Diomande Mamery, Ivory Coast Sari Murni, Indonesia Samuel Rajkumar, India RamaChandran, India
Chennai-April 2005
1 EXECUTIVE SUMMARY With current trends in population growth and industrialization, wastes and pollutants are released faster than the earth can absorb them, and natural resources are consumed faster than it can be restored. If sustainable development is to be achieved, production processes, products and services have to be reoriented towards new patterns in order to alleviate environmental stress and bring better industrial productivity. It is in this perspective, a new concept - Cleaner Production Technology -was proposed and advocated. It is a pro-active and integrated solution to pollution problems by eliminating or reducing pollutants at the source during the course of production processes. By considering this issue and as a part of the Technology and Sustainable Development program, a team consisting of four members, have worked from 15th March to 15th April 2005 with TVS-Sundram Fastener Limited, Padi, located in Thiruvallur District on the theme Cleaner Production Technology. Sundram Fastener limited belongs to the TVS Group and it is first company in India to get ISO 9001. This company has shown lot of interest in environmental protection and its improvement. In view of this, the company has been chosen for this project and during one-month field visit, the two indispensable areas of cleaner production Technology - the Environment and Energy have been focussed. In these areas data have been collected, the process have been studied in detail and suitable cleaner technologies have been offered to improve the process and thereby the waste generation in the following areas have been minimized. ENVIRONMENT In the coolant management, recycling techniques for cutting oil and demineralised water instead of tap water for water-soluble oil have been suggested to improve the durability. In the electroplating process, reduction in the water usage, improvement in the process, process modification using new solution, spent acid reuse have been suggested. In the Effluent Treatment Plants, reduction in acid usage, reuse of sludge as filler material in the fertilizer plant, introduction of panchyakavya liquid in the 2 sewage treatment plant for improving the performance of the treatment plant have been suggested. ENERGY In the energy sector, generation of Bio gas from kitchen waste, using solar energy for street lighting and recovery of waste heat to reuse the same for pre washing and furnace pre heating have been suggested Cost benefit analysis have been calculated for each suggested technologies.
ACKNOWLEDGEMENT It is time for the closure of the successful course on TSD, and it is with heartfelt thoughts we sit down to write this acknowledgement. Before we proceed to think of the Success 3 of this course we are highly pleased to express our immense gratitude to our Course Directors Prof S.Mohan and Prof Musy who have sowed the seed for its fruitful thought of this course that has strengthened our technical capability on Sustainability Development. One month has passed since we first met, what was going to be our group project entitled Cleaner Production Technology. Little did we know how fun, interesting and challenging being a part of a field project would be? For such an experience to be possible, however, we need to be surrounded by people that have the ability to inspire, listen, and give advice and share of their time. One such person to whom we are particularly thankful to Mr P. Ramasubramanian shortly called PRS, Senior Manager, SFL Padi, with his knowledge, kindness, consideration and support, he has created an environment that has truly encouraging our team members to proceed in a proper direction on our field work. We are also grateful for all the opportunities he has made possible for us to meet interesting people in SFL. Our Sincere thanks goes to the following SFL personnel for their constant encouragement and support during our study: - Mr.S. Ramasubramanian-Senior General Manager- Business Strategy and System, - V.M.Ravikumar Assistant General Manager-Personnel - Mr. S. Durairajan Senior Executive- Maintenance We are pleased to submit our gratitude to Dr.V. Ravichandran Enviro Energy System, Chennai for his technical support and invaluable advice.
