Ashok Leyland : A Brief History
§ 2nd Largest Commercial Vehicle Manufacturer in India
  and market leader in technology
§...
Ashok Leyland, Hosur – II



    Ø Established in 1994
    Ø Spread over 197.15 acres
    Ø Manpower – around 1250
    Ø A...
Comparison with Global norms /
                                    benchmark
Inefficent water us e by indus try
The ratio ...
Water Saving Projects
Project: I
                                             Zero Discharge Effluent Project


Objective:...
Zero Discharge Reverse Osmosis (R.O.)
                 Plant Process Flow
  TO ETP                              25 KL     ...
Quality of Effluents
Sl.       Para meter            TNPCB           Af ter            Af ter
No                          ...
Benefits of the Zero Discharge
                                          Project
                         The occurred sav...
Project - II


 Project description
        To reduce soft water consumption in Paint process


Objective:
        To reus...
R E D U S ET H EB A T HL E V E L
                                                     Current situation analysis:


      ...
AFTER THE MODIFECATION IN P T LINE




                                                  Rinses 1
     Dip Degrease

Spray...
Tangible Benefits:


Process Tank            Before Pr oject      After Pr oject

Rinse 2 draining        7 days once     ...
Project - III

 Project description

         Elimination of water softener usage.


Objective:
      Reduction of Effluen...
Feasibility study

Quality of soft water required
Sl   Application             water             Remarks
No               ...
Results - BENIFI TS   FROM THIS P ROJE CT



      Effluent reduction by eliminating softener per day

     • The daily ri...
Aging durati on: Solid v s Liquid S ur face Conditi oner

v Solid Surface Conditioner

    Chemical            Nipaf in ZS...
Com parison of S olid & liqui d Sur face Condi tioner


                  PL ZS                                        PL ...
33
Excellence in W ater Man agement 2 008




                                              17
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Conserve Water Need of the Hour presented by Ashok Leyland

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This is a presentation from Ashok Leyland, Hosur II one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008

The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.

This presentation was in the "Within the Fence" category.

We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

Published in: Education, Technology, Business
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Conserve Water Need of the Hour presented by Ashok Leyland

