Asia’s largest Pharma Complex - Green Business Centre

1

Asia’s largest Pharma Complex , Visakhapatnam, India

Reactor Volume

(in Lakhs Lts )Installed Capacity

(in MT) (per Annum)73.2 36,878

DD.Prasad RaoR.Appa Rao

NUMBERS SAY IT ALL

25+

years of expertise

in pharmaceuticals

Amongst the world’s

largest manufacturers of

APIs

& ARVs

30+

state-of-the-art

manufacturing facilities

Global presence

120+

countries

15,000+

employees worldwide

300+

products in portfolio

India’s

largestclosely held

pharmaceutical company

2

3

Column

ANFD

REACTOR

DISTILLED RECEIVER

ANFDML’S

RECEIVER

STORAGETANK

PHARMASTORES

Recovered Solvent

REFLUX

REBOILER

STORAGE TANK

Process ,Recovery & Reuse Integration

Source 2015-16 2016-17 2017-18

Wind Power 77190845 70173261 75324321

Co Generation 40887798 32218049 34529062

APEPDCL/OA 28567029 18758508 27115694

DG Power 1423009 812390 765031

Total 148068681 121962208 137734108

Power Consumption Scenario – In kWh

52.13%

57.54%54.69%

27.61% 26.42% 25.07%

19.29%15.38%

19.69%

0.96% 0.67% 0.56%

2015-16 2016-17 2017-18

Wind power Co-Generation APEPDCL/OA DG Power

Installed in three Locations

Wind Power Generation (Captive Power)

a) Tirumalayapalli, Kadapa, AP, 54 MW (36Nosx1.5MW)July’2013.

a) Isapur, Maharashtra31.5MW (10.5Commissioned)

5MW Solar Power Plant inMothkur , Nalgonda Dist

6

54.69%25.07%

19.69%0.56%

Power Supply (Source wise)

Wind Power Co Generation APEPDCL/OA DG Power

63.00%,

37.00%,

Power Demand

Utilities Production

Energy Mapping

7

Specific Energy Trend Over Last Three Years

44525

35054 34913

FY 2015-16 FY 2016-17 FY 2017-18

Electrical Energy/Kg of Drug

353485

322993

226995

FY 2015-16 FY 2016-17 FY 2017-18

Thermal Energy/Kg of Drug

36%22%

Refrigeration System

Description Design

Tem Mfg STD (KW/TR)

Present Operation (KW/TR)

Target (KW/TR)

Screw Compressor

+ 5°C 0.70 0.85 0.80

-5°C 1.00 1.15 1.10

-15°C 1.40 1.60 1.50

-20°C 1.55 1.80 1.75

-40°C 2.60 3.00 2.80

-70°C 5.40 6.50 6.10

Boiler Description Mfg. STD Present Operation Target

Fuel to Steam Ratio with Imported Coal (kg/kg)

4.00 4.00 4.10

Steam Condensate Recovery % 80 -90 51.00 70.00

Industrial Bench Marking of Utilities

9

AnnualEnergy Saving

kWh units 176.6Lakhs

AnnualThermalSaving (kcal)

323220Lakhs

SimplePayback

5 months

ROI 183.3 %

ENCON Projects Summary in Year 15 -16

Total Cost Saving Rs.1619.5 Lakhs

Number of ENCON Projects 29

Investment Rs.571.6 Lakhs

10

AnnualEnergy Saving


AnnualThermalSaving (kcal)52000Lakhs

SimplePayback

5 months

ROI 189%




Investment Rs.109 Lakhs

11

AnnualEnergy Saving


SimplePayback

2 monthsROI 521%




Investment Rs.44 Lakhs

12



Investment Rs.724.60 Lakhs

Total Cost Saving Rs.2209.14 Laks

AnnualEnergy Saving


AnnualThermalSaving (kcal)

375220Lakhs

SimplePayback

12 months

ROI 205%

S

No.Title of Project

Annual

Savings

in Lakhs

Invest Year

1Optimization Chilling Plants Operation - Stopping of low load running minus 5°C refrigeration systems(<60 TR)

1.7 0 2015-16

2Modification of Reactor Utility Line for increasing cooling efficiency and reducing of time cycle

0.2 0 2015-16

3Enhanced daylight usage by replacing Translucent, Strip/Roof sheets by high performance prismatic transparent sheets for roofing.

