Erode based Chemin Enviro Systems which is a manufacturer of Zero Liquid Discharge (ZLD) solutions has managed to reduce energy costs for the ZLD’s produced by the company. Additionally, the company also strives to continuously improve the efficiency of its ZLD’s.
Dramatic Cost Reduction: Rs 1.75 Crore Annual Savings for 100 KL Plants
“A ZLD consumes lots of chemicals, steam and electricity with the last two accounting for 90-95% of the operating costs. Steam is produced in the range of Rs 1.5 to Rs 2.0 per kg, while electricity costs around Rs 8 to Rs 9 per unit. Assuming the treatment cost of one KL reject effluent is Rs 1,100 with the MVR system, we have brought it down to Rs 600 to Rs 650 per KL, which translates into a saving of Rs 500 per KL or Rs 50,000 per day or Rs 1.75 crore per annum for a 100 KL plant,” Mr Vikas Rathi, President at Chemin Enviro Systems informed The Textile Magazine.
German Engineering Meets Indian Innovation: The Blower Revolution
“This has been made possible due to the German blowers which are six times costlier than a comparable Indian blower. But still our customers are able to recover their capex within five years, due to the drastic reduction in operating costs,” he added.
Eveready Spinning Mills: First Adopter of Energy-Efficient Technology
The company first imported the German blowers and ran it in a pilot plant and after rigorous trials for 18 months sold the first ZLD with a German blower to Eveready Spinning Mills. Since Chemin Enviro Systems is located close by, Chemin provided the confidence to Eveready Spinning Mills that Chemin will ensure that the ZLD will work properly and if it does not work, it will be taken back. “But the German blowers delivered as per our promise of reducing energy costs. We thank Eveready for trusting us even with the higher investment,” Mr Rathi observed.
Comprehensive ZLD Portfolio: 360 Installations Across India
Chemin Enviro is known for its comprehensive range of ZLD solutions for the textile sector, including technologies like Multi Effect Evaporator (MEE), Mechanical Vapour Recompression Evaporator (MVRE), Agitated Thin Film Dryers (ATFD), Caustic Recovery plants, Salt Recovery systems and Sludge Dryers, among others. Over the years, Chemin has installed nearly 360 ZLD’s across India, with a significant portion of these catering to the textile sector.
Exceeding Expectations: ZLD Plants Running at 110% Efficiency
The company also strives to improve the efficiency of its ZLD’s and its ZLD plants are even running at 110% efficiency. “For example we supplied a ZLD of 100 KLD to a textile mill but after seven years it is running at 110 KLD while normally the efficiency reduces with passage of time. The operating efficiency of our ZLD plant never drops over passage of time. It is important to note here that customers expect just 70% efficiency even from a new ZLD plant,” he explained.
Built to Last: Installations from 2009 Still Operating Successfully
The company strives to make its ZLD very sturdy and robust due to which installations sold even in 2009 are running successfully till date. The reason is mainly due to the direct intervention of its MD Mr. Prakash Narayanan who is personally involved in the design of each and every order. So, while everyone supplies the ZLD equipments in the metallurgy of the customer choice, Chemin differentiates in the design and technologies that it employs.
MVRE vs MEE: Steam Savings Offset Higher Electricity Costs
In case of MEE, steam has to be supplied continuously for 24 hours, while in the case of the MVRE, steam has to be supplied only for maybe 60-90 minutes. This steam goes into a loop and keeps circulating without the need to continuously supply steam like in the MEE. If the ZLD plant runs continuously even for six months, the steam would not need to be supplied again. The steam will need to be replaced only if the plant is stopped.
Salt Recovery: Achieving Capex Recovery Within One Year
“However, the electricity cost is higher by 40% in MVRE when compared with MEE, but still the savings in steam, still makes the MVRE an attractive proposition. Savings can also be generated by recovering the salt, which costs Rs 12 per kg and if the recovery is around 5 tons per day and is reused, the whole ZLD pays for itself in just one year. Through this we have reduced the capex burden of the customer since they are able to recover the capex within a short period of time through our technologies. Our technology also helps in reducing carbon footprint of our customers due to lesser consumption of wood, brickets or coal to generate steam, which in turn makes their textiles attractive for foreign buyers,” he stated.
Customers Include Vardhman Spinning & Leading Textile Mills
Within textile industries, the company has recently received an order from Vardhman Spinning for a 100 KLD ZLD for their Ludhiana unit which will be commissioned by January 2026. In the past, Chemin Enviro has also sold its ZLD’s to Nitin Spinners Ltd, Kanchan India Ltd, Victus Dyeings, Sri Lakshmi Textile Processors, Sagar Manufacturers, KPR Mill Ltd, Jeyavishnu Clothing Pvt. Ltd to name a few.