  1. 1. Ashok Leyland : A Brief History § 2nd Largest Commercial Vehicle Manufacturer in India and market leader in technology § Established in 1948 § Six Manufacturing facilities across India and joint ventures abroad § Annual Turnover of Rs. 8300 Crores § About 12000 employees § All manufacturing plants in India are certified for ISO14001 & TS16949 § Vehicles and Engines - Complying to Euro Norms § Launching First hybrid electric vehicle of India § Market leader in CNG Powered bus 2 Excellence in W ater Man agement 2 008 1
  2. 2. Ashok Leyland, Hosur – II Ø Established in 1994 Ø Spread over 197.15 acres Ø Manpower – around 1250 Ø Annual turnover of 1597 Greene ry: crores Ø No of Trees – around 19500 Ø TS 16949/ ISO 14001 Certified Ø Garden Area – 1,70,000 Sq.m. Rain Water Harvest ing : Ø Total storage capacity 70,000 KL/season 3 Excellence in W ater Man agement 2 008 Plant Block Diagram FRAME CABIN AXLE FR AME PRES S FR AME P AIN TING C AB WELD C AB P AIN T AS S Y. & SHOP & ASS Y SHOP SHOP P AIN TING OTHER UNIT CAB TRIM & CHASSIS ASSY SUPPLIES ASSEMBLED VEHICLE 4 Excellence in W ater Man agement 2 008 2
  3. 3. Comparison with Global norms / benchmark Inefficent water us e by indus try The ratio of water consumption and eco nomic value creatio n in Indian industry is poor. Fo r every cubic metre o f water t hat Indian industry uses, it generat es merely US $7.5 eco nomic pro duct ivity Indust rial Industrial water water use Industrial pro duct ivity At Ashok Leyland, Unit II (billio n cubic productivity (US $ / cubic Country metres) (millio n US $) metre) Total Indu str ial W ater : 71213 C u Mt. Argentina 2.6 77171 30 Produ ctivit y : US $879007 Brazil 9.9 231442 23.4 Indust rial water pr oduct ivit y : 12.3 India 15 113041 7.5 (US $ / cub ic m etre) Ko rea, Rep. 2.6 249268 95.6 Norway 1.4 47599 35 Sweden 0.8 74703 92.2 Thailand 1.3 64800 48.9 Unit ed Kingdom 0.7 330097 443.7 Sourc e: World Bank, 2001 5 Excellence in W ater Man agement 2 008 Specific Process Water Consumption Specific Process Water Consumption 8 7 6.9 6.3 6 5.7 Cu Mt per Vehicle 5 6.00 4.8 4 5.60 3 4.20 4.20 2 1 0 04-05 05-06 06-07 07-08 A ctual Projected 6 Excellence in W ater Man agement 2 008 3
  4. 4. Water Saving Projects Project: I Zero Discharge Effluent Project Objective: To recycle effluent (through Effluent Treatment Plant +Reverse Osmosis Plant) to use for Paint Process like: 1. Rinse water in paint line. 2. Feed to hot water generator. 3. Cooling circuits in compressor house & weld shop. 7 Excellence in W ater Man agement 2 008 Before Zero Discharge Project: Process Flow of Industrial Effluent Efflue nt fro m Equalization tank Process Us age of Treat ed Effluent for To Garden Flocculation Tank Reaction * Ph Correc tio n Clarifier PSF ACF Thicke ner Sludg e Dr yi ng (Clarifier ) Leg end: Bed PSF : Pr essur e Sand Filt er ACF : Activat ed C arb on F ilt er 8 Excellence in W ater Man agement 2 008 4
  5. 5. Zero Discharge Reverse Osmosis (R.O.) Plant Process Flow TO ETP 25 KL 10 KL 6.5 KL PRETRE 75 KL REVE RSE 15 KL REVE RSE 3.5 KL REVE RSE ATMEN T OSMOSIS-I OSMOSIS- OSMOSIS-III (85% ) (75 %) II (60%) (35 %) FEED FROM ETP PRETR EATE D WATER FEE D 100 KL 93.5KL PERME ATE MULTIPLE DRY SL UDGE SLUDGE 6.17 KL 6.5 KL DRYI NG WATER EFFECT TO SLF BED S STORAGE EVAPO RATO R (99.6 7% ) 99.67KL 0.33 KL LEGEND : FEED FILTERATE FILTERATE WATE R TO TO THE PAINT PERME ATE SLUDGE ETP PROCE SS& COOLING REJE CT BA CKW AS H 9 Excellence in W ater Man agement 2 008 Zero Discharge Reverse Osmosis (R.O.) Plant R.O.Plant Multiple Effect Evaporator UF R.O. -3 R.O. -2 R.O.-1 Compr es sor Boiler 10 Excellence in W ater Man agement 2 008 5
  6. 6. Quality of Effluents Sl. Para meter TNPCB Af ter Af ter No Tol erance Treatment Treatment limit Through Through ETP R.O. 1 pH 5.5 – 9.0 6.5 – 8.5 7.0 2 TSS (mg/l) 100 < 10 <1.0 3 TDS 2100 < 1000 52.0 4 BOD 30 < 15 <1.0 5 COD 250 < 100 <1.0 6 Copper (as Co) mg/l 3 < 1.0 <0.05 7 Zinc (mg/l) 1 < 0.5 <0.01 8 Chlorides (as Cl) mg/l 1000 < 500 13.0 9 Oil & Grease 10 <3 <1.0 10 Sulphates (as SO4) mg/l 1000 < 500 <0.2 11 Dissolved phospate mg/l 5 <3 <0.05 11 Excellence in W ater Man agement 2 008 Investment in Zero Discharge Project PA RTICULA RS COST IN RS. LA KHS RO PLA NT 85 MECHA NICAL EVA PORA TOR 98 CIV IL CONSTRUCTIO NS 48 STEA M BOILER 8 PIPING WORK 13 ELECT RICA L WORK 23 TOTAL COST OF PROJECT 275 12 Excellence in W ater Man agement 2 008 6
