National Award for “Excellence in Water Management


Ou r Approach…
“ The difficulty lies, not in the new ideas of water m...
Hydromet Route of Zinc Production




                                            Efflue nt    Efflue nt
                 ...
Our Implementation Methodology


n   An integrated and structured approach -- comprising of Involvement of
    executives ...
Maintaining Zero Discharge… Pragmatically




                              Quanti ty    Quanti ty     Quanti ty
         ...
Water Saving project implemented



                                                    Annu al Water    Invest.
         ...
Annu al Water   Invest.
                                               Savings        Made     Payback
      Title of Wate...
Establish
D                                 Project & Business Synergy                                                    ...
Defi ne
D                                                                                   a
0    Project Scoping        ...
Identif y
D                                                                                     Vari ati on
0    List of X...
Water Saving & Financial Impact in terms of Monthly Saving:-

                                                            ...
PROPOSED PROJECT

                                           Proposed recycling
             DM plant                     ...
Monitoring & Reporting Systems



                          DAILY W A TER CONSU MP TION D A TA S HEE T

               DA ...
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Enduring value through values presented by Hindustan Zinc Limited

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This is a presentation from Hindustan Zinc Limited, 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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Enduring value through values presented by Hindustan Zinc Limited

  1. 1. National Award for “Excellence in Water Management Ou r Approach… “ The difficulty lies, not in the new ideas of water management and conse rvation, but in escaping the old ones” ENDURING VALUE THROUGH VALUES Hindustan Zinc Limited Chanderiya Lead Zic Smelter 2008 About Hindustan Zinc Ltd. HZL w as created from the erstw hile Metal Cor pora tion of I ndia (MCI) i n 1966 as a Public Sector Under taking. In April 2002, became a part of S terlite gr oup HZL - India’s leading base me tal producer and w orld’s III Largest producer. 1
  2. 2. Hydromet Route of Zinc Production Efflue nt Efflue nt Treatm ent Dis pos al to S ecur e L an d Fil l Jarofi x Po nd Tank Hous e Our Approach to Sustainable Development in Smelter n Adoption of 5 R waste management principles n Adoption of su stainability framework by International Council of Mines & metals n Benchmarking with World’s be st in all operating parameters n Focu sed environmental initiatives for effective water management, wa ste minimization and recycling, reducing air emissions, energy conse rvation and su stainable development drivers. n Comprehensive G RI G3 guidline based online data management sy stem to capture all Triple Bottom Lime dimensions n Implementation of British Safety Council ‘s safety management sy stem 2
  3. 3. Our Implementation Methodology n An integrated and structured approach -- comprising of Involvement of executives and contract labors like Water S tewards nominated for each Plant, further report to Water Mana gers and Unit Head for Water Con servation activities n Discu ssion of underlying factors behind the trends of HSE key performance indicators by top management during the monthly HSE review meetings. n Training - an efficient tool to improve the KPIs by motivating employees. q Frequent training programs for external environment, safety and health, supervised by the HR head. The CEO u sually take s feedback from Environment head and external faculty members who conduct the training program. Specific Water Consumption Figures Specific Annual Water consum pti on Water Year Quanti ty (m3) Consum pti on (Apr-Mar) Indus trial Domes tic Source m3 / MT Captive 2005 – 06 1407000 142.9 21.87 dam Captive 2006 – 07 1755000 131.2 12.99 dam Captive 2007 – 08 1867670 93.1 dam 11.72 3
