1st Project : Hyderabad Waste Management Project (1999-2000)

AusAID, the Australian Agency for International Development, manages the Australian Governments official overseas aid program. The project is being implemented for the Government of India through the Andhra Pradesh Pollution Control Board (APPCB). It is being jointly undertaken by Kinhill Pty Ltd and the Overseas Projects Corporation of Victoria (staff for this project being largely provided by the Victorian Environment Protection Authority). Earth Systems provides specialist technical input to the project as a sub-consultant to Kinhill. The Hyderabad Waste Management Project is funded by AusAID to improve the management of industrial waste in that city. The development of a central facility for the treatment, storage and disposal of hazardous industrial waste (TSDF) is an important component of this project

VASANT CHEMICALS LTD. AND VASANT ORGANICS LTD., Sector : Dye Intermediate Manufacturing Units Location : Jeedimetla Industrial Estate, Ranga Reddy Dist. A.P Implementation by : Kinhill Pty. Ltd and the Overseas Projects Corporation of Victoria.
Project Type: 1. Process Change/ Process Modification : The complete replacement of sodium hypochlorite oxidation by forced air oxidation in the presence of a catalyst. 2. Recycle/ Reuse: Installation of a filtration system to recover the residual final product from the spent iron sludge and also reduce the moisture content of the iron sludge for recycling in the cement industry. Description of Process Modification : The modified process technology of air oxidation includes a triple effect evaporator as a unit operation for concentration of the solution before crystallisation and recovery of the condensate water for reuse in the oxidation process. The wastewater generated after DNSDA recovery contains sodium sulphate with trace quantities of organic impurities. To recover the sodium sulphate from the wastewater as solid and recycle the condensate water, the modified process also incorporated a quadruple effect evaporator and a fluidized bed incinerator. Except the incinerator the rest of the equipment have been installed. Impacts in terms of reduction in Pollution: a) c) Use of chlorine, which is about 90TPM, is completely eliminated. Waste water generation is reduced from 59m3 to 37 m3 per ton of product and estimated to be further reduced to 16m3 once the evaporator and incinerator are put into operation. b) Use of caustic lye is reduced from 216TPM to 86TPM.

d) The total dissolved solids (TDS) load in waste water is reduced by 40%, and is estimated to be further reduced by another 40% once the evaporator and incinerator are put into operation for recovery of 16 TPD of 98% sodium sulphate as a byproduct. The recovery of sodium sulphate in pure form is feasible as the wastewater stream now contains only sodium sulphate with some organic contaminants unlike mixed salt (NaCl and Na2SO4) waste water earlier generated when oxidised with hypochlorite. e) The yield of the final product DASDA, has improved by 20% i.e., from 860 kg to 1030 kg per batch.

Project Costs: 102 lakhs/annum

Impact in terms of savings: Savings on recovery of Na2SO4 @Rs.1.25/kg = Rs.66 lakhs Savings on recovery of water = Rs. 8.66 lakhs Savings on treatment of Waste water = Rs.67.32 lakhs Net savings (142 102) = Rs. 40 lakhs Capital investment = Rs. 200 lakhs Pay back period (200/40) = 5 years

MAHENDRA TEXTILES:Sector: Textile Processing Unit Location : Kothur, Mahboobnagar Dist., A.P. Implementation by : Kinhill Pty. Ltd and the Overseas Projects Corporation of Victoria. Project Type: Process Change/ Process Modification :
1.0 Continuous counter current washing range to minimise wastewater generation and chemical usage 2.0 Vertical stenter to minimise energy consumption leading to reduced air pollution 3.0 Thermic fluid heating instead of steam in the jet dyeing machine to reduce energy and water consumption Impacts in terms of reduction in Pollution:

1. a. Reduction in wastewater generation by 50% b. Reduction in chemicals usage in the washing section by 50% c. Elimination of the use of hydroextractor (centrifuge) at the end of washing process
2.

Better utilization of hot air, thereby reducing the quantum of fuel, electrical energy and labour. b) Less space required in new system.
a) c) Horizantal stenter requires 29KWH/hr of power and consumes 4 lakhs Kcal/hr of heat energy. Vertical stenter, on the other hand, requires, 9 KWH/hr of power and consumes 2.8 lakhs Kcal/hr of heat energy, thereby saving 20 KWH/hr of power and 1.2 lakhs Kcal/hr of heat energy. So, Power savings per year (20 KWH/hour X 20 hours X 300 days)=1,20,000 KWH Total savings/year on power consumption (1,20,000 KWH X Rs.3.70/KWH)=Rs.4.44lakhs Heat energy saving per year(1,20,000 kcal/hourX20hours X 300days)=72,00,00,000 kcal

Reduction in wood usage per year = 4,11,428 kgs

(calorific value of wood=3500 kcal/kg, combustion efficiency - 50%)

Savings per year @Rs.650/ton of wood Impact in terms of Savings:

= Rs.2.65 lakhs

1. Reduction in water consumption(17.5 l/kg cloth processed) = 2,500 kl/yr Savings on water consumption per year @Rs.25/kl = Rs. 62,500 Savings on chemical consumption per year = Rs.94, 350 Savings on energy consumption on hydro extractor (incl.labour cost) = Rs.50, 425 Total savings per year = Rs.2, 07,275 Capital investment on the new process = Rs.7, 00,000 Pay back period = 3.5 years Note -Operating costs are almost same as that of the previous process