Diomande Mamery, RamaChandran, Sari Murni, Samuel Rajkumar
Table of content
EXECUTIVE SUMMARY i 4 ACKNOWLEGEMENT ii
I. INTRODUCTION 1.1 PREAMBLE 1 1.2 OBJ ECTIVES OF THE PROJ ECT 3 1.3 SCOPE OF THE PROJ ECT 2. CLEANER PRODUCTION TECHNOLOGY 5 2.1 CONCEPT OF CLEANER PRODUCTION 5 2.2 CLEANER PRODUCTION: A WIN-WIN SITUATION 5 2.3 CLEANCONCEPTS CLOSED TO CP 6 2.4 CLEANER PRODUCTION AND SUSTAINABLE DEVELOPMENT 7 3. PROCESS INDUSTRY DETAILS 7 3.1 SUNDRAM FASTENERS LIMITED 7 3.2 PRODUCTS 8 3.3 MANUFACTURING PROCESS IN TVS 9 3.4 CLEANER PRODUCTION INITIATIVES 11 4. COOLANT MANAGEMENT 12 4.1 INTRODUCTION 12 4.2 COOLANT AND ITS USE 12 4.3 HOW DOES COOLANT WORK? 12 4.4 COOLANT FUNCTIONS 13 4.5 METAL WORKING FLUIDS TYPES 13 4.6 COOLANT CONSUMPTION 14 4.7 CRITERIA FOR COOLANT OIL SELECTION 14 4.8 PRESENT SCENARIO 14 4.9 CLEANER PRODUCTION PROGRAMME 15 5. ELECTROPLATING PROCESS 20 5.1 INTRODUCTION 20 5.2 SFL PLATING PROCESS 20 5.3 ELECTROPLATING PROCESS DESCRIPTION 20 5 6. EFFLUENT TREATMENTS 32 6.1 INTRODUCTION 32 6.2 ORIGIN AND SOURCES OF WASTEWATER 32 6.3 EFFLUENT TREATMENT PLANT 33 7. ENERGY 41 7.1 INTRODUCTION 41 7.2 SOURCES OF ENERGY IN THE COMPANY 43 7.3 ENERGY CONSERVATION 47 CONCLUSION 55 REFERENCES LIST OF FIGURES/TABLES ANNEXURE GLOSSARY 6
CONCLUSIONS
Industries have always been a major contribution to the wealth and well being of people, despite the fact that it is also considered a source of environmental problems. However a major achievement of the Rio Summit was the realization that environment and development are inseparable and that industry is an important contributor to development. The need for preventive approaches to industrial pollution has been recognized and cleaner production is now seen as one of the central tool for industry to achieve environmental improvements while remaining competitive and profitable. The need for this approach is particularly great in small-and medium-sized enterprises whose cumulative impact on the environment is often greater than that of large-scale incidents. In this context, a medium scale industry, Sundram Fastener limited belonging to the TVS Group has been subjected to the study as part of the Technology and Sustainable Development program, on the theme Cleaner Production Technology. In this study, two major areas have been focussed 1) Energy and 2) Environment. In these areas, data have been collected, processed and studied in detail and suitable cleaner technologies have been suggested to improve the process and thereby minimize the waste generation in the following areas In the coolant management, In the electroplating process, In the Effluent Treatment Plants, In the energy sector. In addition, the Cost benefit analysis have also been calculated for each suggested technologies. The above cleaner production technology study in Sundram Fastener limited points out many suggestions that could be used not only for the economic benefits of the industry but also for the major environmental benefits leading to the sustainable development. of our country.
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GLOSSARY OF TERMS
Additive Sulfur, chlorine, and other materials added to cutting fluids to improve lubricity, stabilize oil emulsions and prevent chip welding under high heat and pressure
Biocide An EPA registered product added to metal working to inhibit the growth of bacteria, fungi and molds
BOD Biochemical oxygen demand of water: a measure of the oxygen required by bacteria for oxidation of the soluble organic matter under controlled test conditions.
COD Chemicals oxygen demands: a measure of organic matter and other reducing substances in water.
Coolant Fluid that reduces temperature buildup at the tool/work piece interface during machining
Cutting Fluid Liquid used to improve two-piece machinability, enhance tool life, flush out chips and machining debris, and cool the work piece and tool. Three basic types are: straight oils, soluble oils, which emulsify in water; and synthetic fluids, which are water-based chemicals solutions having no oil. Each category often exhibits some properties of the other.
