Sustainability & Responsible Care - Heubach India & Responsible Care ... • In the Blue Pthalocynine plant, urea consumption has ... -Heubach won the award for the World’s Best

Presentation

Sustainability & Responsible Care

Heubach Colour Pvt. Ltd.

Heubach Unit- I, Ankleshwar 1993



Not a Resort ! But a Pigment Plant, Unit- I, Ankleshwar

Heubach Unit- II, Ankleshwar 2013

Heubach Unit- III, Ankleshwar 2005

Heubach Unit- III, Ankleshwar

• More than 50,000 trees have been planted

at our production sites.

• Multi canopy foliage has been

planned and implemented.

• Kitchen garden to grow vegetables to

be used by our cafeteria.

• The biodiversity of the birds visiting our

sites has increased from 2 to 36 species.

• Rain water harvesting has been

implemented to conserve water.

• Vermiculture has been introduced to

recycle organic & kitchen waste.

Heubach from “1995 to 2012” : Biodiversity

Heubach Is the first pigment company in India to be awarded the

Responsible Care certification. This initiative has played an

integral role in the sustainable development of Heubach.

The six Responsible Care codes are an important aspect of our work

culture and we strive to ensure they are implemented at every level at

Heubach.

The six codes are:

1. Process Safety

2. Employee Health & Safety

3. Pollution Prevention

4. Emergency Response

5. Distribution

6. Product Stewardship

Heubach and Responsible Care

• HAZOP study is mandatory for all new projects and risk analysis are

carried out on existing projects .

• Multilayer protection in critical processes, viz., alarm system, sensors,

safety valves, rupture disc, flame arrestors, nitrogen blanketing, steam

purging, emergency scrubber systems, installed at appropriate places.

• Electrostatic earthing continuity is tested and recorded periodically.

• Hazard Identification & Risk Assessment is carried out for all processes.

• Continual improvement in process and technology.

• Training of man power.

• Critical processes are covered under a comprehensive emergency plan.

• P&I diagram is reviewed and updated from time to time.

• PLC systems have been installed for monitoring and control of processes.

1. Process Safety

Chlorine Shed

Caustic

Emergency

Tank

Water Curtain for

Emergency

control system- Vapour

on-off valve (work on pressure)

PRV

Safety Valve

Pressure Transmitter

Cl tonner vapouri

ser

emergency

hood

Plant Use

1st satge

scrubber

1st satge

scrubber

Stage

Stage

• Multilayer protection given to critical

processes like, chlorination,

bromination and handling of

hydrogen sulphide gas.

• Emergency preparedness plan is

rehearsed regularly.

• Monitoring of critical processes is

established and Incident / Accident

records are maintained for further

improvement.

1. Process Safety

• Free medical insurance for all employees and their families.

• Pre-employment medical check-up.

• Annual comprehensive medical tests.

• Free healthy wholesome cooked meals for all employees of Heubach.

• Social programs for providing free meals to all persons including non Heubach

personnel



Hazard Communication.


Safety instructions displayed at various locations.


Culture of “Safety First” is drilled into every operation at Heubach.


Participation in Safety Road Shows

• We integrate Sustainability and Green Chemistry in every aspect of our

business.

• Heubach is committed to ensure our production sites and products

adhere to the highest environmental regulations.

• Heubach practices a ‘Cradle to Grave’ approach in the production and

management of its resources.

• We look to future growth with sustainability forming the backbone of our

strategy.


Sustainability


• Process optimization for waste minimization

• Process improvement to yield better conversion

• State of the art technology for solvent recovery

• Ammonia Recovery Plant

• Ammonia Stripping Plant

• Aluminium Hydroxide Plant

• Copper Recovery Facility

• Natural gas used in key equipment to reduce emissions

• Waste Management :

- Granular Activated Carbon Treatment Facility

- Plastic and Hazardous waste recycling


Crude Blue Production

• In the Blue Pthalocynine plant, urea consumption has been reduced by 31%

through process modifications.

• Ammonium carbonate consumption has been reduced by 40% in the process.

• Heubach has invested in new technology for

pthalocynanine blue production to erect a

5000 ton per annum plant.

• The acid utilized in crude blue production is

recycled.


Ammonium Recovery Plant

Ammonia Stripping & Recovery Plant CPC Blue Manufacturing

• Recovery of useful products from the waste rather than end-of-the pipeline treatment

approach

• Ammonium Carbonate solution gets

generated from CPC Blue synthesis

• Principle: Scrubbed ammonium carbonate

solution is reacted with caustic to strip off

ammonia which is absorbed in water to

produce 24% aqueous ammonia


Ammonia Stripping Plant

ALUMINIUM HYDROXIDE PLANT –

AERIAL VIEW


Process Optimization Aluminum Chloride Reduction

• In 2000 Heubach adopted Technology in which Aluminium Chloride

consumption was reduced by 20%.

• Reduction of AlCl3 consumption saved raw material & also reduced

sludge generation.

• At Heubach waste stream from Green (Aluminium Chloride Solution) is converted to

pharma grade Aluminium Hydroxide.

• Before Aluminium Hydroxide manufacturing facility

- One ton of CPC Green generates 13 tons of Sludge.

- 3000 tons of CPC Green would generate 39000 tons of Sludge

• After Alumininum Hydroxide manufacturing facility

- One ton of CPC Green generates 3.25 ton of Sludge.

- Sludge Reduction is 75% (9.75 ton per ton of CPC Green).

Thus the Sludge Reduction is 30000 tons per annum !

