ABRIDGEMENT ON PROJECTS EXECUTED


  Dr. REDDY'S LABORATORIES LIMITED


1. Dr. REDDY'S LABORATORIES LIMITED, Mirylaguda.

Project : Steam conveying system for triple effective evaporation system.

Scope of work : Our scope of work involves design, detailing, preparation of pipe line layout, supply of equipment, work supervision, erection of equipment, pipe line laying, commissioning and handing over the system as a whole in running condition.

Codes used : IBR 1965, ASME Section VIII, Division 1, BIS and Good Engineering Practice

Description : Preparation of Process flow diagram, design and detailing of all equipments, as mentioned above as per the respective design codes, preparation of bill of quantities for pipes, plates, valves, etc.

 

2.
Dr. REDDY'S LABORATORIES LIMITED, Unit - IV, Jeedimetla

Project : 8TPH Boiler and High & Low pressure Steam pipeline supply, fabrication, erection & commissioning on turnkey basis.

Scope of work : Our scope of work involves design, detailing, preparation of pipe line layout, supply of equipment, work supervision, erection of equipment, pipe line laying, commissioning and handing over the system as a whole in running condition.

 
Codes used : IBR 1965, ASME Section VIII, Division 1, BIS and Good Engineering Practice
 
Description : Preparation of Process flow diagram, design and detailing of all equipments, as mentioned above as per the respective design codes, preparation of bill of quantities for pipes, plates, valves, etc.


3. Dr. REDDY'S LABORATORIES LIMITED, Bulk Active Unit - II, Bollaram

Project : Effluent Recycle Plant (ERP)

Scope of work : Design, detail engineering, project management, including Civil, Mechanical, Electrical, Third party Inspection, utility freezing, etc. from foundation to Mechanical commissioning of the plant

  Codes used : IBR 1965, ASME Section VIII, Division 1, BIS and Good Engineering Practice
 
Description : In this, “EFFLUENT RECYCLE PLANT” (ERP), the effluents coming from process and utility of utilities will be collected in two different streams, called process and non-process respectively, of different capacity, separately from all the four bulk active units, located in Bollaram and Jedimetla.
The main equipment can be classified in to four parts, based on the service of the same, as mentioned below:
Multiple Effect Evaporation System (MEE): Used for process stream Processing capacity: 400 cu.m per day
  Reverse Osmosis plant (RO): Used for non-process stream Processing capacity: 200 cu.m per day.
  Spray Dryer: Used burn the reject coming out of MEE and RO systems Processing capacity: 365 kg/hr
  Utilities: Services, like, steam, compressed air, cooling water, soft water, transformer, DG set, etc., required for the above streams
 

PROJECT OBJECTIVE:
The objective of this project is mainly to avoid pollution in and around the factory and also to recover the utilities, maximum possible extent, solvents and reuse the same in the process, in place of fresh utilities and solvents, in the unit – II and also in the near by units – I and III depending on the surplus quantity available.

  PROJECT DESCRIPTION:
As mentioned above this project consists of Multiple Effect Evaporation system, Dryer, Reverse Osmosis System and other utilities.
 
The effluents coming out of the four units will be segregated as process and non process streams, at the respective bulk units, and sent it to this plant where in the facilities to collect the same in the respective sumps.
Then the feed, process stream (Multiple Effect Evaporation System), fed to the steam stripper at the top and it is controlled by maintaining level at bottom of the stripper. A plate heat exchanger is provided as re-boiler at the bottom of the stripper. Steam is introduced as heating media on the shell side and the product is re-circulated on the tube side. It works like an assisted flow rising film type evaporator and vapors generated are supplied as heat source to the stripper at the bottom. The product which is free of solvent is pumped out from bottom though a feed pump to the evaporator. The vapors supplied at the bottom of the stripper column, where they get enriched with solvent vapors and also get stripped off from water vapors. Therefore, bottom is free of solvents. Focus is given more on purity of bottom products as compared to top products. From here the feed free of solvents is sent to the evaporator. The top solvent vapors are condensed in the condenser by cooling water.

The non condensable from each shell will be drawn and sent to condenser. The uncondensed non condensable are sent out by vacuum pump hooked up to the condenser. These can be burnt in the hot air generator of the spray dryer section.

The entire operation of the plant is controlled through a PLC same as evaporator system.
UF, NF and RO System (Non process stream): This is membrane based separation system for treating 200 cu.m/day of secondary treated effluent. Most of the functions in the system are for automatic operation in terms of flow, pressure and temperature by way of selector switch so as to distinguish between process mode and CIP mode.

The feed to the system is suitably pre-filtered through a built in back washable hollow fiber based UF system. The filtrate thus obtained is subjected is to two step membrane process namely: NANOFILTRATION SYSTEM followed by REVERSE OSMOSIS. While NF takes care of most of the COD, color and part TDS the subsequent RO removes TDS and remaining COD to produce reusable grade water. The overall product capacity is designed at 135cu.m/day.

Composition of Waste Water and Expected Product Stream.
 
PARAMETERS PRE TREATED FEED EXPECTED PRODUCT
Total dissolved solids < 15,000 ppm < 100 ppm
Suspended Solids * < 1 ppm Nil
Ph 6.5 – 7.0 7.5 – 8.5
COD < 4,000 ppm < 50 ppm
  The suspended solids load in the secondary treated effluent is considered to be around 200 ppm. This will be reduced to < 1 ppm by UF & other pre-treatment.
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