Company

A small scale pharmaceutical unit in Gujarat. The unit is manufacturing Mebendazole which is consumed as Anthelmintic drug.

After the meeting with the representatives of Gujarat Cleaner Production Centre, the industry came forward for CP-Exercise.

Process

Nitro Chlore Benzo Phenone obtained by the aryalation of Nitro Chloro Benzoic Acid undergoes amination and reduction to form 3,4,Diamino Benzophenone. Then it is condensed with adduct to form Mebendazole

CP-Programme

AAfter 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.

CP-Results

• Thermic Fluid boiler and Steam boiler (single pass) were the two boilers using for getting the temperature of 1600C. There were several reasons which lead to CP-option of changing boiler, like the temperature was 2630 C which was more than required, very less efficiency i.e. 65% and loss of costly high thermic oil while washing the Thermic Fluid Boiler after every 2-3 batches. A three pass, automatic boiler having super saturated heat at required temperature and imported burner with required supply oxygen was selected to install instead of those two boilers. This has given the required temperature, 20% reduction in fuel consumption, 25 % increment in Efficiency and saving of 6000 liters of water which was earlier used for washing after 2-3 days. The investment made after this implementation was Rs.9,00,000/- (one time), while they are saving Rs.1,89,000/year with reduction in effluent load.
  
  
• The Natural Draft Wooden Cooling Tower was used for Benzene and Methanol recovery before CP. A New cooling tower with exhaust fan facility with 165 TR capacity is installed, which has increased Benzene and Methanol recovery by 25% and 15% respectively. Earlier both were going to environment. This option was implemented at the cost of Rs.1,25,000(one time) which has earned Rs.3,58,800/year.
  
  
• A walk through survey of plant, show the fugitive emission of Thionyl chloride and Mebendazole. A glass lined storage vessel, metering pump and lay down glass lined pipe line and vacuum cleaner worth Rs.2, 56,000 (one time) has been installed to cope up with emission problems. This has saved Rs.10,25,000/year and increase environmental benefit in terms of dusting & workers safety as well.
  
  
• An installation of chilling plant has been suggested as CP-option with the purpose of recovery of Benzene and Methanol and saving of power. Rs.10,00,000 is invested for that which gives savings of Rs.23,57,756 (pay back period six months). Also it has reduced Effluent load.
  
  
• By changing the scrubbing media, the industry is now able to scrub the flue gas initially it was done with chilled water and then with caustic slurry. This option has reduced the amount of unscrubbed flue gases of SO2 and HCl in to atmosphere. This is possible without investment with savings of Rs.2,30,400.
  
  
• The segregation of valuable By-product called Aluminum chloride/Aluminum hydroxide from waste stream lead to saving of Rs.10, 00,000 without making any investment.
  
  
• Earlier the waste stream contained excess quantity of adducts, Acetic acid, Methyl Chloro Formate and EDTA. An appropriate quantity of several raw materials was decided after the material balance was successfully carried out in the industry. A tremendous amount of Rs.1.33 Crores has been saved without any investment.
  
  
• A successful implementation of CP-tools has opened new doors for the industry like the company is going for FDA (USA) permission for certain products and also company is doing expansion.
  

Summary:- Economical benefits Investment : Rs.25,05,000(one time) Saving : Rs.1, 98,00,000/year Environmental benefits Reduction in fugitive emission of Thionyl chloride, Methyl chloro format. Better recovery process of Benzene, Methanol, SO2, HCl which were earlier added to the environment. Savings of around 2400 KL Water Reduction in COD,TDS and effluent quantity. Improvement in Working Environment.