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Heranba Industries Vapi, achieves energy and cost savings

Compressor and air network where leakages have been arrested at Heranba in Vapi IE

Summary of the success

Heranba Industries Ltd is an agrochemical company situated at the Gujarat Industrial Development Corporation’s (GIDC) Industrial Estate at Vapi. Despite the fact that the company fulfilled the inlet standards set by the Common Effluent Treatment Plant (CETP) at Vapi, they decided to further improve the operation of their ETP and minimize inefficient utilization of resources like energy.

In addition, the German consultancy, adelphi, conducted a comprehensive RECP study in order to identify possible inefficiencies in the utilization of resources like water and energy. Major energy and cost savings were realised as a result and working conditions for workers have been improved due to the taken measures.

The company is going to implement further measures for energy and cost savings in the future as awareness and trust has been raised significantly, hence, allowing additional improvements.

About the problem

There are more than 1,500 industries from various sectors, such as chemical, paper, dye, drug and pharmaceutical, pesticide, fertilizer, electroplating, etc., located at GIDC Vapi industrial estate. Most of these companies are members of the CETP of Vapi which has a capacity of 55 MLD. Due to the large volume and diversity of wastewater, the treatment of the effluent at the CETP, however, is very challenging. Hence, pre-treated and more homogenous wastewater streams from discharging companies would reduce inlet pollution values at the CETP and lead to its improved operation.

Despite the fact that Heranba Limited, met all the CETP inlet norms, they wanted to improve on the inefficient use of resources. In particular, they faced problems in identifying cost and energy-saving opportunities that can be utilized.

Actions initiated

To systematically improve the situation, the Industrial Estate Vapi of the Gujarat Industrial Development Corporation (GIDC) was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project under Indo-German technical cooperation. Jointly with GIDC, Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has been implementing the SEIP Project at Vapi since 2016.

Under SEIP, a German consultancy, adelphi, was hired to assess the operations of 10 ETPs installed at chosen companies. In 2017, national and international experts visited those companies to collect data and samples in order to do preliminary assessments. Subsequently, more detailed assessment for improvements was undertaken and recommendations were given.

Whilst the detailed assessments are still ongoing, some suggestions on improvements were already given during initial site visit. 

Efficiency improvement

The consultants have identified energy saving opportunities in the light bulbs that were used. These metal halide lights were outdated and consuming excessive electricity.  Energy-efficient LED lights were installed in their place as a substitution. In total, 250 new light bulbs were replaced yielding to annual electricity savings of 49,920 kWh further leading to economic savings amounting to 379,392 INR per year.

In addition, another no-cost measures was recommended and implemented to further enhance efficiency gains. Compressed air leakages were found to be present in different parts of the compressed air network. By arresting these leaks an immediate savings effect can be utilised and needed maintenance in form of regular checks further ensures this and contribute to enhanced environmental awareness. By doing so, 9,000kWh electricity consumption per year is reduced and result in 72,800 INR monetary savings.

The savings measures are summarised in the table below.

Problems identified

Solutions

Costs

Results

Inefficient metal halide light bulbs consuming excessive energy

Replacement of old light bulbs with new LEDs

170,000 INR

Energy savings of 49,920 kWh per year translating into monetary savings of approximately 380,000 INR

Major leakage near air compressor and 5 smaller leaks in the pipeline

Proper insulation and reparations of damaged spots

No cost

Energy savings of 9,000 kWh per year translating into economic savings of 72,800 INR

Total costs:

170,000 INR

Total savings:

452,800 INR/year

Estimated payback period:

5 months

The success – The benefits

In total, the implemented measure led to energy savings of 58,920 kWh per year, resulting in cost savings of 452,800 INR since less electricity is in use now. Tackling the inefficient use of energy was neither expensive nor a complex task as the payback period is already reached in 5 months and yielded environmental relief immediately.

Before the intervention, there was a general lack of knowledge and awareness regarding saving potentials through more efficient alternatives. The fact that cleaner production is not merely a good deed for the environment, but also helps to increase operational efficiency, leading to cost-savings and increased competitiveness is being vividly demonstrated by the implementation of these simple, yet, effective measures.

 

 
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