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Atul Limited
UNIT PROFILE :-
Atul Limited is one of the leading manufacturers of over 500 products including
agrochemicals, Bulk Chemicals, Bulk drugs & bulk drug intermediates, Cresols & cresol
derivatives, Dyes & dye intermediates, Epoxy resins & epoxy hardeners, Formaldehyde,
Speciality chemicals and Wood adhesives. Atul Limited ( formerly Atul Products Ltd) was
established in 1947 on the banks of river Par in Valsad district of Gujarat 200 km north of
Mumbai, stretching over in 1300 acres area.
[2] ENERGY CONSUMPTION :-
Atul Limited Consumes Energy in the form of Coal, Fuel oils and Electricity both purchased
and Generated. Atul Limited consumed 1519.94 lac kWh electrical energy and 543463
million kCal thermal energy during 2001-02.
[3] ENERGY CONSERVATION COMMITMENT, POLICY AND SET-UP :-
Atul Limited has six strategic business units:-
3.1 Agrochemicals
3.2 Aromatics
3.3 Bulk Chemicals & Intermediates
3.4 Colors
3.5 Pharmaceuticals
3.6 Polymers
With Technology Unit at corporate level. Each business unit has energy conservation team
headed by Vice President (Technology). The team members are from various disciplines.
The Energy Conservation activities are basically divided into three parts and given prime
importance since 1990.
(a) Energy Audit :-
The team conducts the Energy Audit of each plant once a year and identifies the
areas of improvement.
(b) Implementation of Energy Conservation Measures :-
The team prepares feasibility reports of various proposals identified during the
plant Energy Audits. The team monitors the implementation of such proposals by
respective units.
(c) Awareness among the employees :-
The team organises seminars, lectures, video shows, competitions, display
stickers, banners, posters, etc. and distribute booklets to all employees to bring
awareness among the employees and their family members.
[4] ENERGY CONSERVATION ACHIEVEMENTS :-
Various energy conservation schemes have been implemented major of which are
highlighted herebelow
1. Installing of Natural Gas Engine based Cogeneration Set.
2. Modified PCD purification process from steam distillation to Vacuum distillation.
3. Use of energy efficient agitator inplace of conventional agitators.
4. Installing of molten sulphur filters in sulphuric acid plant to prevent pressure drops in SO3
gas stream due to ash.
5. Heat Recovery from Sulphuric Acid plant and using for SO3 generation inplace of steam.
6. Converting HSD fired DG Set to Dual fuel fired unit to operate on a combination of HSD
and Natural Gas
7. Modification of process of product extraction from Nitrobenzene by using RVD
instead of steam distillation filtration and drying.
8. Installation of PSA based nitrogen plant inplace of LDO Fired plant.
9. Installing of Variable frequency drive on Blackley mills
10. Installation of Induced draft counter flow cooling towers with PVC fills inplace of
forced draft cooling tower with wooden splatter plates
11. Replacing of 60 HP motors of CW pumps by 75 HP and operating two pumps
instead of three pumps earlier being operated in throttled condition to prevent
overloading.
12. Replacement of Blended lamps by CFL lamps (87 ftgs)
13. Relocating capacitor bank from distribution end to user end.
14. Replacement of old cooling water pumps by new high efficiency pumps
15. Installation of Effimax system on boilers operating on N Gas.
16. Replacing of MS tube bundle in heat exchangers by SS tube bundle to prevent
corrosion and adherence of scale.
17. Installation of Gas-O-Max on gas fired boilers.
18. Installation of gas meters in Cresol II plant to monitor and control gas consumption
in fusion units.
19. Installation of additional 400 KVAR capacitors
20. Using thermostatic steam traps inplace of TD and IB traps on steam traced and
jacketed lines.
21. Use of Perlitemp Insulation inplace of Mineral wool insulation
22. Circulating reactor mass through external heat exchangers so that cooling can be
done using cooling water instead of Chilled water.
23. Connecting underloaded motors in star.
24. Operating chilled brine plant at 0 deg C as required by the process instead of -10
deg C as was the original practice.