Deionization Removal of ions from a water-based solution
Educator A simple chemical/water proportioning device that operates based on a pressure drop across orifice.
Hazardous A chemical that has a negative affect on the environment or poses a threat to human health
Lubricant Substance that reduces friction between moving machine parts. Can be liquid (hydrocarbon oil), solid (grease), or gaseous (air). Important characteristics are to prevent metal-to metal contact between moving surfaces, be a cooling medium, and protect surfaces from rust and corrosion
Swarf Metal fines and grinding wheel particles generated during grinding
Tramp Oil Oil that is present in a metalworking fluid and is not from the product concentrate. The usual sources are machine tool lubrication systems and leaks
Waste An unwanted by-product of a manufacturing process. 8
List of Figures Figure 3.1 The range of SFL products Figure 3.2 Differentiation of SFL products Figure 3.2 Process Flow Chart Figure 4.1 Average Coolant Consumption per month Figure 4.2 The Flow Chart of the Proposed on site Recycling Unit Figure 4.3 Eductor Proportioning Device Figure 5.1 Electroplating Process Figure 5.2 Existing Continuous Rinse System Figure 5.3 Proposed Counter Current Rinse Systems Figure 5.4 Spray System Equipment Figure 7-1. Variable and Fixed Power Usages in SFL Figure 7-2 Consumption of Variable Power Figure 7-3. Consumption of Variable Power in the HT Plant Figure 7-4. Consumption of Fixed Power Figure 7.5. Methodology of Energy Saving Figure 7.6 Arrangement of Biogas and LPG after the Project is Implemented Figure 7.8 Waste Heat Recovering unit for the Pre-washing Unit Figure 7.7 Waste Heat Recovering Unit for the Preheated Combustion Air
9 List of Tables
Table 4.1 Types of Metalworking Fluids Table 4.2 Existing Coolant Maintenance Activities Table 4.3 Economic Analysis of on site Recycling Coolant Table 4.4 The Economic Analysis due to Extend Water Soluble Coolant Life Table 5.1 Economic Benefits due to Reduction in Water Consumption Table 5.2 Economic Benefits due to Process Modification Table 6.1 Economic Benefit of Spent Acid Usage Table 6.2 Economic Benefit due to Acid Reduction Table 6.3 Report of Analysis of Sewage Effluent Table 6.4 Economic Benefit of Sludge Disposal Table 7.1 Consumption of LPG Table 7.2 Consumption of LDO Table 7.3 Consumption of DO Table 7.4 Financial Analysis of the Biogas Project Table 7.5 Economic Analysis of Solar Bulbs Lighting Table 7.6 Economic Analysis Recovery Heat Project Table 7.7 Economic Analysis of the Heat Recovering for the Pre-washing Unit project Table 7.8 Table Total Electricity Saving Table 7.9 Table total fuel saving
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REFERENCES
1. Cleaner Technologies Issues and Options (1996), Information Manual on Pollution Abatement & Cleaner Technologies Series, Central Pollution Control Board, Delhi,
