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     Alternative Use of Potassium and Sodium Salts CHALLENGE The major products of Dr. Reddy's unit API Nalgonda Plant are Naproxen and DL Naproxen. These two products generate effluents containing sodium sulphate, potassium chloride & potassium sulphate. On an average, 450 TPM of crude sodium sulphate and 220 TPM of crude potassium chloride salts were sent to secured landfills. The goal was to reduce the quantity of waste being sent to secured landfills and put the waste to productive use.   INTERVENTION The operations management team took a decision to upgrade the manufacturing and treatment process, such that the waste produced was pure salts which had productive alternative usage. They also substituted certain raw materials and segregated streams of potassium chloride & potassium sulphate and sodium sulphate. These individual streams were pre-treated and processed in dedicated multiple effect evaporators. .   OUTCOMES An average of 220 TPM of potassium salts were recovered and sent for alternate reuse to the fertiliser industry and oil exploration industry.     The sodium sulphate stream had a dedicated five stages multiple effect evaporator followed by a pusher centrifuge. As a result, about 200 TPM of sodium sulphate salt with 98% purity was recovered.     An average of 2,722 TPA of potassium salts have been redirected to productive use in the past three years resulting in reduction of landfill occupancy by 2,177 m3/annum and conservation of natural resources by avoiding fresh production.