  4. 4. Maintaining Zero Discharge… Pragmatically Quanti ty Quanti ty Quanti ty Year generated recycled discharged (Apr - Mar) (m3) (m3) (m3) 2005 – 06 74325 74325 0 2006 – 07 62358 62358 0 2007 – 08 52928 52928 0 Beyond Benchmarks/ Global Norms… Specific Water Conservation vs Bench mark 25 21.87 20 Hydro I 15 12.98 m3/MT 14 14 14 11.72 10 Bench mark- US Clarksville 5 0 2005-06 2006-07 2007-08 4
  5. 5. Water Saving project implemented Annu al Water Invest. Savings Made Payback Sl Title of Water Sa ving Year of Period No project impleme nted Implementation Rs. Rs. M3 (Mont hs) Lakhs Lakhs 1 ETP treated water to 05 - 06 339190 25.43 215 55 RO-I plant (88 m3/hr) 2. P rocess optimization of 06 - 07 29200 2.19 Nil Nil DM plant operation to reduce regeneration by increasing the OBR 3. Reduction in 06 - 07 27375 2.05 Nil Nil evaporation by optimization of C T fan operation according to the heat load Contd.. Annu al Water Invest. Savings Made Payback Sl Title of Water Sa ving Year of Period No project impleme nted Implementation Rs. Rs. M3 (Mont hs) Lakhs Lakhs 4. Recirculation of vacuu m 07 - 08 36500 2.73 4.63 21 pumps seal cooling water To C T as Make up water 5. Recirculation of stea m 07 - 08 73000 5.47 3.46 8 Condensate fro m Leaching & purification to CT as make up water 6. RO treated water 07 - 08 27375 2.05 0.20 1 directly taken to Filter water storage tank, reduced P SF backwash fr equency 7. Recirculation of Boiler 07 - 08 87600 6.57 0.72 1.5 blow down water to CT as Make up water 5
  6. 6. Annu al Water Invest. Savings Made Payback Title of Water Sa ving Year of Sl No Period project impleme nted Implementation (Mont hs 8. Optimization of CT 07 - 08 154395 11.58 Nil Nil water circulation rate by switching on/off pump as & when require under six sigma project 9 Optimization of COC at 07 - 08 CT by chemical treatment & continuous monitoring under six sigma project 10. P roviding Level probe 07 – 08 in all CT to avoid overflow under six sigma project 11 ETP treated water to 07 - 08 192720 14.45 135 61 RO-II plant (50 m3/hr) Total 901655 72.52 359.01 D M A I C Reduction of Specific Water Consumption in Hydro –I CASE STUDY 6
  7. 7. Establish D Project & Business Synergy CTQ 0 Char ac teris tics 1 Who is the M customer in 2 What is the 3 your project? Customer CTQ? What is the A 4 n Hydro -I Project 5 6 n Conservation CTQ? of Natural I Resources n Reduction of 7 8 Specific 9 Water Consumption C 10 in Hydro-I 11 12 D Defining a Project 0 T heme Selection Matrix 1 Departme Al ignmen Cust omer Financia l Priori ty Stre am SN Theme Name Cus tomer CTQ Inte rnal CTQ/CB P Sat isf act i Eff ort s** Se lec tion nt t t o CBP Be ne fit s* Score on M Misce llane o us 1 R edu ctio n o f Sp ecif ic Wa ter Con ser vat ion of Natu ra l Con ser va tion of Wat er 9 9 1 3 2 43 Yes C ons up tion Reso ur ces 2 R edu ctio n o f S/S Red uct o n of i Red uct ion of Mn O2 in L eac hing & 2 in Ca lcine COP Impr ove me nt of Cell Ho use Op er atio n 9 9 3 3 7 29 Yes 3 R edu ctio n o f Ro aste r Au xiliar y Powe r Cust omer 's 3 Cos t Re duc tion 8 3 3 3 2 16 Yes C ons umptio n in Satisf actio n Ac id Plan t R edu ctio n o f A 4 W ate r S lub le o Zin c in Jer ros ite Red uct o n of COP i Rec ove ry I mp ro vemen t 9 9 3 3 7 29 Yes 4 Le ach ing C ake R edu ctio n o f Zn Red uct o n of i To Re du ce c ons ummable s 5 5 D ust in COP Con sump tion 9 9 3 3 7 29 Yes p ur ifica tion 6 imp rov emen t of 6 a vaila bility o f Red uct o n oin i OEE Imp rov emen t 9 9 3 3 7 29 Yes C astin g M/C in COP Hydr o C ell Ho use . I mp ro vemen t o f I Cell Ho use 7 C ell Ho use R atin g Red uct o n oin COP i Powe r Sa ving 9 9 9 1 7 29 Yes I mp ro vemen t o f 7 Eq uip me nts Red uct o n oin i 8 Impr ove me nt of OEE 9 9 3 3 7 29 Yes 8 a vaila bilty i C ellHo use n COP 9 R edu ctio n o f Au xillar y Powe r Red uct o n of i 9 Red eu ction of Powe r c on sumptio n 9 9 9 1 7 29 Yes C ons umptio n in COP C PP C CPP 10 R edu ctio n o f Co al C ons umptio n in Red uct o n of COP i Cus tomer 's Sat isfac tion 9 9 9 1 7 29 Yes Po wer pla nt. 10 I mp ro vemen t o f Cust omer s 11 11 Mills Ava ilab iit y l Satisf actio n Qu ality I mp ro vemen t 3 9 3 3 2 43 No 12 R edu ctio n o f SO2 Envir onme nta l 12 Emissio n f ro m Red uct ion of S x o 3 1 1 3 9 No Prot ect i n o C PP 7