2. Edwards, H. W, Kostrzewa, M. F, (1998) Combined Pollution Prevention Assessments, 91st Annual Meeting and Exhibition, Air & Waste Management Association 98-MP13B.02, 3. Edwards, H. W, Kostrzewa, M. F, (1994) Combining Pollution Prevention and Energy Conservation at Small Manufacturing Plants, 87th Annual Meeting & Exhibition, Air & Waste Management Association, 94-RP137.04, 4. Edwards, H. W, Kostrzewa, M. F, (1993) Pollution Prevention at Small Manufacturing Plants, 86th Annual Meeting & Exhibition, Air & Waste Management Association, Paper No. 93-WA-87.07, 5. Edwards, H. W.; Kostrzewa, M. F, and Ketzenberger, C. K, (1999) Pollution Prevention Through Productivity Improvement, Paper No. 99-151, 92nd Annual Meeting & Exhibition, Air & Waste Management Association. 6. Environmental Management in Electroplating Industries (1996), Training Manual, Anna University & Tamil Nadu Pollution Control Board, Chennai, 2004, Terminal Report, UNIDO & Central Leather Research Institute, 7. Extending the life of Metal Working Fluids (1993), Ohio EPA Fact Sheet - Number 11, Pollution Prevention Section, Ohio Environmental Protection Agency, 1993 8. Freeman, H. M. Industrial Pollution Prevention Handbook, and McGraw-Hill: New York, 1995. 9. Gimbel, Bill, Benefit of Continuous Fluid Clarification, BAzell Technologies Corporation, Concord, USA
10. Higgins, T. E, (1995) Pollution Prevention Handbook, CRC Lewis: Boca Raton,. 11. Higgins, T. E, (1995) Pollution Prevention Handbook, CRC Lewis: Boca Raton,. 12. Muller, M. R, Briggs, D, Kasten, D; Comer, K, Simek, M.; Tierney, C.; Garcia, G, (1996) Industrial Productivity Training Manual, Rutgers, State University of New J ersey: New Brunswick,. 13. Keshav, A.M, (1986) Environmental Audit, An In-Depth Guide to Rule 14 of the Environment Act, Media Enviro, 14. Long, B.L, Cleaner Production in OECD Countries (1994), Industry and Environment Volume 17 No.14, p 23-27, UNEP Publication, Paris, Monga, G,S, 11 Environment and Development (2003), Deep & Deep Publications PVT Ltd, New Delhi, 15. National Renewable Energy Laboratory (1994), DSM Pocket Guidebook, Volume 4: Industrial Technologies, prepared for U.S. Department of Energy and Western Area Power Administration, 16. Pachauri,R.K, (1990) Energy Efficiency and Conservation in India, Indutry and Environment Volume 13 p.19-24, UNEP Publication, 17. Scoullos, M.J , (1990) Energy Conservation and Efficiency: a Safe response to Global Warming and Other Environmental Problems, Industry and Environment Volume 13 p.6-8, UNEP Publication, Paris,
18. Shop Guide to Reduce the Waste of Metalworking Fluids (1997) A Competitive Advantage Manual for the Metal Fabricating and Machining Industry, Institute of Advanced Manufacturing Sciences and Waste Reduction and Technology Transfer Foundation,
19. Ten Ways to Reduce Machine Coolant Costs (1994), Environmental Services Division, State of Michigan, Departements of Commerce and Natural Resources, 20. U.S. Environmental Protection Agency (1994), Air and Radiation Division, Green Lights Update,EPA 430-N-94-006, USEPA, Washington, DC, 21. Wang,,L.K; Hung, Y;Lo Howard; Yapijakis, (2004) C, Handbook of Industrial and Hazardous Waste Treatment, Second Edition, Revised and Expanded, Marcel Dekker,Inc, New York,