  7. 7. Benefits of the Zero Discharge Project The occurred savings :Rs. 12.6 lakhs/annum. Ø The entire treated w ater is being us ed for the plant paint process and cooling circuits(100 kl /day present volume) . • Rinse w ater in paint line. • Feed to hot w ater generator. • Cooling circu its in com pressor house & weld shop. Ø Being 3 stage R.O. Plant, the membrane recovery achieved is 90-94%. Ø Lesser the reject quantity the operation of Multiple Effect Evaporator ( Tr iple Effect) evaporator is less. 13 Excellence in W ater Man agement 2 008 After Zero Discharge Project: Process Flow of Industrial Effluent Effluent from Oth er Equalization tank Proc es s Proc es s Cab Paint Pro cess Zero Discharge R.O. Plant with Multip le Cooling Effect Evapor ator Circuits Flocculation Tank Reaction * Usage of RO produ ct for Ph Correc tio n Clarifier PSF ACF Thicke ner Sludg e Dr yi ng Bed 14 Excellence in W ater Man agement 2 008 7
  8. 8. Project - II Project description To reduce soft water consumption in Paint process Objective: To reuse pre treatment Rinse-I water to Rinse-II there by reduce the soft water consumption in paint process. Target : To reduce soft water consumption by 5% / day in pretreatment line. 15 Excellence in W ater Man agement 2 008 Problem identification : HIGHER SOFTWATER USAGE IN PT LINE Additi on of 2KL Level drop of 2KL/day due Rinse water to Degrease fres h Soft water to evaporation & Spray loss Level drop 0.75KL/da y` DIP Degrease Sof t Water Bath temp. - 55-65°C Rinses 1 Level drop Spray Degrease - 1.25KL/da y` Discard of 80KL water / month Sof t Water In Rinses 2 Rinses 2 Weakly one time drain WHY REDUSE THE BATH LEVEL IN PT TANK ? WHY REDUSE THE BATH LEVEL IN PT TANK ? 16 Excellence in W ater Man agement 2 008 8
  9. 9. R E D U S ET H EB A T HL E V E L Current situation analysis: PRO CESS C ARR Y O VER P The carry over solution Is in Rinses 1&2 EV APOR ATI ON X Bath temp. - 55-65°C EV APOR ATI ON SP AR Y L OSS ES X Through exhaust fan 17 Excellence in W ater Man agement 2 008 Re use of Rinse 1& Rinse 2 discarded Water: Rinse water to Degrease Spray & dip degrease Level make up Additi on of 2KL From R1 & R 2 fres h Soft water Level drop - 0.75KL/da y` DIP Degrease Sof t Water Bath temp. - 55-65°C Rinses 1 Level drop - 1.25 KL/da y` Discard of 40KL water / month Sof t Water Spray Degrease In Rinses 2 Rinses 2 15 days one time drain Water conservation per month, 40 KL Water conservation per month, 40 KL 18 Excellence in W ater Man agement 2 008 9
  10. 10. AFTER THE MODIFECATION IN P T LINE Rinses 1 Dip Degrease Spray & dip degrease Level make up From R1 & R 2 Rinses 1 19 Spray Degrease Benefit to Environment • Soft water saving of 480 KL/annum by reusing Rinse water • Soft water Plant regeneration reduction by appx. 2 times/annum • Reduction in regenerating chemicals by 400kg i.e.Rs.1800 / annum 20 Excellence in W ater Man agement 2 008 10
  11. 11. Tangible Benefits: Process Tank Before Pr oject After Pr oject Rinse 2 draining 7 days once 15 days once frequency Rinse 2 water 80 KL 40 KL requirement/month Cost Saving Source Quantity,/annum Rs./annum Water 480 KL Rs. 24000 21 Excellence in W ater Man agement 2 008 Tangible Benefits: Water conservation per annum: 480 KL i.e. Rs. 24000 Water conservation per annum: 480 KL i.e. Rs. 24000 Reduction in Effluent generation: 3080 KL i.e.Rs.27104 Reduction in Effluent generation: 3080 KL i.e.Rs.27104 Intangible Benefits: 1. Improv ing Env ironme nt by Conserv ing Resources & Re ducing Efflue nt to E TP 22 Excellence in W ater Man agement 2 008 11