0.1 0 2015-16

4 Reduction of Drying Time by using Steam in place of Hot Water 0.3 0 2015-16

5Replacement of -40 deg C brine in place of -15 deg C brine to reduce batch time

29.4 0 2016-17

6Rectification drive on Faulty Installation of evaporative condensers

59.5 0 2016-17

7 Introducing Evaporative condenser for refrigeration systems 12.1 0 2016-17

8 Optimization of Coal handling plant operating hours. 16.0 0 2017-18

9 AHUs operation control as per demand. 50.0 0 2017-18

10Control of Air Requirement in crystallizer room by optimizing AHUs

47.0 0 2017-18

Total 10 No’s Projects 216.3

ENCON Projects Summary – Zero/Low Investment

14

S.No. Title of Project

Annual Electrical Saving,

Million Rs

Annual Thermal Saving, Million

Kcal

Total Annual Savings,

Million Rs

Investment Made

Payback

1Reduction in Power Plant Boiler DE aerator steam consumption

11037 16.8 3 2

2Reduction in steam distribution losses with steam lines temperature mapping and insulation strengthening.

13797 21 4 2

3Power Saving and Turbine loading improvement by installation of VAMs in place of +5 compressors

26.8 26.8 15.6 7

4 Optimization of Coal handling plant operating hours. 0.16 0.16 0 0

5 Installation of De super heaters for SRS - I&II 1776 2.67 1.5 7

6Increasing the utility pressure & stopped secondery pumps by optimizing the process.

9.14 9.14 0 0

7 AHUs operation control as per demand 5.04 5.05 0 0

8Control of Air requirement in crystalliser room by oprtimazing AHUs

4.69 4.69 0 0

ENCON Projects Implemented in FY-2015-16

15



Million Rs


Kcal


Million Rs

Investment Made

Payback

9installation of VFDs for cooling Tower fans & pumps

2.34 2.34 0.6 3

10 Installation of Pan Dryers in place of ANFDs 2.9 2.9 5 2111 Installation of Solar Daylighting system 0.04 0.04 0.08 27

12Turbine load improvement by Increasing the process steam line size to reduce exhaust pressure

26.1 26.1 14 6

13Optimization of RT pumps usage by operating valves.

9.35 9.35 0 0

14Control of RT water cooling tower fan based of outlet temperature & Pump running time

0.62 0.62 0 0

15Reduction of lossed in +5 chilled water line by strengthening insulation

0.93 0.93 0.5 6

16 Utilization of flash steam for MEEs in ETP 5274 7.92 0.5 1

17Installation of VFD for Desalination plant DMF feed pump

0.31 0.31 0.1 4

18Modification of reactor Scrapper to reduce cooling time

0.38 0.38 0.5 16

19Sprinkler agitator arrangement to reduce distillation time

0.06 0.06 0.1 21


16



Million Rs


Kcal


Million Rs

Investment Made

Payback

20Installation of Liquid Liquid extractor system to improve THF recovery

2.34 2.34 2 10

21Filtration of N - hexane & Acetone with Pressure in place of Vacuum

0.21 0.21 0 0

22 Batch size increase in MacDowell in I Block 0.5 0.5 0 0

23 PNG filtration with ANFD in place of Centrifuge 0.11 0.11 0 0

24Installation of VFDs for AHUs to control RPM as per requirement

2.21 2.21 2 11

25Chiller primary pump interlocking with compressor

5 5 0.2 0

26Block wise and Product Specific power consumption monitoring (Power quota fixing)

