboobnagar Dist.

42. Sl. No. Name of the Industry Proposal 1. M/s.Hyderabad Industries Ltd, Hyderabad “Zero Trade effluent discharge and alternate curing methods for reducing water consumption” 2. M/s.G.T.N.Textiles Ltd., Mahaboobnagar Dist. “To achieve Zero Trade effluent discharge and recycling the treated waste water into the process” 3. M/s.Natco Pharma Ltd., Mahaboob Nagar “Installing RO plant to reduce trade effluent discharge on step by step basis to achieve zero discharge”. M/s.Sarda Agro Oils Ltd., Shamsha bad, R.R.Dist. “Changing Chemical batch refining to continuous physical refining by adding degumming system, continuous bleaching and pressure leaf filter”. 4. 5. M/s.Lohiya Vanaspathi, R.R. dist. “Changing from Conventional caustic refining to physical refining process with the special degumming machinery, pressure leaf filter and continuous physical deodorization Plant” 6. M/s.Perfect Tanners, Waranga Dist. “In-house management techniques to reduce water consumption and also proposed to reuse chrome sludge recovered from CCRP and proposed to change chemicals in soaking section”.

50. VIRCHOW LABORATORIES (A Bulk drug Manufacturing unit)