  12. 12. Project - III Project description Elimination of water softener usage. Objective: Reduction of Effluent generation by eliminating softener usage. Target : To reduce effluent generation by 4380 KL / annum 23 Excellence in W ater Man agement 2 008 Feasibility study Soft water usage Soft water is being used for our 1. Paint process 2.Hot water Generators, 3.Cooling circuits in Compressors Chiller Plants,weld guns Daily requirement of soft water is 75 KL. 24 Excellence in W ater Man agement 2 008 12
  13. 13. Feasibility study Quality of soft water required Sl Application water Remarks No Hardness in ppm 1 Paint pre treatment <5 Sensitiv e process rinsing to quality 2 Cooling circuits in <5 Sensitive Compressor, weld to scale guns, 3 For hot water <5 Sensitive to generators in paint scale shop 25 Excellence in W ater Man agement 2 008 Feasibility study Quality of R.O.water available Sl Critical water Conclusion No Parameters quality in ppm 1 pH 7 R.O. water qua lity is 2 TDS 52 super io r t han 3 Hardness <2 soft water. Action taken • Taken approval from Paint process team •Laid pipeline for inter connecting R.O.treated water piping and soft water storage sump . 26 Excellence in W ater Man agement 2 008 13
  14. 14. Results - BENIFI TS FROM THIS P ROJE CT Effluent reduction by eliminating softener per day • The daily rinsing +regeneration water: 12 KL Net water saving / annum is =4380 KL Tangible benefits per annum: • The softener regeneration Chemical cost / annum Rs. 46800/- • The water cost : Rs. 13,140/- • Cost of avoidance at ETP+R.O. : Rs. 672768/- Total cost saving/ annum in Rs- 732708/- 27 Excellence in W ater Man agement 2 008 Project - IV Project : Ne w Liquid s urface c ondit ione r P L-X Proj ect - II Objective : Water Co nservation through a lternat ive s urface activatio n chem ica l Present stat us : Water co nsumption in surface act ivatio n pro cess present ly 3,120 m 3/year Ta rget : To re duce the wate r c ons umpt io n to 620m 3/year,res ulting in net saving of 2,500m 3/year 28 Excellence in W ater Man agement 2 008 14
  15. 15. Aging durati on: Solid v s Liquid S ur face Conditi oner v Solid Surface Conditioner Chemical Nipaf in ZS Type Solid Draining f req. Weekly Water used 60 KL v Liquid Surface Conditioner Chemical PL - X Type Liquid Draining f req. Month ly Water used 60 KL 29 Excellence in W ater Man agement 2 008 Conv entional Sur face Condi tioner Ba th Surf ace conditioning Water rinsing Degreasin g Phosphati ng Helps to ac hieve low temperatur e and Helps to ac hieve low temperatur e and high paint perfor mance phosphate high paint perfor mance phosphate System. System. The stability of the Ti colloid is poor The stability of the Ti colloid is poor & ititrequires draining & replenishment & requires draining & replenishment of bath of bath 30 Excellence in W ater Man agement 2 008 15
  16. 16. Com parison of S olid & liqui d Sur face Condi tioner PL ZS PL X Solid type Liquid type Shorter bath life Longer bath life Good Phosphate coating Superior phos phate c oati ng Fine Crystal mor phol ogy Finer crystal morphol ogy Longer phos process ti me Shorter phos process time Auto drain required Auto drain not required Hash marks c an be s een Hash marks c annot be s een Poor phos phatibiliy on hard to react steel Good phosphatibili y on hard to react steel 31 Excellence in W ater Man agement 2 008 Results and Sta ndar dization Water s aved thr ough the project ((Raw + DMW): 2706 KL Water s aved thr ough the project Raw + DMW): 2706 KL Waste w ater reduction through the pr oject: 2706 KL Waste w ater reduction through the pr oject: 2706 KL Sludge c ontent reduction: Approx. 1125 kg per annum Sludge c ontent reduction: Approx. 1125 kg per annum DM water con sumption @ Rs. 150 / KL Rs. 3,60000 per annum Water con sumption @ Rs. 20 / KL Rs. 6120 per annum Wa ste wate r treatment @ Rs. 7 / KL Rs.18942 per annum Energy savings @ Rs. 3.67 / unit Rs. 14006 per annum Chemical consumption @ Rs. 69 / kg Rs.103170 per annum Potential savings per annum, Rs. 3.89 lakhs Potential savings per annum, Rs. 3.89 lakhs 32 Excellence in W ater Man agement 2 008 16
  17. 17. 33 Excellence in W ater Man agement 2 008 17

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