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Cost savings achieved through Energy Efficient Production Methods at M/s Richter Themis Medicare Pvt. Ltd., Vapi

Pic: Insulation of pipes at M/s Richter Themis Medicare Pvt. Ltd.

Summary of the success

A consortium of experts in the field of resource, energy and water efficiency in industrial processes, led by the German consultancy, Adelphi, visited 50 companies at Vapi to undertake rapid assessments of their production facilities. Companies interested in increasing their resource efficiency and reducing the pollution caused by their production processes were selected for a more detailed assessment, given that potential for the implementation of efficiency measures existed. Amongst the companies selected for a detailed assessment is M/s Richter Themis Medicare Pvt. Ltd. Whilst the detailing of measures is currently still ongoing, some energy and fuel cost savings have already been realised through the implementation of simple, low-cost insulation measures.

M/s Richter Themis Pvt. Ltd. is a pharma company within the Vapi Industrial Estate of the Gujarat Industrial Development Corporation (GIDC). Significant energy savings were realised at their plant after the group of consultants undertook a comprehensive Resource Efficiency and Cleaner Production (RECP) audit assessing the potential of water, energy and raw material savings. The implementation of first low-cost measures has already yielded energy and cost savings.

About the problem

Vapi Industrial Estate spread over an area of 1140 hectare of land, is located in Valsad district of Gujarat which was developed by Gujarat Industrial Development Corporation (GIDC). It came into existence in 1967. Vapi is an important industrial city in Gujarat, located 180 km north of Mumbai. It is an integral part of the Delhi Mumbai Industrial Corridor and contributes greatly to the country’s economy. The Vapi Industrial Estate houses around 1,500 industrial units mainly comprising of chemicals (Inorganic and Fine), pesticides, dyes and dye intermediates, pharmaceuticals, textiles, plastic processing and paper and pulp units. The estate lies between the Damanganga River in the South and the Kolak River in the North.

In general, the companies in the estate do not have environmental management systems in place. Waste and wastewater generated is often not adequately treated, and raw materials, water and energy is consumed inefficiently further leading to waste and environmental pollution. Companies lack the technical data as well as the knowledge about Best Available Techniques and Technologies in the Indian or international context. 

Actions initiated

To systematically improve the situation, GIDC’s industrial estate at Vapi was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation. Jointly with GIDC, a public agency owning the industrial estate, the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has been implementing the SEIP Project since 2016.

Under SEIP, a German consultancy (Adelphi) was hired to assess and audit the potential of environmental improvements in companies directly. On one hand, end-of-pipe solutions, i.e. an improvement in the treatment of wastewater and waste are being considered. On the other, the main focus lies on increasing resource, water, and energy efficiency in the companies’ processes. The objective is to reduce environmental impacts of industrial operations along with reducing costs of waste treatment and disposal.

The approach is to target technological modifications as well as changes in techniques applied, and optimisation of manufacturing processes. The latter two usually do not require large investments, but rather entail changes in the production steps, change of input materials, or the training of workers. These measures tend to build the trust of companies in the viability of efficiency measures and provide the basis for larger interventions requiring monetary investments.

The companies chosen for RECP audits in Vapi belong to chemical, dye, pharmaceutical, pigment, pesticide, paper, textile and colour industries.

Pic: Industries in GIDC’s industrial estate of Vapi that want to improve energy, water and raw material efficiency under the SEIP Project

Efficiency improvement

M/s Richter Themis Medicare Pvt. Ltd. is a pharma industry located at GIDC industrial estate in Vapi eager to improve its energy and water efficiency performance. The consultants accordingly undertook a comprehensive Resource Efficiency and Clean Production (RECP) study to reveal potential cost-saving opportunities.

An easy and low-cost improvement solution was identified in fixing steam leakages in the steam pipelines. The thermographic and visual mapping of the steam lines identified heat loss hotspots and major leakages in the distribution system, e.g. from flanges, glands, and pipe joints. Accordingly, the consultant team suggested fixing these leakages in order to minimise losses. This effectively led to a reduction of the coal consumption of the boiler. The implementation of this low-cost measure will result in cost savings of over INR 200,000 annually.

Problems identified

Solutions

Costs

Results

Major steam leakages in flanges, glands and pipe joints in the steam pipelines of the steam distribution system leading to steam losses of 1%

Repair and replacement of leaking valves, flanges and pipe joints in order to close major steam leakages in the distribution system

INR 5,000

  • Reduction in steam leakages leading to savings of INR 216,640 per year.
  • Improved insulation leads to lower temperature at the workplace, thusly improving working conditions.

Total investments:

INR 5,000 

Total savings:

INR 216,640 per year

Estimated payback period:

1 month

Economic benefits

Environmental benefits

Social benefits

Energy cost savings of INR 216,640 per year

Reduction of energy    consumption by 39 tonnes of coal per year

Improvement in working conditions through temperature reduction

Pic: Situation before: Steam leakages in pipes

Pic: Situation after: Fixed steam leakages

The success – The benefits!!!

The implemented measures did not require sophisticated technology or large monetary investments but led to significant energy and cost savings in the plant where they were implemented. At M/s Richter Themis Medicare Pvt. Ltd. savings of over 200,000 INR per year are expected from this simple measure.

Apart from achieving economic savings, the intervention allowed the manager and technical personnel to realise the potential of efficient and cleaner production- opening doors for further improvements in the companies. At M/s Richter Themis Medicare Pvt. Ltd., the benefits achieved from fixing steam leakages, encouraged the management to undertake further interventions, such as employing an economizer, optimizing oxygen percentage in the flue gas, and the insulation of scrubber.

Testimonials

Mr. Himanshu Pattnaik, General Manager, M/s Richter Themis Medicare Pvt. Ltd.

“The findings of the RECP measures of the SEIP Project have been really helpful for us. The loss of steam was our biggest concern and measures have been implemented instantly. With minimum investments, we were able to achieve far greater results and quite assume that the measures could benefit us in the long run.”

 

 

Ms. Shriveni Swain, Executive Environmental, Health and Safety, M/s Richter Themis Medicare Pvt. Ltd.

“When the consultants did their regular visits to our company, they highlighted many points which we were ignoring until then. But with their help we have listed many points where we can conserve lots of energy, lots of water and definitely it will help us saving costs. There are many grateful, that our company was included in the project, helping us to improve in many aspects.”

 

 

 
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