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Overall Methodology

E – Learning on Green Productivity & Environmental Management System (ISO 14001) 21 – 24 August 2006 Presentation on Case Study of Soya Oil Processing Industry Sri Lanka. Overall Methodology. Three teams were formed comprising 5 – 6 members in each group with a team leader

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Overall Methodology

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  1. E – Learning on Green Productivity & Environmental Management System (ISO 14001)21 – 24 August 2006Presentation on Case StudyofSoya Oil Processing IndustrySri Lanka

  2. Overall Methodology • Three teams were formed comprising 5 – 6 members in each group with a team leader • Each group was requested to analyze the full case by having brainstorming sessions • Each group was requested to make a presentation • After the presentations of each group a brainstorming session was carried out to finalize the presentation

  3. Tools & Techniques used • Review of documents Each group reviewed the document of case study and the summary of the said case study presented by Dr. Saxena and identified the areas in relation to organizational, production, materials so on and so forth

  4. Tools & Techniques used • Based on the above each team developed a walk – through survey assuming the operational activities of the Soya oil processing company Next slide shows the walk – through survey

  5. Walk – through survey Seed Receiving area Laboratory Administration block Unloading- Silos Utilities section ETP Production Facilities Seed Preparatory Solvent extraction plant DOC Packing

  6. Tools & Techniques used • Base on the walk-through survey a process flow chart was developed identifying each processing point and the relevant waste streams generated through the relevant operations. Next slides denotes the relevant details

  7. Soya Seeds Bags Spillages Dust Noise Labors Unloading Oil Spillages Spillages Dust Noise Electricity Lubricants Transferring Storing Energy loss Odor Spillages Dust Noise Electricity Lubricants Transferring

  8. Storing Energy loss Odor Spillages Dust Noise Electricity Lubricants Transferring Energy loss Dust Husk Traces Spillages Noise Electricity Screening Energy loss Spillages Stones Mud balls Dust Noise Electricity De Stoning

  9. Energy loss Odor Spillages Dust Noise Electricity Cracking Heat loss Steam Condensate Odor Steam Conditioning Spillages Energy loss Noise Odor Electricity Flaking Air emission Moisture Heat loss Odor Hot air Drying

  10. Oil Spillages Energy loss Electricity Lubricants Transferring Spillages Hexane vapor loss Energy loss Odor Hexane Electricity Extracting Miscella De-oiled-cake (DOC)

  11. Miscella Heat loss Steam + Hexane Vapour * Preheating Evaporating Distillation Hexane Stripping/ Drying Crude Oil Flash recovery Hexane vapor Hexane Chiller Cooling Hexane Mineral oil Contaminated With Hexane

  12. Dust Noise De-oiled-cake (DOC) Heat loss Hexane Dust Odor Steam + Hexane Vapour Steam Desolventisation Heat loss Toasting Steam + Hexane Vapour * Cyclone Steam + Hexane Vapour Heat loss Hexane Hot air Drying Cyclone Dust Noise Heat loss Hexane Dust Air Cooling

  13. Spillages Dust Noise Screening Electricity Energy loss Dust Noise Crashing Dust Spillages Damaged bags Bags Packing DOC

  14. Cause and Effect Diagram for Hexane Losses Method Man Lack of quality assurance Inefficient separation of micella and DOC Lack of Commitment No record Keeping Improper Handling Methods No compliance to Specifications (Retention Time) Inadequate Data Collection Carelessness No periodic checks of raw material Lack of Awareness Lack of Training No proper operational instructions Defects in Measuring Hexane High ambient temperature Hexane Losses (2300 Litres/day) Unskilled Labour Poor Process Control Environment Leaks Absence of measuring indicator equipment High wind Steam Hot Air Poor raw material quality Improper Seed Preparation Faulty Condenser Wear and Tear Cracking, Cooking, Flaking, Lack of scheduled maintenance Poor cleaning Power interruptions Seed Hexane Excessive or inadequate use of hexane Interruptions in steam supplies Machine Material

  15. Waste streams, relevant causes & GP options

  16. Waste streams, relevant causes & GP options

  17. Objectives & Targets Objective: Minimize the Hexane losses

  18. Objectives & Targets Objective: Introduce a substitute

  19. Objectives & Targets Objective: Minimize dust generation

  20. Green Productivity Policy M/s Rama Phosphates Limited (Oil Division) Indore, Madhya Pradesh, Central India Green Productivity Policy We being an organization engage in processing of Soya bean oil are committed to, • prevent environmental pollution by reducing emissions and waste water generation and comply with all legal & other requirements • increase productivity by optimizing resource consumption • encourage recovery and recycling of waste rather than disposing to the environment • use GP and ISO 14001 EMS as tools to improve environmental performances of the activities on continual basis. The policy is made available to general public. We ensure that the policy is communicated to all employees and maintained at all levels of the company. Signed by The Chairman

  21. Thank You

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