At Himadri, we notably meet 90% of the power required for our operations through our own power plant, with a capacity of 32MW. We have furthered our commitment to environmental protection by finding innovative ways to reduce waste gas and off-gas venting during carbon black production. By implementing a process that circulates and feeds off-gas into power generation, we have significantly contributed towards lowering Greenhouse Gas (GHG) emissions.
The primary components of this power plant consist of three boilers, sufficiently meeting the energy demands of the entire unit in West Bengal. Any excess electricity generated beyond the requirements is sold to the local grid, making this initiative a key driver of the energy saving and environmental benefits. We have managed to sell 60,620 MWH of electricity to the local grid after fulfilling our own requirements. The power generation process involves three waste heat recovery water tube boilers, with two having a capacity of 40tph and one with a capacity of 75 tph. The off-gas generated during carbon black production is fed into an external combustor chamber. After combustion, the off -gas produces flue gas, which is then distributed through a pipeline to generate steam.
The steam generation occurs through the circulation of flue gas on the shell side and water on the tube side of a panel tube. All three boiler follow the same process, and the generated steam is collected in a common steam header and redistributed to the three respective turbines for power generation. Out of the three turbines, two turbines have a capacity of 12MWH each, and one turbine has a capacity of 8 MWH.
By utilising process emissions for power generation, we have effectively reduced our consumption of conventionally produced electricity. This reflects our strong commitment to sustainability and environmental stewardship.
During an investigation, it was observed that the LT Feeders of the plant had remarkably high levels of Total Voltage and Current Harmonic Distortion (THDV & THDI), causing significant impact on most LT motors due to various odd-order harmonics. This situation led to a substantial increase in line losses. Moreover, the LT Capacitors in the Automatic Power Factor Control Panels experienced dangerous harmonic resonance, resulting in occasional drops in the power factor at the LT Power of Control Centre of Transformers. Measurements in Feeders and Motors indicated that power factor at motor terminals dropped due to the harmonic effect. The problems caused by harmonic currents were quite concerning. They led to overloading of neutrals, overheating of transformers, nuisance tripping of circuit breakers, and over-stressing of power factor correction capacitors. Additionally, there were issues related to the skin effect. Harmonic voltages, on the other hand, resulted in voltage distortion and zero-crossing noise, further complicating the situation.
The effects of these harmonics were widespread, causing overheating and failure of electric motors, power factor correction capacitors, distribution transformers, and neutral conductors. It also reduced the efficiency of power generation, transmission, and utilisation, while prematurely aging the electrical plant components and shortening their lifespan. To make matters worse, electronic equipment malfunctioned, metering equipment experienced high measurement errors, and protective equipment showed spurious operation. With a clear understanding of the problems, the objectives were set to address the issues effectively. The primary goals were to reduce input current harmonics to less than 5% and improve the power factor from 0.75 to a much more desirable 0.98. For this purpose, an active harmonic filter (AHF) was introduced as a potential solution.
The AHF panel came with impressive features, including a closed-loop active filter with source current sensing, harmonic attenuation of upto 96%, programmable selective harmonic elimination, and PF compensation that worked for both leading and lagging power factors. It enabled us to switch between PF and harmonic compensation. The design relied on IGBT-based inverters and offered the option for multiple paralleling. Notably, the AHF panel was equipped for shunt operation and had self-current limiting capabilities.
The AHF panel, together with the Capacitor Bank, produced remarkable results. The input power showed a considerable decrease, going from 803 KW to 765 KW, while the power factor improved significantly, going from 0.86 to 1. Additionally, the input current distortion was impressively reduced from 2.4% to a mere 0.9%. The input KVA also experienced a significant reduction, dropping from 939 to 767 KVA, which meant a direct reduction of 172KVA.
Moreover, the implementation of the AHF panel and Capacitor Bank held the potential for substantial energy savings, with an estimated annual energy saving potential of approximately 13,62,240 KVAH, considering 330 working days.
At Himadri, we have successfully implemented a high-performance multifunctional fuel additive across our reduction processes, targeting various fuel applications such as furnace oil, carbon black feedstock, light diesel oil, low sulfur heavy stock, and more. This additive has led to remarkable improvements in fuel efficiency and carbon emission reduction, optimising our production operations. The specially formulated compound, dissolved in aromatic solvent and readily soluble in fuel oil, acts as a combustion catalyst, significantly accelerating the oxidation of unburnt hydrocarbons during heavy fuel oil combustion. With this implementation, we have effectively addressed the challenge posed by asphaltenes' complex structure, which previously hindered complete combustion and resulted in carbon deposits, soot, and particulate matter emission. The benefits we have obtained after fuel additive implementation are extensive and encompass various aspects:
We have implemented an efficient condensate recovery system, which allows us to recover 60% of the low-pressure (LP) steam used in all equipment, line tracing, and coils. Through an effective steam trap system, we exchange heat and convert LP steam into condensate water, which is collected in a condensate tank. This water is then transferred to a main storage tank and is reused in our processes, significantly reducing the quantity of RO water generated and thus lowering our ground water consumption. This, in turn, leads to reduced electrical power consumption from the RO unit. Additionally, measures like Steam Line Walk and Trap Maintenance have been implemented to minimise steam leakage and further improve condensate recovery. Our future goal is to achieve 80% condensate recovery through the implementation of efficient steam traps. To recycle wastewater, we have set up a Water Recovery Plant (WRP). The WRP receives treated wastewater from various sources such as ETP, DM plant backwash, RO plant reject water, and cooling tower blowdown water. After going through the treatment process, the water is reused for cooling tower makeup, process utilisation, and RO plant feed. This significant water recycling effort reduces our reliance on ground water resources. To ensure efficient monitoring and control of water consumption, we have installed flow meters in various water streams. This allows us to perform deviation analysis and include water consumption KPI in our daily and monthly review meetings. Regular calibration schedules are in place for each flow-meter as a preventive measure. Our commitment to water recycling and conservation is reflected in our efforts to optimise condensate recovery and efficiently manage water usage across different processes and areas within the plant