9.9 9.9 0 0

27 Installation of VFDs for Reactors 3.7 3.7 6.68 22

28Installation of Preheating condenser for Methanol distillation

438 0.66 0.5 9

29Connecting capacitors at Motor end for BFW pump and ETP agitators

0.52 0.52 0.3 7

Total 112.91 32322 161.96 57.16


17




Million Rs

Annual Thermal Saving,

Million Kcal


Million Rs

Investment Made

Payback

1 Utilization of RT water in place of +5 alcohol plant 0.95 0.95 0 0

2 Raw material lifting with Jumbo bags instead of EOT cranes. 0.264 0.264 0 0

3 Reduction of distillation operation by reduce the reactor RPM 2.64 2.64 0 0

4 Reduction of distilled time with continuous feeding of FFE 0.096 0.096 0.36 37

5 Condenser size increasing to reduce load on utilities 2.64 2.64 1.5 7

6Reduction in cycle time from 13 Hrs to 5 Hrs by increasing chilling -6 to -19

0.396 0.396 0 0

7Replacement of -40DegC -52 TR and -15 DegC 264 TR with -28DegC 298 TR

1.78 1.78 0 0

8Distillation with PAN dryer for distillation to avoid Co-Distillation

9.62 9.62 3.5 3

9installation of I save technology Desalination Plant Energy Recovery

5.5 5.5 5 11

10Installation of Flash Vessel to use flash steam in SRS - 1 & 2 and ETP

1500 2.22 0 0

11Usage of contaminate condensate water for Hot water Generation

2000 3 0.1 0

12Usage of contaminate condensate water for Hot water Generation

1700 2.5 0.5 2

Total 23.886 31.606 10.96 60

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Million Rs

Annual Thermal Saving,

Million Kcal


Million Rs

Investment Made

Pay back

1 Relocation of Capacitors from PCC End to MCC End 0.065 0 0.065 0 1

2 Agitator Design Change 1.59 0 1.59 1 8

3 Reduction of Distillation time by changing Utility 0.4 0 0.4 0.3 10

4 Installation of Leaf/Carbon Filter 0.135 0 0.135 0.1 9

5 Replacement of ANFD Bag filter with SS Sintered Candle 0.3184 0 0.3184 0.3 11

6 Installation of ATFDs 0.53 0 0.53 0.5 12

7 Installation of VFDs 2.65 0 2.65 1 5

8 Reduction in Air changes at Crystallizer Rooms 5.33 0 5.33 0.1 1

9 Clean room operation restriction 5.95 0 5.95 0.1 1

10 Switching Off the Utility Secondary Circulation pumps. 10.39 0 10.39 1 1

Total 27.3584 0 27.3584 4.4

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Present time cycle13Hrs (35°c U/V)

1.Earlier Reactor Agitator is not removing the Solvent traces from wet material2.Anchor Agitator modified by arranging Bullets.3.Distillation Time cycle is reduced from 19Hrs to 13Hrs

Monetary Saving/annum :10.60 LakhsInvestment : 0.8 Lakhs

Annual Energy Saving:1.51Lakh KWh Pay back period: 0.3 Month

Previous time cycle19Hrs(35°c U/V)

Innovative 1. Modification of Reactor Agitator

Bullets

20

RTD

chilled inlet RTD

chilled outlet

6"

34m2

RTD

e) RTD - Chilled Brine

f) RTD - Chilled water

RTD

b) On-off vavle - 15 NB-N2

c) On-off vavle - 15 NB-N2 break I/L

d) APT-Vac. & Pres.

e) RTD - Steam vapor O/L

f) RTD - ATFD vapor

Rota meter g) RTD - Rotor cooling

h) Rotary Air Lock valve - 10" & 8"

XV (15NB)

TT

O/L

APT I/L

VFD

½"

PT Powder Receiver

1½"

N2

CV(50NB)

APT

a) On-off vavle - 50 NB-Vac.

b) Control vavle - 25 NB-Vac. Control

Steam PRV

CV(80NB)

ATFD PROCESS DIAGRAM

ATFD

a) On-off vavle - 80 NB-Vac.

