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Welcome

Shri A. K. Goswami (IAS)Shri A. K. Goswami (IAS)Secretary, Govt. of IndiaDirector General, NPCChairman, NCPC

Dr. P. K. GuptaDirector, NCPC

Shri Bharatbhai JainMember Secretary,GCPC

Plant Visit ofMilestone Catalyst Pvt. Ltd.Milestone Catalyst Pvt. Ltd.

September 28, 2001

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Background

Milestone was incorporated in 1984 andpresently operates three manufacturingfacilities in Naroda

Cast Iron plant is the largest in thecountry

Tube / Pipe redrawing plant is thelargest in Gujarat

Vat Dyes plant is the only SSIunit in the world

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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 printingof cotton yarns & fabrics.

We are exporting more than 90% of gross

production to developed & developingcountries.

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CP Initiatives

Adaptation of CP, GHK, EMS, IndlSymbiosis concept by management

GCPC endorsed VD plant as CP demo

projectThree days workshop on GHK conductedat plant

Evaluation of EMS is under progress

Industrial Symbiosis helped to divertGypsum to Cement factory

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CP Findings

Install temperature

scanner

Indicated poor

utilization ofcondensers

Tray Dryer effi..

IR Thermographs

of entire plant

AQ bags to bewashed and stackedafter drying

AQ bags werestacked dry

Reduction of AQdust

Qualitydeterioration

Employ qualifiedpersonnel

Lack of qualifiedpersonnel

ManagementAttitude

Optimum optionfor improvement

ExistingPractice

Potentiality

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CP Findings Contd..

Gypsum purityimproves from 30%to 80-85%

Using LSP toneutralize effluent

Low Gypsum %

Use of HL withLSP in ETP

Use screen withcalculator font

Drum markingwas hand written

Drum Labeling

Save manpower,electricity andreduce handing loss

Conventionalbatch sizes

Increase batchsize to reactorcapacity

Change to tubeside

Vapour passingthrough shell side

Change ofcondenser inlet

Scope forimprovement

Existing PracticePotentiality

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CP Economic Benefits

2.4 months> 15,000(300 X 12)

3,600

Drum Labeling

> 1,00,000

2.6 months2,70,000

NilIncrement of

batch sizes

58,000Realignment ofETP Stirrers

5.5 months24,00011,000Change ofCondenser inlet

3 months72,00018,000TemperatureScanner

Payback

period

Savings,Rs.

CapitalInvestment

Option

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GHK Findings

Good House Keeping (GHK) workshop wasorganised by GCPC from 30th April- 02nd May2001 with participation of 18 students fromCEPT & LD Engg. College.

Nearly 74 waste streams wereidentified by the students

Many options are beingimplemented and more are yet to

be reviewedGHK adaptation reduces waste by10% with NO Investment

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EMS Status

Under the guidance of Prof. Vipul Shah,Environment Management System (EMS)evaluation and implementation is beingcarried out by CEPT student.

Feasibility of cluster based EMS on theline of Swiss model

The time frame would be fourmonths

Organisational Environment Policyhas been arrived and framed.

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Environmental policy Environmental aspects

Legal and other requirements

Objectives and targetsObjectives and targets

Environmental management

program Structure and responsibility

Training, awareness andcompetence

Communication

EMS documentation Document control

Operational control

Emergency preparedness andresponse

Monitoring and measurement Nonconformance and corrective

and preventive action

Records

EMS audit

Management review

EMS Status Contd..

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ScopeforfurtherCP Area

Application of advance technology

Use of phase transfer catalyst

Use of different solvent

reduce loss with improved yieldUse of raw material as per stoicheometry

Improvement in energy utilisation

Steam generation

Boiler grate area

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Barriers

Financial Strength of SSI unit

Scale of operation

Lack of expertise in many fields

Long term planning & visionR & D and state of art testing facilities

Lack of measuring and monitoring

Historical database

Missing links with academyTechnical literature

New development

Alternatives ..many more

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Recommendation

Scope of CP exits everywhere

Make CP a Habit

CP is cyclic process that never ends

Sharing of information benefits bothCP: Avoid, reduce & recycle

CP: Hear, observe & share

Blend of CP with GHK, EMS and Indl

symbiosis benefits individually andcollectively

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Acknowledge

We acknowledge sincere thanks

CII

GCPC

GDFE

GPCB

NCPC

NIA

NPC

School of Planning

University of Kaiserslautern, Germany

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