LANXESS India –Integrated Water Management - Nagda Site
Devendra Dhami
Sr. Manager - HSEQ
April 23, 2014
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Agenda
Introduction to LANXESS‒ Introduction to LANXESS and its global presence
‒ Overview of LANXESS in India
‒ Positioning of Nagda site in LANXESS business
Waste Water Management at LANXESS
Nagda site
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LANXESS – a leading specialty chemicals company with global leadership in synthetic rubber
Background� Name: combination of French word “lancer” (to set in motion)
and “success”
� Manufactures and markets advanced rubber polymers,
plastics, intermediates and specialty chemicals
� Listed on Stock Exchange and part of DAX indices, Germany
Global success story
� 52 production sites worldwide (2 in India)*
� ~17,500 employees* in 31 countries
� Global sales of € 8.3 bn *
� EBITDA*** of € 735 mn *
Young company with strong roots
� More than 100 years of history in India
� Consolidation of parts of previous Bayer polymers and
chemicals businesses into new entity in 2004
� Inception of LANXESS as independent company in Feb 2004
* As on December 2013
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� Material Protection Products
� Inorganic Pigments
� Functional Chemicals
� Leather
� Rhein Chemie
� Rubber Chemicals
� Liquid Purification
Technologies
� Advanced Industrial
Intermediates
� Saltigo
� Butyl Rubber
� Performance Butadiene
Rubbers
� Keltan Elastomers
� High Performance
Elastomers
� High Performance Materials
Business Portfolio – 3 Strong Business Segments and 14 Business Units
Performance ChemicalsAdvanced IntermediatesPerformance Polymers
Leading supplier of Synthetic Rubber, High-tech Plastics, Specialty Chemicals
and Advanced Industrial Intermediates in India and globally
Globally No. 1- 3 Europe No. 1- 2 No. 1- 4 in niches
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LANXESS with more than 100 years of history in India
� LANXESS established in India since
February 20, 2004
� A leading supplier of specialty
chemicals and advanced polymers to
customers in India and global markets
� Organizational set-up
– All 14 LANXESS business units are
represented locally
– 2 production sites: domestic sales
and exports
– 3 sales offices and country-wide
dealer and indent agent networkSales officeProduction site
Note: Dealer and indent agent network all over the country
Jhagadia (RUC, LPT, MPP, RCH, HPM)
Delhi
Nagda (AII)
Thane - LANXESS India Private Limited HQ
Chennai
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LANXESS India site at Nagda, Madhya Pradesh
Introduction
� Located at Birlagram, about 55km
from Ujjain
� Substantial investments in
sustainability since acquisition of
the site assets in 2009*
� Production of Advanced
Intermediates (AII business units)
� The largest contributor to the
LANXESS India business
*Acquisition of chemical businesses and production assets belonging to Gwalior Chemical Industries Ltd.
Facilities continuously
modernized since acquisition
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Aerial view of Nagda site
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Business Unit Portfolio – Advanced Industrial Intermediates (AII)
� 3 business lines of BU - AII
� Nagda site belongs to BL- BIA
� Production volume of approx. 3,00,000
metric tons/year
� Major products include Benzyl
Chloride, Benzyl Alcohol,
Benzaldehyde, Thionyl Chloride,
Benzyl Acetate and Cinnamaldehyde
Picture/Artwork size:
Height = 6.28 cm
Width = 14.69 cm
� Serving wide range of domestic and
export customers with more than 50%
exports
� Catering to various application
segments like agrochemicals,
pharmaceuticals, dyestuff, flavors and
fragrances, coatings
Aromatic Network
Polyols and Oxidation
Products
Benzyl Products and
Inorganic Acids
N
A
G
D
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Agenda
Introduction to LANXESS
Waste Water Management At LANXESS
Nagda Site‒ Global philosophy on Sustainable Development
‒ Sewage Treatment Plant
‒ RO Section
‒ Forward Integration of Waste Water Management at Nagda:
Implementation of Waste Water Post Treatment plant
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Sustainability at LANXESS
Overview
� Future success is closely linked to the future of
customers, communities and environment thus
sustainability is a responsibility shared by all
� Systematic steps taken for sustainable and profitable
growth – involves an integrated approach considering
ecological, societal as well as economic factors
– Includes all HSEQ related aspects
– Continuous improvement of products and processes
at all levels
– Investment in bio-based fuel / raw material
– CSR in the vicinity of operation areas
– Commitment to global sustainability indices
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Nagda Plant – Role Model for Sustainable development in India and Globally
Picture/Artwork size:
Height = 5.28 cm
Width = 7.09 cm
Picture/Artwork size:
Height = 5.28 cm
Width = 7.09 cm
Picture/Artwork size:
Height = 5.28 cm
Width = 7.09 cm
Picture/Artwork size:
Height = 5.28 cm
Width = 7.09 cm
Picture/Artwork size:
Height = 5.28 cm
Width = 7.09 cm
Effluent Treatment
Plant