Feed Tank

ROTARY VALVE

Vacuum pump

SUV

c) Level Transmeter

a) Level Transmeter

b) Mass flow meter

c) Control Valve

d) VFD for Pump

Condensers

a) PT - Chilled Brine.

b) PT - Chilled water.

c) PT - Nitrogen

d) PT - Inst. Air

Steam control Valve

Vacuum pump

Distilled Receiver

a) Level Transmeter

Vacuum Pump

a) APT

Feedtank 10 kl

ATFD

HE2

(-15) (14.7m²)

HE1 (+5) (34m²

)

DistilledReceiver (2.0 KL)

suv

Innovative 2.Installed ATFD instead of Reators

21

Investment : 75 LakhsMonetary Savings : 5.93 Lakhs/AnnumAnnual Energy Savings: 0.85 Lakh KWhPay back period : 13 Months

▪ To reduce the distillation time cycle from 24hrs to 12hrs and improve the Productivity.

22

Innovative3.Replaced ANFD Bag filter with SS Sintered Filter

Investment : 5 LakhsMonetary Savings : 33.55 Lakhs/AnnumAnnual Energy Savings: 4.80 Lakh KWhPay back period: 0. 2 Months

▪ SS Sintered Filter Provided in place of Bag filter in ANFD for better Drying▪ Nitrogen purging is given at regular intervals to dechoke the Sintered candles to

get efficient vacuum throughout the Drying process.▪ Reduced Drying time from 48hrs to 30hrs

Project Details :

▪ Avoided shutdown and manual cleaning of condenser

▪ Avoided Scale Formation & Depositions in Condenser tubes

▪ Noted Low Compressor Discharge Temperatures and low energy consumption

▪ Achieved high Cooling Tower Approach

Using Parking Sheds &

▪ Savings = Rs. 14 Lakhs▪ Investment = Rs. 11.5 Lakhs▪ Payback = 10 Months

Note: Savings related to Water Quality

Automatic Tube Cleaning System for Condensers

24

Sr.No. YearOrganic Residues

In TonsSpent Carbon

1 FY' 15-16 1823.92 473

2 FY' 16-17 10938 1892

3 FY' 17-18 10074 2088

Utilization of Waste as fuel

1823.92

1093810074

473

1892 2088

0

2000

4000

6000

8000

10000

12000

FY' 15-16 FY' 16-17 FY' 17-18Organic Residues Spent Carbon

2,9

0,7

40

3,1

5,0

13

3,0

6,2

95

3,2

7,7

10

24

,36

,74

0

23

,80

,69

5

25

,38

,92

4

35

,99

,63

9

0

5,00,000

10,00,000

15,00,000

20,00,000

25,00,000

30,00,000

35,00,000

40,00,000

2014-15 2015-16 2016-17 2017-18

IN M

T

Carbon Emission Level & Production

CO2 Emission

Production

Carbon Foot Prints

26

Procurement Policy :-•We have Procurement strategy to procure only Energy efficient motors & 5 star rated equipments.

• Considering Life cycle cost in all New Equipment Finalization .

• Ensuring Paperless Environment through SAP

• Sharing our Energy Conservation Ideas to Vendors , and ensuring to implement wherever applicable for sustainable development

• We have carried out vendor audits and Ensured Energy conservation practices in their plant.

Green Supply Chain

27

Bottom Up Approach

EnMS Core Team

TopManagement

Support

Steering Committee

Director(Operations)

V P(Operations)

AVP(Engg & Proj)

Sr. V P(TSD)

MR-EnMS

HOD-Utilities HOD-Power plantHOD-Electrical HOD-Corp Engg HOD-Purchase

ManagerUtilities

ManagerPower Plant

ManagerInstrumentation

Executive Mechanical

Executive Power Plant

Executive Instrumentation

ManagerElectrical

ManagerProjects & Engg

Executive Utilities

ExecutiveProjects & Engg

Level of Co-ordination & Implementation

Energy Performance of the Plant is reviewed by Top Management on the Monthly basis.Ideas generation through : Suggestion Scheme, Plant Visits, Technology Scanning, Seminars, Technical Journals, Knowledge Management, Brainstorming Sessions, etc.,Encouragement and recognitions : Cash awards, Part of Appraisals, etc.,

Energy Management Team - Employee Involvement

28

✓ Implementation of ISO 50001 Energy Management systems.

