Welcome

Shri A. K. Goswami (IAS)

Secretary, Govt. of India Director General, NPC Chairman, NCPC

Dr. P. K. Gupta
Director, NCPC

Shri Bharatbhai Jain

Member Secretary,GCPC

Plant Visit of Milestone Catalyst Pvt. Ltd. September 28, 2001

Background
Milestone was incorporated in 1984 and presently operates three manufacturing facilities in Naroda Cast Iron plant is the largest in the country Tube / Pipe redrawing plant is the largest in Gujarat Vat Dyes plant is the only SSI unit in the world

Vat Dyes Plant

Milestone Vat Dyes plant is manufacturing Vat Green 1 Vat Green 2 Vat Green 9 Vat Dyes is being used for dyeing and printing of cotton yarns & fabrics. We are exporting more than 90% of gross production to developed & developing countries.

CP Initiatives
Adaptation of CP, GHK, EMS, Indl Symbiosis concept by management
GCPC endorsed VD plant as CP demo project Three days workshop on GHK conducted at plant Evaluation of EMS is under progress Industrial Symbiosis helped to divert Gypsum to Cement factory

CP Findings
Potentiality
Management Attitude Reduction of AQ dust
Quality deterioration

Existing Practice

Optimum option for improvement

Lack of qualified Employ qualified personnel personnel AQ bags were stacked dry AQ bags to be washed and stacked after drying Install temperature scanner

IR Thermographs Indicated poor utilization of of entire plant condensers Tray Dryer effi..

CP Findings
Potentiality
Change of condenser inlet Increase batch size to reactor capacity Drum Labeling Use of HL with LSP in ETP

Contd..

Existing Practice Scope for improvement

Vapour passing through shell side Conventional batch sizes Drum marking was hand written Using LSP to neutralize effluent Low Gypsum % Change to tube side Save manpower, electricity and reduce handing loss Use screen with calculator font Gypsum purity improves from 30% to 80-85%

CP Economic Benefits
Option
Temperature Scanner Change of Condenser inlet Realignment of ETP Stirrers Increment of batch sizes Drum Labeling

Capital Investment
18,000 11,000 58,000

Savings, Rs.
72,000

Payback period
3 months

24,000 5.5 months 2,70,000 2.6 months

Nil > 1,00,000 (300 X 12) 3,600 > 15,000 2.4 months

GHK Findings
Good House Keeping (GHK) workshop was organised by GCPC from 30th April- 02nd May 2001 with participation of 18 students from CEPT & LD Engg. College.

Nearly 74 waste streams were identified by the students Many options are being implemented and more are yet to be reviewed GHK adaptation reduces waste by 10% with NO Investment

EMS Status
Under the guidance of Prof. Vipul Shah, Environment Management System (EMS) evaluation and implementation is being carried out by CEPT student.
Feasibility of cluster based EMS on the line of Swiss model The time frame would be four months Organisational Environment Policy has been arrived and framed.

EMS Status
Environmental policy Environmental aspects Legal and other requirements Objectives and targets Environmental management program Structure and responsibility Training, awareness and competence Communication

Contd..
EMS documentation Document control Operational control Emergency preparedness and response Monitoring and measurement Nonconformance and corrective and preventive action Records EMS audit Management review

Scope for further CP Area

Application of advance technology
Use of phase transfer catalyst

Use of different solvent

reduce loss with improved yield

Use of raw material as per stoicheometry Improvement in energy utilisation

Steam generation Boiler grate area

Barriers
Financial Strength of SSI unit Scale of operation
Lack of expertise in many fields

Long term planning & vision R & D and state of art testing facilities Lack of measuring and monitoring
Historical database

Missing links with academy

Technical literature New development Alternatives

..many more

Recommendation
Scope of CP exits everywhere Make CP a Habit CP is cyclic process that never ends Sharing of information benefits both CP: Avoid, reduce & recycle CP: Hear, observe & share Blend of CP with GHK, EMS and Indl symbiosis benefits individually and collectively

Acknowledge
We acknowledge sincere thanks
CII GCPC GDFE GPCB NCPC NIA NPC School of Planning University of Kaiserslautern, Germany