Waste Water Post
Treatment Plant
Occupational Health
Center
Co-gen (bio-based)
Plant
Sewage Water
Treatment Plant
Incinerator
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Benjamin Franklin
“When the well is dry, we know the
worth of water”
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Background
LANXESS water requirement (formerly GCIL*) met through Grasim
Industries till 2007
Plant situated at the bank of river Chambal
Surrounded by industries (e.g. Grasim Industries Ltd.) having very
high water consumption
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2
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Type of water Quantity ( m3/day) Purpose
Fresh water 36 Drinking
Raw water 800 Cooling Tower
Steam generation 450 Plant steam
Water requirement (2007)
*Gwalior Chemical Industries Ltd.
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Alternatives Explored
Using sewage water was a workable option
Use of ground water from bore well, not feasible due to quality
concerns
Water from nearby villages by tankers would mean adding to the
problem of scarcity
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2
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Final alternative selected
� Obtain clearance from Grasim for use of their sewage water (otherwise drained to river)
� Install sewage water treatment plant with capacity of 3,000 m3/day and use water for Cooling Tower
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Sewage Treatment Plant
Overview
� First of its kind in MP
used to treat and recycle
domestic sewage water
from nearby colony
� Capacity of treating
3,000 cum/day of
sewage water
� Award received from
Indian Chemical Council
in 2009 for innovative
approach to recycle and
harness domestic
sewage water for
industrial useLANXESS harnessing grey water
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Aerial View Of Sewage Treatment Plant
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Schematic Diagram Of Sewage Treatment Plant
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Taking Next Step – Setting up a Reverse Osmosis (RO) plant
� Treated sewage from the sewage treatment plant is used for cooling tower
makeup
� Fresh water was still being used for Boiler feed water
� Treated Sewage was available after meeting the cooling water demand
� Further treatment can help to enhance the quality of water to be later used
as boiler feed water
� To achieve this, RO plant has been installed
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RO plant
Boiler feed waterSewage treated water
Short title EShort title E
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RO plant – Enhancing the Quality of recovered water
� Treated sewage from the sewage
treatment plant is fed to the RO
plant
� Permeate is used as boiler feed
water
� Condensate from stream traps is
recovered and economized in
various processes
� Some portion of condensate is
recycled as boiler feed water
through condensate polishing unit
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Front View of RO & DM plant
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Schematic Diagram of RO plant
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62,791
283,225
410,935
468,342
511,778
679,383
0
100,000
200,000
300,000
400,000
500,000
600,000
700,000
800,000
2008 2009 2010 2011 2012 2013
Water recycled through STP and RO Fresh water consumption
Recycled Sewage Water Quantity and Quality
All quantities are in m3 / annum
Reduction in Fresh Water Consumption
Parameters of
recycled water
�pH = 7.5
�COD = 40 ppm
�TDS = 800 ppm
�Chlorides = 300 ppm
�Hardness = 300 ppm
(CaCO3)
�TSS = 80 ppm
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Benefits accrued from STP and RO operations
Benefits
� Judicious utilization of the water
� Conservation of natural resources
� Reduction of river water pollution
� Reduction of CO2 emission by about 400 tons/year
� Sludge from clarifier is used as natural manure
� Cost savings with continuous plant running even during dry months
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Forward Integration towards Sustainability
� Reduce environmental footprint – reduce dependence on conventional water
sources
� Prevent contamination of river Chambal, the primary source of water for villagers
downstream
Second project to harness waste water after STP (ICC Award 2009)
in which water utilization and conservation efforts maximized with
state-of-the-art ZLD concept
Drivers for zero liquid discharge (ZLD)
� Decision to study possibility of recycling entire treated waste water at site resulted in
the Waste Water Post Treatment Plant project
� Development process involved water quality surveys, water composition analysis
from different sources and additional measures for water pre-conditioning (incl. trials
and pilot runs)
� Finally zeroed in on concept involving reverse osmosis process followed by
evaporation step
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Forward Integration of Water Management
Schematic diagram
SludgeCooling tower bleed
Sewage
water
Evaporation/
Crystallization
Filter/
Centrifuge
Disposable
salt
Lime or soda
softening
(option)RO2
RO1
Boiler feed
water
RO
existing
Ion Exch.