✓ Energy Management Structure.

✓ Employees involvement at all levels

✓ Daily Energy Report

✓ Energy Critical Parameters Operating Limits

✓ Tool Box – Energy Talks

✓ Regular Energy Awareness Training

✓ Modifications are routed through Change Management Committee

✓ Built in controls to prevent negative impact on energy conservation.

✓ Pre-Design Check Lists special emphasis on energy conservation.

✓ Ensuring procurement of Energy Efficient Products & Services

✓ Motor Procurement – only high efficiency (IE3 Class)

✓ Procurement policy of Star Rated Electrical Appliances

Operational

Control

Design

Procurement

Energy

Conscious

Culture

Energy Management System

Highest Installation of ANFD’s (300 Nos)

Renewable Energy – Wind Power Generation

High Efficient Agitator in Process Vessels

Highest Population of Dry screw Vacuum Pumps

Invertor type and Five Star Rated Air Conditioners

Advanced Process & Laboratory Equipment

World Class Screw or Centrifugal Chillers with Evaporative Condensers

Sea Water Desalination Plant with Turbo/ERI/I Save

Most Energy Efficient Lighting System – LED’s

The Best Energy Efficient Equipment in Hetero Group

30

Gap Analysis for Process equipment

S.NoDescription of area/Equipment

Reason for failure Remedy Action plan Savings

01-15 Deg C 450TR, 400kw motor DE bearing

Structure supports

Strengthened the structure

Rs. 6 Lakhs /Annum

Failure Vibration Vibration analysis

02Failure of secondary condenser partition plate

due to Ageing & Erosion

Replaced all condensers with SS plate 60KWh/ day

03Failure of Mechanical seals in process pumps

Dry run, lack of compatibility

1. Electrical interlock to avoid dry run

Rs. 8Lakhs /Annum

2. Compatibility of "O" rings

31

2015

20172016

20182019

2020

20132014

Sustainability

1.Installation

of Energy

Efficient

Desalination

Plant(2MLD)

2.Energy

Audit

Conducted by

NPC

3.Installation

of Energy

Savers, EE

Motors,EE

Transformers,

LEDs.

4.Implementat

ion of ISO

50001:2011

Energy

management

System.

1.Installation

of Energy

Efficient

Evaporative

condensers.

2. Commissio

-ning

of 6.1MW

Co-

Generation

plant

3.Installation

of Energy

efficient

chilling

plants

1.Steam

Distribution

System

TEAP Audit

by

Uniklinger

India.

2.Pumping

Study by

Grundfos.

3.Solar

Power plant

5.0MW

installed.

4.Installation

of VAMs to

increase

Power

Generation

1.Global

Sustainabilit

y Leadership

Award for

Sustainable

Resource

impact.

2. Steam

distribution

system

Thermograp

hy conducted

and Desuper

heater

installed.

3.Installation

of Pan

dryers

1.Energy

Audit

conducted

by TERI

on 45TPH

AFBC Boiler

2.Installatio

n of High

Efficiency

Distillation

Columns.

3.Dedicated

Energy

Team is

formed.

4..Installatio

n of

pressure

powered

pump units

1.Energy

Audit

2.Zero

Investment

Projects.

3.Wind

power

plant

54MW

installed.

4. 6.1MW

Power

Plant

Budget

Approval

1.Installati

on of

132KV

switch yard

I n place of

3x33KV

and

2x11KV

switch

yards.

2.Installati

on of Solar

Power

Plant at site

1.Replaceme

nt of Utility

pumps with

EE pumps

2.Installation

of

Desuperheate

r in ETP

3.Condensate

& flash steam

recovery.