As part of our initiative to reduce Greenhouse Gas emissions and explore alternative sources of LPG gas, we have installed a Biogas plant with a capacity to process 200kg of canteen waste per day, resulting in 20m2 of Biogas generation. The Biogas generation process involves segregating the waste and converting it into a slurry, using a mixer. This slurry undergoes aerobic digestion in a pre-digester tank using thermophilic bacteria and hot water. The main digester tank then carries out methanation or anaerobic digestion by methanogenic bacterial consortium, producing biogas mainly composed of methane, which collected from the floating head of the tank. The remaining slurry is sent to manure pits, where nutrient-rich water separates out and can be recycled for gardening purposes. The energy generated by the biogas plant can be used as a substitute for LPG gas in cooking, while residue serves as organic manure for our internal horticulture. The biogas plant offers convenient and hygienic way to treat biodegradable waste, creating a clean and pollution-free environment without attracting flies, mosquitoes, or rodents. Additionally, it consumes very little water and electricity, leading to cost savings. Moreover, the compact size of the plant reduces the need for water transportation. We contribute to sustainability by reducing our reliance on LPG and other petroleum-based fuels. The production of organic manure as a by-product further adds to the plant's environmental benefits. The biogas plant consists of various components, including the Mixer/ Crusher for processing organic water into a uniform slurry, the primary digestor for methane fermentation, and BOD reduction. In cases where there is a large quantity of garden waste, a fungal digester is employed to handle lingo-cellulosic materials. The biogas produced in the main digestor is collected in a gas holder and transferred using 1" GI piping to a balloon made of HDPE for additional storage. The treated overflow of the main digester is directed to sludge drying beds or manure pits to produce high-quality organic manure
This is the narrative of 40 field operators and staff at Himadri Speciality Chemical Ltd who embodies a remarkable transformation. These individuals, entering the industry as either fresh graduates or lateral entrants, realized the weighty responsibilities associated with their roles, including the handling of volatile materials. The turning point came when the HR Department orchestrated a comprehensive Practical Firefighting program, engaging external experts. This safety training initiative, featuring a meticulously selected cohort, covered a range of essential skills, from fundamental fire prevention strategies to advanced fire control techniques. Over months of immersive training, the group absorbed knowledge about fire dynamics, extinguishing methods, and rapid decision-making under pressure through practical drills and lifelike simulations. Their defining moment arrived unexpectedly when a minor fire erupted in the plant. With fire extinguishers and Fire Spraying Nozzles in hand, they demonstrated their newly acquired skills, effectively containing and extinguishing the flames, preventing potential catastrophe. Their swift response garnered admiration and promotions as safety overseers. Their commitment to continuous improvement, through ongoing training and knowledge sharing, not only elevated plant safety records but also exemplified the transformative potential of dedication to learning and workplace safety. This narrative serves as a powerful reminder that with the right training and unwavering commitment, anyone can emerge as a hero in times of adversity, ensuring the safety and security of the organisation.
Our Zero Liquid Discharge (ZLD) process is a comprehensive and environmentally responsible approach that ensures our plant generates zero liquid discharge into surface waters, thereby eliminating pollution associated with ZLD treatment. Beyond this environmental benefit, our ZLD system optimizes wastewater treatment, recycling, and reuse, actively contributing to water conservation by reducing our fresh water intake. This achievement is made possible through various chemical techniques, including membrane-based and multiple effect evaporation-based systems, along with the recovery and recycling of water through ETP and WRP systems. The driving factors behind our adoption of ZLD are the critical issues of water scarcity, water economics, and stringent environmental regulations, as well as the cost savings derived from water and salt recovery, which enhance our operational efficiency and overall sustainability. Our ZLD methods encompass thermal processes (evaporation), membrane technologies like RO and electrodialysis, forward osmosis, and membrane distillation. This systematic ZLD approach consists of three main components: pre-treatment involving physicochemical and biological processes, RO employing membrane techniques, and evaporators/crystallizers utilizing thermal processes. Despite the numerous advantages, including reduced water pollution and resource recovery, we acknowledge the challenges ahead for wider ZLD adoption and remain committed to bridging the gap between theoretical research and practical industrial applications through ongoing research efforts, aligning with our vision of sustainability.
At Himadri Speciality Chemical Ltd our commitment to social welfare drives us to implement various welfare initiatives for improving the quality of life for the communities we operate in. Our endeavours include repairing village roads and offering financial assistance to residents to help them build shops and secure sustainable livelihood opportunities.
We have taken significant steps towards enhancing rural development. Himadri has successfully built durable RCC (pucca) houses in five neighbouring villages of its Mahistikry plant, providing shelter and improving the lives of around 1700 residents. These beneficiaries are part of the following local gram panchayats (village councils), which serve as the fundamental governing bodies in Indian villages.
Moreover, the company has inaugurated Nasibpur Kishalaya, a specialized school designed to cater to the educational and support needs of differently-abled children within the area.
The safe housing initiative seeks to offer secure and long-lasting housing solutions to individuals from economically weaker sections of the society, who were previously residing in substandard conditions. Alongside the construction of durable homes, the company has also established kitchens and sanitation facilities to address the essential requirements of underprivileged villagers. These endeavours are geared toward enhancing the overall quality of life and hygiene standards within the community.