Waste Minimization Initiative

Aluminum Hydroxide Facility


Copper Recovery Facility

CPC Green

Manufacturing

Aluminum Chloride

Solution

Copper Removal &

Purification

Purified Aluminum

Chloride Solution

Copper

(For Sale)

Ammonium Carbonate

Solution

Ammonium

Recovery Plant

By Product

Aluminum Hydroxide

Plant

CPC Blue

Synthesis

Pharma Grade Aluminum

Hydroxide

Cement

Manufacturing

Gypsum

Filtration

Stripping

Ammonical Nitrogen

Contained Stream

NH3 Gas

24% Aqueous

Ammonia

(For Sale)

Integrated Waste Management

3. Pollution Prevention-Waste Management

Granular Activated Carbon (GAC) at Effluent Treatment Plant

• GAC is an important option in wastewater treatment processes for

the removal of refractory organics.

• GAC is a reliable and an environment friendly solution.

• Widely used in Europe & US as tertiary treatment for Effluent.

• Heubach utilizes the GAC tertiary treatment to reduce

the amount of contaminant in the effluents.


• Waste Minimization Initiative Reduction in hazardous

waste packaging materials by 80%.

• Recycling of plastic drums and reduction of disposal of plastic waste



Periodic Emergency Drill Rehearsal


Emergency Handling Drill


Environment Monitoring

5. Distribution

• Heubach ensures all its raw material vendors meet the highest safety and

environmental standards.

• Key vendors are audited from time to time for compliance of safety measures.

• Heubach follows safe procedures for unloading and loading raw material and

products in its carriers.

• All products are packed and transported in

the most environmentally sustainable methods.

6. Product Stewardship

• Heubach performs a Life Cycle Analysis on all its products.

• We Implemented global harmonized system compliant safety data sheets to give

proper health and environmental information.

• We offer universal quality standards for overseas and domestic market.

• Detailed toxicological studies are conducted before releasing products in market.

• Awareness programs for all stake holders in the supply chain of the product

Dioxin Testing Lab

• The Dioxin testing facility of Heubach India is the first in India and has

now been authorized to test samples on commercial basis for outside parties.

• Dioxin facility is accredited by NABL (National Accreditation Board for Testing and

Calibration Laboratories)

Corporate Sustainability

HEUBACH and Ecological & Toxicological Association of

Dyes and Organic Pigments Manufacturers (ETAD)

• Heubach is an active member in the ETAD consortium.

• ETAD aims at ensuring all its members maintain environmentally sustainable

practices in day to day business activities.

• Heubach is proactive in its efforts and helps organize seminars related to product

safety and toxicology all over the world.

• ETAD’s policy on waste management and product safety is used as a platform for

all our business decisions.

HEUBACH and Indian Chemical Council

• Heubach is an active member of Indian Chemical Council.

• Through ICC meetings and seminars Heubach is an active player in the

propagation of Responsible Care.

• Heubach has also helped organize the first help desk on Chemical weapons

convention.

• Heubach plays a key role in organizing round tables on waste management and

green chemistry.

Corporate Sustainability

Community Impact

School adopted by the company.

Community Impact

Earthquake Relief fund raising

Community Impact

Regular financial support to the local hospital

The top managers at Heubach are encouraged to attend seminars on safety,

Responsible Care and waste management across the globe.

The Managing Director Mr. Ravi Kapoor, has a number of leader ship positions in

organizations promoting sustainability such as:

• Chairman of the Indian Chemical Council, Gujarat and is on the National Executive Board.

• President of the “Ecological and Toxicological Association of Dyes and Organic Pigment

Manufacturers” (ETAD); a global organization based in Basel.

• Member of Responsible Care Leadership Group (RCLG)- Core Committee

• Member of Managing Committee of the “Heritage Trust”, which looks after interests of

heritage structures including the famous “Champaner”, a World Heritage site.

Leadership at Heubach

Continued from previous page, Mr. Kapoor Leadership positions

• Head of the Plastics, Chemicals, Petrochemicals, Environment and Climate

Change Committee – Federation of Gujarat Industries

• Member in Sectoral Innovation Council for Chemicals & Petrochemicals sector –

‘Decade of Innovation’ with a focus on inclusive growth – Govt. of India

• Board of Directors at Narmada Clean Tech Ltd. (A subsidiary of GIDC) as

Govt. of Gujarat nominee

• A number of presentations given at:

- Dyes Manufacturers Association of India

- Organization for prevention of Chemical Weapons ,The Hague UN

- India-Chem at Federation of Indian Chambers of Commerce and Industry (FICCI)


Awards and Accolades

• Heubach Colour Pvt. Ltd. has won a number awards for their efforts related to

sustainability and green chemistry such as:

- Rotary Club of Ankleshwar awarded Heubach the “Safety and Environment

Shield” in 1996.

- Disaster Prevention Management Center, Ankleshwar appreciated the high

standards at Heubach, Ankleshwar by awarding “Certificate of Appreciation

for Good House Keeping” in the year 2000.

- Heubach won the award for the World’s Best Run Power Plant by the Diesel

and Gas Turbine Magazine in February 2003.

- The Federation of Gujarat Industries in 2011 awarded Heubach the

Certificate of Excellence in “Environment Pollution Abatement and

Preservation"






Heubach Unit- I, Ankleshwar

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Sustainability & Responsible Care - Heubach India & Responsible Care ... • In the Blue Pthalocynine plant, urea consumption has ... -Heubach won the award for the World’s Best