Coolant oil consumption (liter) Machine Oil Name Tank Capaci ty (lt) Average Consump /month(lt) Oil Change Frequency Average Consump/ 4 months (lt) Price/lt (Rs) Total price 1000LS Muses 35 500 1035 15 days once 4140 35.84 148378 1012BM Muses 35 500 635 3 months once 1810 35.84 64870.4 PH Muses 35 400 780 3 months once 3080 35.84 110387 3/8 BM Muses 35 180 180 3 months once 1080 35.84 38707.2 10L4 Muses 35 250 260 1 months once 1040 35.84 37273.6 56 HEADER Muses 35 100 100 3 months once 600 35.84 21504 S2 BM Muses 35 80 20 1 months once 400 35.84 14336 SACMA Muses 35 300 490 1 months once 1960 35.84 70246.4 8S3 BM Muses 35 200 420 1 months once 1680 35.84 60211.2 H36 T/R Muses 35 100 150 4 months once 700 35.84 25088 H 24 T/R Muses 35 210 30 4 months once 330 35.84 11827.2 WMW T/R Muses 35 200 40 4 months once 360 35.84 12902.4 LANDIS T/R Muses 35 130 110 4 months once 570 35.84 20428.8 T- SUGAMI Muses 35 180 50 4 months once 380 35.84 13619.2 S3 PH Chemlub e R 150 300 280 4 months once 1020 34.39 35077.8 S3 BM Soluble S50 180 15 1 month once 780 61.97 48336.6 CFTR Vesta 51- 10 160 270 3 months once 760 31.16 23681.6 SASPI T/R I Vesta 51- 10 150 210 3 months once 580 31.16 18072.8 SASPI T/R II Vesta 51- 10 180 10 3 months once 400 31.16 12464 W P 803 T/R Vesta 51- 10 300 440 3 months once 1040 31.16 32406.4 Total 5525 22710 819818 Source: Sundaram Fasteners Limited (SLP SR)
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ANNEXURE 2 . Average Coolant Kool-Cut Consumption
Machine Oil Name Tank Capacity (lt) Consump/month (lt) Oil Changing frequency Consump/4 months (lt) oil Price/lt (Rs) Water price/lt (Rs) Total price Gringhilli CLess Grinder Kool Cut - 40 200 800 Weekly 12800 48.83 0.4 62502.76 Russian C Less Grinder Kool Cut 40 280 1020 Weekly 16320 48.83 0.4 79690.92 WMW C Less Grinder Kool Cut 40 300 1200 Weekly 19200 48.83 0.4 93753.96 Nissin C Less Grinder 64.12 Kool Cut 40 300 1200 Weekly 19200 48.83 0.4 93753.96 Nissin C Less Grinder 64.11 Kool Cut 40 200 800 Weekly 12800 48.83 0.4 62502.76 Takasiwa - I Kool Cut 40 200 800 Weekly 12800 48.83 0.4 62502.76 Takasiwa II Kool Cut 40 200 800 Weekly 12800 48.83 0.4 62502.76 Hunger Lathe Kool Cut 40 80 320 Weekly 5120 48.83 0.4 25001.32 NCM 20 Kool Cut 40 70 280 Weekly 4480 48.83 0.4 21876.2 Ecoster Kool Cut - 40 80 320 Weekly 5120 48.83 0.4 25001.32 Total 7540 120640 589088.72 Source: Sundaram Fasteners Limited (SLP SR)
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ANNEXURE 3. Energy saving projects handled in SFL from 2002-2005
POTENTIAL SAVINGS Proposal / Action plan Qtity Units / month Rs. in lakhs /month Replacing 40 W conventional tube lights to Energy saving 28W E+lamps (Savings/lamp=5.1 units per month) 200 1020 0.046 Installation of energy saver in LDB of Main plant and Tool room (savings=25% in current consumption) 1 200 0.009 Installation of energy saver in LDB of WDP (savings=25% in current consumption) 1 150 0.007 Installation of automatic power factor controller in SB4, SB14 and SB9(savings =30units/Hr) 3 15000 0.669 Installation of automatic power factor controller in UMB and HDWD(savings = 15units/Hr) 2 7500 0.335 Installation of Energy savers for fume exhausts of forging machines(savings= 10units/hr) 5 5000 0.223 Interlocking of machine accessories with main motor to eliminate idle running 4500 0.201 Switching over from contactor control to thyristor control in Endo panels 1 3600 0.161 Installation of energy saver in LDB of WDP (savings=25% in current consumption) 1 150 0.007 Installing AC variable speed drives for main motors of grinding machines 2 4800 0.214 Usage of Energy efficient motors for Hydraulics of all rolling machines (savings = 7.5units/Hr) 6 3750 0.167 Use of energy efficient Air Conditioners 10 1430 0.060 Total savings 64100 2.858 Source: Sundaram Fasteners Limited (SLP SR)