25. Installing of Pressure powered pump inplace of centrifugal pump for condensate
recovery
26. Adding extra nozzles in spray dryer to improve atomisation of slurry and proper
mixing with drying air to increase drying efficiency and capacity.
27. Reducing aeration time in filter press by dividing press into section and providing
two air inlets and alternating between forward and reverse aeration.
27 measures were implemented during the year resulting in annual saving of Rs 511.68
lacs against an investment of Rs 466.75 lacs. The specific electrical energy consumption
has come down from 1850.9 kWh/MT in 1999-00 to 1686.22 kWh/MT in 2001-02 whereas
specific thermal energy has reduced from 6.075 x 106 in 1999-00 to 5.617 x 106 in 2001-02.
In recognition of the commitment of the management towards Energy Conservation:
4.1 Atul Limited received The Jawaharlal Nehru Memorial Award for Energy
Conservation & Pollution Control in the year 1992-93 from International Greenland
Society.
4.2 Erstwhile Atic Industries Limited now a part of Colors Division of Atul Limited were
awarded the National Energy Conservation Award second prize in Chemical
Sector for two consecutive years 1994 and 1995.
4.3 Atul Limited was awarded the National Energy Conservation Award second prize
in Chemical Sector for the year 1996.
4.4 Atul Limited was awarded by Federation of Gujarat Industries for Excellence in
Energy Conservation for the year 1997.
4.5 Atul Limited was awarded the National Energy Conservation Award Certificate of
Merit in Chemical Sector for the year 1998.
4.6 Atul Limited was awarded ICMA Award for Excellence in Energy Conservation and
Management for the year 1998.
4.7 Atul Limited was awarded the National Energy Conservation Award second prize
in Chemical Sector for the year 2000.
4.8 Atul Limited was awarded the National Energy Conservation Award Certificate of
Merit in Chemical Sector for the year 2001.
[5] ENERGY CONSERVATION PLANS AND TARGETS :-
To improve the energy performance further and to conserve energy, the following projects
are under process :-
5.1 To modernise power plant and installation of 50 TPH AFBC boiler. Investment Rs.
2000 lac the project is in advance stage and shall be commissioned during the
current year.
5.2 Installation of second Natural Gas Engine based Cogeneration set.
5.3 Heat recovery from second Sulphuric Acid Plant and generate additional steam.
5.4 Recovery of flash steam from condensate, at higher pressure.
5.5 Modernisation of utility plants by new state of art technology, Replacing VCR by
Vapour Absorption systems, replacing old wooden splatter plate cooling tower by
energy efficient cooling towers, etc.
5.6 Conversion of Stoker bed boiler to fluid bed combustion boiler.
5.7 Further replace conventional agitators by energy efficient agitators.
5.8 Implementation of all newly developed concept such as Auto control on tray
dryers, intermittent stirring, Speed Reduction, Auto Stop of drives, Auto Control of
compressed air etc. at remaining places.
5.9 To carry out in depth process study to identify areas where process can be
modified to save energy.
[6] ENVIRONMENT AND SAFETY :-
Atul Limited has been having primary treatment facility for liquid effluent for over a decade
and has provided for secondary (Biological) and tertiary treatment using state of art
‘Degremont’ technology able to handle 20,000 M3/day. Erstwhile Atic Industries have
installed an Effluent Treatment Plant with technology from Pielkenrood Water Treatment,
Netherland of 10,000 M3/day capacity. The total investment in the ETP is around Rs. 30
crores. The treated effluents meets the specified standards and are transported in
pipelines to be discharged in zones demarcated for this purpose. Numerous scrubbing
systems and Electrostatic precipitators are an integral part of all manufacturing activities.
Analysis of vent gases and ambient air is done routinely. Organic chemical waste is
incinerated. Extensive tree plantation has been an ongoing activity in the complex. To-day
the complex has more than 3,00,000 trees.
Atul has received various awards for Safety and Award from Federation of Gujarat Industry
for Excellence in Environment Protection in 1994.