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M/s Micas Organics Ltd. Vapi, achieves cost savings through energy efficient production

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 in the Integrated Industrial Estate (IIE) at Haridwar to undertake rapid assessments of their production facilities. Those companies interested in increasing their resource efficiency and reducing the pollution caused by production were selected for a more detailed assessment, given that potential for the implementation of efficiency measures existed. Amongst those companies selected for the detailed assessment is M/s Micas Organics Ltd. Whilst the detailing of measures is currently still ongoing, some energy and, hence, fuel cost savings have already been realised through the implementation of simple, low-cost insulation measures.

Micas Organics Ltd. is a pigment-producing industry located within the Vapi Industrial Estate of the Gujarat Industrial Development Corporation (GIDC). In their plant significant energy savings were realised 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 the first low-cost measures has already yielded energy and cost savings.

About the problem

Vapi Industrial Estate is an industrial area located in Valsad district of Gujarat which was developed by Gujarat Industrial Development Corporation (GIDC). It came into existence in 1967 and spreads over an area of 1140 hectare of land. 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 avoidable 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 audit and assess the potential of environmental improvements in companies directly. On the one hand, end-of-pipe solutions, i.e. an improvement in the treatment of wastewater and waste are being considered. On the other, however, the main focus lies on increasing resource, water and energy efficiency in the companies’ processes since tackling pollution at the source is generally a more economical solution. The objective is to reduce the environmental impacts of industrial operations at the same time also to reduce 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 measure and lay the basis for larger interventions requiring substantial investments.

The companies chosen for RECP audits in Vapi are from the 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 Micas Organics Ltd. is part of the pigment industry located at the GIDC Industrial Estate Vapi. The management of Micas Organics Ltd. invited the consultant team to undertake energy and water use audits in order to improve the firm’s performance in these fields.

With the help of thermographic mapping, the consultants identified thermal hotspots where heat is lost in the steam distribution system of the plant. It was found that the insulation on the steam pipelines was broken at several places and some parts along the pipelines were not insulated at all. The consultants, hence, suggested to repair the damaged parts of the insulation and insulate parts not covered. The thermographic and visual images were taken clearly showed heat loss ranging between 90°C to 135°C.

A positive effect of insulation was the decrease in room temperature leading to more favourable working conditions for employees at the plant. Also, the risk of fire hazards has been reduced through the measure since electrical wires are no longer running in parallel to the steam line with damaged insulation.

Problems identified

Solutions

Costs

Results

Damaged insulation and uninsulated parts of steam pipelines.

Repair damaged insulation parts and insulate uninsulated parts along the steam pipelines


Repair leaking joints and insulate economizer, replacement of faulty steam traps and recovery of blow-down and cooling water

 Low Cost Lower energy input for boiler fuel leading to energy savings. Savings are yet to be quantified.

Improved insulation leads to lower temperature at the workplace, thusly improving working conditions.

Boiler steam was not optimised; many steam traps were faulty resulting in continuous leakage of steam and condensed water

Repair of leaking joints and insulation of economizer


Replacement of faulty steam traps


Recovery of blow-down and cooling water

 Low Cost Lower energy input for boiler fuel leading to energy savings. Savings are yet to be quantified.

Improved insulation leads to lower temperature at the workplace, thusly improving working conditions.

Total Cost:

1,50,000 INR

Total Savings:

6,66,000 INR

Estimated payback period:

12 - 14 months

The success – The benefits!

The implemented measures did not require sophisticated technology or large investment but led to significant energy and cost savings in the plant where they were implemented. Apart from achieving economic savings, the intervention of the consultant teams opened the eyes of manager and technical personnel regarding the potential that lies in efficient and cleaner production opening the doors for further improvements in the companies.

At Micas Organics, the company management has planned the systematic improvement of the boiler area including the repair of faulty steam traps, the repair and insulation of the economizer, the improvement of steam distribution in the reactors, and the recovery of cooling and blow-down water.

 

“The GIZ and adelphi team got associated with Micas Organics Ltd, Unit 1 for the last three months in which they had made a number of visits to our plant to identify the potentials to save energy and water in our plant. They have conducted audits and listed the potential areas where energy and water savings can be done. The company management had implemented insulation of steam pipelines which are identified by the project team. It is a low-cost saving project and was implemented within 1 ½ months after the audit. Micas Organics Ltd. is very happy. We are thankful to the team for helping us to save the energy.”

Mr. Jignesh Oza (Manager-Safety)

 

 

 
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