SRI KRISHNA PHARMACEUTICALS Sector: Bulk drug Manufacturing unit Location : Uppal, Ranga Reddy Dist., A.P. Implementation by : Kinhill Pty. Ltd and the Overseas Projects Corporation of Victoria. Project Type: Process Modification and Recycle :
Recovery unit for calcium sulphate and sodium chloride by combining the mother liquors of two different units of their group. The effluents are pre-treated to remove the organics before mixing the effluents. The mother liquor of stage I above containing 18% of sodium sulphate and 10% sodium chloride is mixed in stoichiometric proportion with the effluent from 1st stage purification of folic acid manufacture containing 15% CaCl2 (transported from M/s. Sri Krishna Drugs) to precipitate calcium sulphate. The precipitate is filtered and dried to get 96% CaSO4. 2H2O.The filtrate, which contains only sodium chloride, is concentrated in a triple effect evaporator, crystallised and filtered to obtain commercial grade sodium chloride. The distillate from the evaporator is recycled to make up for drift loss in chilling plant.

Sl. No. 1. 2.

Effluent Source
I stage of paracetamol Purification I stage of folic acid

Qty. of effluent 16 kld 15 kld

CaSO4. 2H2O recovered

NaCl recovered

Reduction in effluent volume

2.8 tpd

3.2 tpd

21 kld

Impacts in terms of reduction in Pollution; no longer having the constraint of effluent treatment and disposal and also disposal of the sludge from solar evaporation ponds (SEPs). By implementing the project the company is able to reduce the quantity of effluent and the solid waste in the form of sludge from the SEPs by 85%. Impact in terms of Savings : The total capital investment on the project = Rs.34.80 lakhs

Sale revenue from calcium sulphate per year Savings on waste water treatment per year at Sri Krishna Drugs Operating costs (incl. of interest and depreciation)

= Rs.10.08 lakhs = Rs.16.20 lakhs = Rs. 37.30 lakhs

By implementing the above option net increase in cost of paracetamol per kilo has been Rs.0.56

Sri Krishna drugsSector: Bulk drug Manufacturing unit Location :Raikunta vg., Ranga Reddy Dist. A.P. Implementation by : Kinhill Pty. Ltd and the Overseas Projects Corporation of Victoria. Project type: Recycle/ Recover: Recovery of sodium acetate from the effluent generated in purification stage II. In this stage 13,000 lpd effluent is generated containing 7% sodium acetate with traces of calcium and zinc acetates and folic acid. This effluent is passed through carbon bed filter to remove the organics and coloured impurities and then neutralised with sodium carbonate. The clarified solution is concentrated in a triple effect evaporator and finally fed into an agitated thin film evaporator to obtain a thick slurry of sodium acetate with about 5 -10% moisture. This is dried at 50oC under blower to get 98% sodium acetate trihydrate which has a good market. The condensate is recycled to cooling towers.

By-Product Recovery from Effluents Sl. No . 1. Effluent source Qty. of effluent By-product recovery

Folic acid purification I stage Folic acid purification II stage pharma washing

15,000 lpd 13,000 lpd

Reused as CaCl2 solution in Sri Krishna pharmaceuticals for recovery of Calcium Sulphate. Evaporated to recover sodium acetate tri hydrate- 0.9 tpd. Condensate recycled

2.

Impacts in terms of reduction in Pollution;

By implementing the waste minimisation measures the company is able to reduce the effluent quantity by about 50 % and solid waste in the form of sludge from the existing solar evaporation ponds to the extent the by-products are recovered. Impact in terms of savings: The total investment on the project for recovery of sodium acetate = Rs.41 lakhs The sale revenue from sodium acetate per year Payback period for the investment (41/26.73) = Rs. 26.73 lakhs = about 1.5 years

V.B.S. EXTRACTIONS:Sector: Vegetable oil extraction Location : Adoni, Kurnool Dist. A.P. Implementation by : Kinhill Pty. Ltd and the Overseas Projects Corporation of Victoria. Project type: Process Modification : 1. installation of continuous deodorizer, for physical refining of the vegetable oil replacing the earlier caustic soda fatty acid removal process. 2. Replacement of pressurized cloth filters by pressurized SS screen filters for wax extraction, 3. Installation of rain water harvesting system to divert roof runoff to the cooling tower and for other uses
Impacts in terms of reduction in Pollution; 1. Reduction in TDS level by about 60% and the wastewater discharge by about 50%. 2. Reduction in consumption levels of oil that was previously lost on cleaning fabric filter cloth resulting in a much cleaner operation. 3. Small cost saving as well as reducing the storm water discharge from the site.

Cost comparison of the present and earlier process

Parameter Steam Power Water LDO Chemicals O & M, others Total Earlier process (Cost/ MT of oil refined) Consumption Rate(Rs.) Cost(Rs.) 1200 kgs 60 kWh 1000 lts 12 lts X 0.25 X 5.00 X 0.12 X 14.00 300 300 120 168 420 211 Rs. 1519 = = = = Present process (Cost /MT of oil refined) Consumption Rate(Rs.) Cost(Rs.) 800 kgs 50 KWH 500 lts 13 lts X 0.25 X 5.00 X 0.12 X 14.00 = = = = 200 250 60 182 150 389 Rs. 1231

Savings per MT of oil processed

= Rs 288

Savings per year (approx) Capital investment = Rs. 70 lakhs Pay back period = 3.5 years

= Rs 20 lakhs