existing
ETP-effluent
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Waste Water Post Treatment Plant – Stepping it up with Zero Liquid Discharge Concept
Overview
� Treatment of discharge from
ETP in a PTRO (Plate Type
Reverse Osmosis) unit and
Evaporator plant so that no
liquid effluents are discharged
from the site at all
� Water recovered is re-used for
production processes
� Investment of nearly INR 35
crore
Benchmark for the whole Indian
chemical industry
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Overall Process Flow Diagram – RO system
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Selection of Reverse Osmosis System
� PTRO system selection has been done based on the detailed analysis,
several lab trials and pilot runs on waster water
� The study was carried out using water samples from different sources
having different composition
� Frequent fouling consideration
� Plate type module selection
– Can handle high COD /BOD effluent directly
– Easily upgradable
– High quality product water
– Longer membrane life
– Reliable PLC based fail safe units
– No Chemical pretreatment required hence no sludge generation
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Performance of PTRO system
Operational parameter quantity
Parameters PTRO-I PTRO -II
Feed Permeate Feed Permeate
Flow 430 360 400 286
Recovery 84% 72%
pH 6.8 6.6 6.9 6.7
TDS 1,500 130 2,500 160
Chlorides 690 55 2,700 45
COD 150 10 210 12
� Cleaning frequency and method of cleaning
� CIP: Once in a month with Membrane Cleaning agent
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Evaporation System
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Sections of Waste Water Post Treatment Plant
Pretreatment Section
Heat ExchangerVapor Compressors
Crystallizer
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Evaporator Section
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� Wastewater is pumped to the crystallizer through a heat exchanger
� A stream from the recirculating loop is sent to a centrifuge to separate remaining water from crystals
� Vapor is fed to a Mechanical Compressor through a mist eliminator, and sent back to heat the incoming feed
� The recirculating brine enters the crystallizer vapor body; a small amount of brine evaporates
� As water evaporates from brine, crystals form
condensate product
feed
Crystallizer – Flow Schematic
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Feed and Product Quality
� Feed (Brine) - 3.5% TDS (35000 ppm)
� Product (Distillate) – less than 25 ppm TDS
� Byproduct (mixed salt) – less than 20% wt/wt moisture
Feed, Product and Salt Quality
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2701
2154
0
500
1000
1500
2000
2500
3000
Before WWPT After WWPT
20%
Reduction in total water intake at site
All quantities are in m3 / day
Impact of WWPT on Water Consumption
Water Intake at site
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� Sustainable solutions implemented
� Continued plant operation even during summer (water shortage)
� Conservation of water resources/ Reducing water footprint
� Recognition within LANXESS globally
� Recently recognized by ICC through ICC HSE Excellence Award 2012
� Recognition within the community
Advantages of initiatives for water conservation
Summary
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Emphasis on Green Zone development – around 7,000 saplings planted around site
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LANXESS’ commitment recognized by Indian Chemical Council
Received ICC HSE Excellence Award 2012, which bears
testimony to world class HSEQ initiatives at LANXESS sites
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