Atul Limited has been proactively adopting and promoting business practices that are eco-friendly apart from integrating “Sustainability” into work ethos since inception. It is evident from the fact that we are operating our facilities successfully in harmony with the community since 1947 without any adverse impact on the environment. The nature of our activities makes an efficient utilization of resources, environmental protection, operational safety and employee health.
Zero Discharge Concept
Zero discharge concepts has been adopted at Atul based on the principle of recycle, reuse and reduce. Our concentrated efforts under this project yielded massive reduction in overall water consumption apart from awareness amongst all how to conserve resources effectively.
Adoption Of Clean Development Mechanism
We have not limited ourselves to the statutory requirements but have gone beyond compliance. In the process, we have successfully installed a plant for brick manufacturing, having capacity of 100000 bricks per day. As a result we are now in a position to consume entire fly ash being generated from our captive power plant and gypsum sludge at Atul site.
Change Of Technology - Replacement of Mercury by Membrane Cells
The Mercury Cells technology for manufacture of Caustic Soda leads to Mercury pollution of water brine sludge as well as the ambient air in the Cell House. To reduce this pollution and to save the energy, half the number of old Mercury Cells were replaced by Membrane Cells, which do not require the use of mercury and complete switching over to Membrane from Mercury Cell is under active consideration.
Use Of Reverse Osmosis System
Conventional method for separation of impurities from highly water-soluble dyes involved salting out and filtration. In spite of salting, fairly large percentage of dye (~ 5-10%) remained in the filtrate which was sent to the ETP. Now, we have installed and successfully commissioned 5 Reverse Osmosis (RO) units in our Colors Division to purify the water soluble dye by separation of low molecular weight water soluble impurities through membranes of selected pore size. Since the dye has a very high molecular weight, its molecules do not pass through the membrane. During the purification process, some amount of water also gets removed to concentrate the dye. The concentrated and purified (almost salt free) dye is taken directly for spray drying. Thus, the generation of effluent, containing higher percentage of dye and the use of salt giving additional TDS, is avoided.
Lime Stone Injection in Fluidised Bed Boiler
During burning of coal and lignite, some amount of SO2 is generated. To control this emission, we have started charging lime stone granules along with crushed coal. This ensures that the FBC Boiler Stack has SO2 content always within limits. Injected limestone is able to effectively scavenge the low concentration of SO2 because of excellent mixing available in Fluidized bed.
Catalystic Incineration and Heat Recovery (Formaldehyde Plant)
Formaldehyde is manufactured by partial catalytic oxidation of Methanol. After absorption of formaldehyde in water, a catalytic incineration system has been provided for the complete oxidation of vent gases including residual formaldehyde before release in the atmosphere. Platinum based catalyst is used for this purpose. When the vent gas enters the catalytic converter, it gets heated to 300oC. At this temperature in the presence of a catalyst, toxic gases are oxidized and the heat released is recovered in the form of steam.
Minimization of Emissions: DCDA system for H2SO4 plant
We have adopted Double Contact Double Absorption (DCDA) system for manufacture of Sulfuric acid on both of our plants apart from alkali scrubber system. This has ensured that the SO2 emissions are well below the recent prescribed limit.
Vapour Absorption Systems and Ammonia Compressors
For refrigeration system, earlier Chlorofluoro carbons (CFCs) were used. It is well known that CFCs causes depletion of the Ozone layer. Therefore in a phased manner, we have switched over to over to Vapor Absorption refrigeration system.
Carbon Sinks: A Green Belt Development
The growth of forest is a well-known non-conventional method of maintaining clean environment in an industrial complex. Before the commencement of production by Atul, the factory and the surrounding area were grasslands with hardly any trees. The grassland was converted into a 'hill station' like forest with sustained efforts and commitment. More than 9,00,000 trees of different varieties are planted in the complex spread over 1250 acres and the process of tree plantation is going on unabated . These trees consume the large amount of CO2, released from our coal fired Captive Power Plant. Thus, in its small way the Company is contributing towards reducing emission of greenhouse gases. The trees also help in minimizing dusting and in regeneration of Oxygen for our survival.
Presence of humming of birds in forests or gardens is a natural thing but it is really wonderful that in a site full of chemical plants, a variety of birds come to roost among the trees in the factories year after year. These birds build their nests, lay their eggs and hatch them. After staying for several months they fly away with their young ones on their long journey, to wherever, only to return to Atul the next season. Atul Complex provides an interesting demonstration of this extra ordinary occurrence because of our commitment to Environmental Protection and Sustainable Development.
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