SUSTAINABILITY REPORT 2013-15

People Overview Self Managed Teams Mechanisation Safety Overview The Parivartan     Journey Progress on     Roadmap Incident Statistics Robust Governance Standardised     Processes Enhanced Awareness Capability Building Safety Infrastructure Safety Audits Quality Overview Top-down    Accountability Quality by Design Quality Culture     Transformation Quality Assurance Quality     Best Practices All Time Audit     Readiness Availability Overview Strategic Sourcing Risk Management Product    Rationalisation Success stories Environment Overview Roadmap Energy Management Emissions Water Waste Case Study KPIs Community Overview Focus Areas Education Livelihoods Healthcare Infrastructure     Initiatives Creating Change     Makers Productivity Overview Productivity Streams Case Study PACE Update Initiatives Engineering Excellence Overview Digitisation Automation Mechanisation Lean Manufacturing Capital Equipment Strategy Predictive Maintenance Continuous Improvement Overview Continuous     Improvement     at Work Best Practices Annexures GRI Index Acronyms Assurance Statement   Summary Report     ENVIRONMENT PERFORMANCE WASTE Overview    |    Top 3 Materials    |    Waste Disposal    |    Solvent Management    |    Case Study     Solvent Management Effective use of solvents and reduction in waste generation is the key for improving our environmental footprint. Key Features | FY14 & 15   Address major concerns at the developmental stage itself Be responsible in solvent selection and solvent substitution practices Reduce or eliminate the use of hazardous solvents Identify purification, reuse and recycling opportunities Dispose of solvents safely and responsibly   The following table lists the name of some of the key products from which we recovered solvents and the stage at which the intervention was taken up.     This could be achieved through our focus on conservation of resources. We continue to rationalise consumption by reducing solvent usage; enhance its recovery and cut down on repeated testing.   Product Stage Solvent Annual Saving (mn USD) Atorvastatin Calcium RAT-3P Acetonitrile 0.74 Rabiprazole sodium CRAB-2 Chloroform 0.45 Losartan Potassium ESE-24 Acetone 0.33 Metaprolol MET-1 Acetone 0.05 Clopidogrel bisulfate CBS-23 Acetone 0.40 Ramipril TRAM-1 MDC 0.46 Montelukast sodium MOK-1 Toluene 0.43 Levofloxacin LOF-2 Methanol 0.08 Gemcitabine CGH-1 Acetone 0.05 Gemcitabine CGH-2 Acetone Gemcitabine CGH Acetone Gemcitabine CGEM-1 & CGEM-2 Acetone 0.02 Amlodipine besylate CDM-6 IPA 0.03 Ziprasidone ZPH-3 Cyclohexane 0.10 Ziprasidone ZPH-2 & ZPH-3 Methanol 0.04 Ziprasidone ZPH-5 & ZPH-6 Ethyl acetate 0.03 Quetiapine fumarate QUF-2 Methanol 0.11 Quetiapine fumarate QUE 1 Toluene 0.30 Fexofenadine FFA-4 Ethyl acetate + Methanol 0.84 Capecitabine CPB-1 MDC 1.09 Capecitabine CPB-1 Toluene 0.50 Clopidogrel Bisulphate CB24 2-Butanol 0.57 Capecitabine CAP-8 Toluene 0.50 Valsartan VLT-2 Ethyl acetate 0.60 Divalprox Sodium DIV-3 Toluene 0.47 Nizatidine TAZ-2 MIBK 0.74   Initiatives to Build a Circular Economy and Convert Waste to Wealth   Alternate Use of Briquette Ash Biomass briquettes used as boiler fuel generate briquette ash as waste. The average briquette consumption is 900 TPM and the percentage of fly ash generation is about 20%. The entire briquette ash was disposed on land as it is unsuitable to be used for brick making. The potential for use of bio briquette ash as a filler in manufacturing bio- fertilisers was analysed. The ash was found to have a fertiliser value of 2.8% total nitrogen, 4% potassium and 1.2% calcium. Around 208 T of ash has been sent for reuse to fertiliser, organic manure and agriculture biotech industries from October 2014 till date. Alternate Use of Potash 3,000 TPA of potassium salts is generated from the evaporation process and the same is disposed to authorised recyclers to produce valuable fertilisers. Potash is reprocessed by the recycler and 2,000 TPA of potassium salt is produced on dry basis. Out of 2,000 TPA, 800 T of chloride free salt is used for cultivation of tobacco crop. About 400 T is sold as fertiliser for horticulture crops like palm oil, cocoa, coconut, sugarcane, etc. covering 4,000 acres of land. The remaining quantity of 800 T is given to oil drilling companies which results in direct foreign exchange savings. This initiative has been able to minimise the hazardous waste disposed of to landfills by completely reusing the salts. Alternate Use of Sodium Sulphate 450 T/month of sodium sulphate salt is generated from multiple effect evaporators and needed to be disposed in landfills as the salts were coloured with high moisture content. The cost of landfilling amounted to ₹14.5 million/annum. A dedicated multiple effect evaporator was put in place to produce good quality sodium sulphate salts. Authorised recyclers who can reprocess the salt and use it in the making of papers, detergents, barium sulphate and sodium phosphate were identified. 144 T of sodium sulphate has been handed over to the recyclers for alternate reuse from January 2015 till date.