4.Installation

of PPPU

pumps for

condensate

recovery

32

Energy policy

Energy planning

Implementation & operation

Checking

Monitoring measurement and

analysis

Management Review

Internal audit of the EnMS

Nonconfirmativecorrection, corrective and preventive action

EnMS Implementation Methodology

❑ Energy Audit was Conducted by M/s Zenith Energy Servicesand M/s Armstrong International

❑ Boiler performance, steam distribution, trap survey and condensate recovery audit was conducted by M/s Uni klinger Ltd.

❑ Involving and motivating all level of employees by Spot Recognition Award Schemes for effective implementation of energy conservation initiatives.

❑ Nominating all level of employees to various training programs on Energysaving. CII, COPES, Suppliers Locations both in India and Foreign Countries

❑ Installed online Power Energy Monitoring system (EMS) to monitor all areas ofPower consumption round the clock

❑ Installation of i-save desalination plant.

Efforts to Improve Energy Saving

To recognize efforts of our employee and their family members in energy conservation initiatives

Implement innovative Ideas, Modifications, Improvements and up gradation of the equipment

Benchmarking all products/services for energy consumption by comparison at regional as well as national level

Periodic energy Audit, continuous monitoring, review of targets & benchmarks for energy

Identifying potential areas and equipment for energy conservation

To replace old energy inefficient technology/equipment with the latest energy efficient technology / equipment continually

Make energy conservation a mass movement with the involvement of all Employees

Energy conservation awareness and training to all employees.

Methodology for Project Implementation

S.No Energy Saving Proposals

Annual

Savings(Rs.

Lakhs)

Investment

Required(Rs.

Lakhs)

Payback

Period(Months)

Person /

Dept.

Responsible

Target

Date

Remarks

Implementation and Monitoring Format

36

Energy Management System

Implementation of ISO 50001

❖ Vent condensers in series to Reactors, Distillation columns, Driers, centrifuge etc

❖ Vents of process Equipment's are connected to common headers and Scrubbers

❖ All the operations filtration, centrifugation, drying are conducted in closed

conditions

❖ Agitated Neustche filter and drier (ANFD) in place of conventional centrifuges.

❖ Closed Transfer of raw materials/solvents

❖ Mechanical seals to transfer pumps

❖ Material transfer from drums using air operated diaphragm pumps in closed hoods.

❖ Nitrogen Blanketing, Breather valves and reflux condensers to storage tanks.

❖ Low boiling solvents tanks, insulated and connected with reflux condensers with

chilled water supply to minimise the loss.

❖ All Effluent collection tanks are covered with FRP hoods with Scrubbers

Engineering Controls to Mitigate Diffused/Fugitive Emissions

38

Way of Storm

water harvesting

on N.E. area to

pond.

Rain water

harvesting

pond near by East

Corner

Storm water

Purifying at 20

m^3 R.O plant.

Storm water

Storage

Tank

R.O. Permeate

transfer to D.M.

Plant area.

Daily generating 550 KL high Quality

(50 TDS) water .(During rainy season)

Rain Water Harvesting Design

39

Corporate Social Responsibility Initiatives in 9areas

40

Awards & Certifications

Selected asEnergy Efficient Unit in

CII National Award for Excellence in Energy Management–2015,2016& 2017

Secured ‘3 Star Rating’ in the CII Southern region Environment Health & Safety Award.

Certifications from

M/s BSI

ISO9001:2015, ISO14001:2015,

OHSAS18001:2007 & ISO50001:2011

41

ENMS-50001:2011 EMS-14001:2015 OHSAS-18001:2007 QMS-9001:2015

Certifications

4295

Our Energy Excellence Journey Continues

HETERO Energy Mgmt. Planning

Energy Mgmt.

Methodology

Energy Mgmt.

Initiatives

Journey

Excellence is not a destination , It’s a Continuous journey that never ends …

Asia’s largest Pharma Complex - Green Business Centre

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