A small-scale industry, established in 1986 at Gujarat is engaged in manufacturing of Petroleum products like Petroleum Speciality Oil and Petroleum Sulphonate with an installed capacity of 250 KL/Month.

The owner of industry had attended an orientation programme conducted by Gujarat Cleaner Production Centre and decided to implement CP-tools in his industry.

Process

1. Petroleum Speciality Oil
Light Diesel oil is distilled and after removing low boiling fraction the remaining oil is given acid treatment followed by neutralization and clay treatment for color and moisture removal.

2. Petroleum Sulphonate
Aromatic alkylate is sulphonated and neutralized with caustic lye. The neutralized mass is then subjected to desalting operation to get the final product.

CP-Programme

After complete study of process as per CP-methodology potentials for CP-options were developed and evaluated afterwards. After economical and technical feasibility analysis few options were suggested to industry and the results that we got are tremendous and very valuable for industry in current situation prevailing in the Global Market. Raw material consumption and minimization of effluent quantity were decided as Audit Focus Area for the CP-options to be implemented.

CP-Results

" An acid treatment given to the reaction mass during the production of Speciality Oil, was generating huge quantity of sludge. The reaction mass was then neutralized where entrained liquid waste was generated. An addition of antioxidant was suggested in this stage as CP-option. It has almost eliminated the sludge generation and entrained liquid generation. Thus both the problems were solved with investment of Rs.75, 000 (one time) that saves Rs.50, 000/year

• To minimize the consumption of caustic and to filter the acid treated oil, a plate and frame type filter was installed. This option was implemented at the cost of Rs.50,000 (one time), which has given saving of Rs.50,000/year
  
  
• For the recovery of entrained liquid and to decrease the wastage of the product filter press of Rs. 40,000/- was installed which has given the saving of Rs.40,000/year
  
  
• Similarly, the main effluent came out from Petroleum Sulphonate production contained Spent acid, Isopropyl alcohol, Salt and Caustic. By reducing the excess addition of Sulfuric acid and caustic lead reduction in effluent quantity. This has given savings of Rs. 1,00,000 without any investment.
  
  
• In the production of Petroleum Sulphonate, earlier sulphonation was carried out with 98% sulfuric acid. Huge amount of salt formation was the drawback of this stage. After CP, the option of carrying out sulphonation with sulfur trioxide. was suggested. The results are quite interesting. Salt formation has been reduced and spent acid generation has been also eliminated. A one time investment of Rs.3, 00,000 is saving Rs.1, 00,000/year
  
  
• Use of antioxidant instead of acid treatment is useful in the neutralization to avoid gum formation. It has given saving of Rs.1,00,000/year against the investment of Rs.75,000 (one time). It has eliminated the generation of sludge.
  
  
• The use of Toluene as solvent for removal of salt is another cleaner option suggested to industry. This has totally removed the desalting operation and generation of effluent quantity. The investment of Rs.50,000 has given the saving of Rs.3,00,000

Summary:- Economical benefits Investment: Rs. 5,15,000 (one time) Saving: Rs. 7,96,000/year Environmental benefits Elimination of sludge generation. Reduction in wastage of final product Reduction in Effluent generation and spent acid generation reduced. Reduction in quantity of COD,TDS and effluent quantity.