  8. 8. Defi ne D a 0 Project Scoping Proj ect 1 M Longitudinal Scope 2 3 n It start from Raw Water Pond at DM Outside Scope Plant at Hydro-I and ends at ETP A Period when 4 there is 5 6 continuous Lateral Scope heavy rains I When any of 7 n Water saving at each SBU’s at Hydro I SBU is not 8 9 in operation on a C particular 10 11 day for more 12 than 8 hrs. D Loss - Gain Matrix 0 1 Gains Loss M 2 3 Redu ced wat er C onsumption. ETP tr eat m ent co st will b e high Short Maint en ance of z ero discharge W ater cess will b e h igh A Term 4 Lo wer efflu ent g en er ation 5 Sust ain ab le gro wth Vio lation of zero d isch arg e 6 condit ion s Long Cost r edu ctio n During dr aught years I Term continu it y of op er atio ns 7 may suffer 8 9 Leaning & sat isf act ion of t eam memb er s C Better image within st akeho lders 10 11 12 8
  9. 9. Identif y D Vari ati on 0 List of X’s Chosen for Screening Sourc es 1 M 2 3 Sl. No. Name of ‘X’ Description of ‘X’ Cycle of c oncentr ati on i.e TD S i n A X1 COC circul ati on water to TD S i n M ake U p 4 water is to be mai ntai ned > 7 5 6 X2 Water Level Pr obe Probes at all the C T’s were opti miz ed I 7 8 Filter water use at H BF cake was hing as X3 Stoppage of Us e of Filter well as at cloth was hing reduced and 9 Water for replaced with recy cled water. HBF washi ng C 10 11 12 Identif y D Vari ati on 0 List of X’s Chosen for Screening Sourc es 1 M 2 3 Sl. No. Name of ‘X’ Description of ‘X’ Condensate tanks li ne earlier c onnected wit h A X4 Transfer of C ondens ate to Cooli ng T ower CT3, Now s hifted to CT1 & 2 for r educ tion i n 4 makeup water. 5 6 Frequent Cl eani ng of Sc hedule has been made and being foll owed X5 Cooli ng T ower Nozzles for cl eani ng of nozzl es at all CT’s I 7 8 Opti mization of Cooli ng Circulation r ate of CT pumps are opti miz ed 9 X6 Tower Circul ati on based on r equirement at end us e. C 10 11 12 9
  10. 10. Water Saving & Financial Impact in terms of Monthly Saving:- Wat er Consumpt ion M3/M T of Cathode Financial S avings Water Conservation (Rs) Water Linear (Wat er Consumpti on Consumpt Fi nancial M3/MT of Cat hode) Mont h ion Savings M3/M T of (Rs) 16 800000 Cat hode 700000 Base Line 14. 79 15 SST 14. 25 141762 Water M3/MT of Cathode 600000 PT 13. 75 273023 14 Financial Saving 500000 June, 07 13. 05 432400 Jul y,07 11. 83 748007 13 400000 A ugust ,07 12. 57 570289 300000 S ept, 07 11. 82 715241 12 Oct ,07 11. 65 752124 200000 11 100000 10 0 PT SST July,07 Oct,07 June,07 Sept,07 August,07 Base Line Month Present effluent flow at DM plant DM plant CT blow down CT SSF back PSF bac k regeneration 250 m3/day wash wash 110 m3/day 100 m3.day 100 m3/day N- Pit of 200 m3 capacity Pumped to ETP ETP 10
  11. 11. PROPOSED PROJECT Proposed recycling DM plant CT blow down CT SSF back PSF back regeneration 250 m3/day wash wash 110 m3/day 100 m3.day 100 m3/day New Pit of 75 m3 capacity N- Pit of 200 m3 capacity Pumped to ETP Pumped to Roaster water Mixing in boiler WGP & any injection blow down for excess to RO ETP 250 m3/day cooling directly 100 m3/day Water Circuit Hydro I Raw water clari fier RO treated water 3500-3000 m3 2000-2500 m3 W ater treatment 5500 m3 Roaster & Aci d DM plant Cool ing Tower L& P Cell house & Melting 400 m3 1500 m3 2500 m3 600 m3 500 m3 Boiler Blow down Regeneration Blow down Mg Bleeding Anode & Cathod washing ACF & PSF GCP area back wash Vacuum pump cooli ng Pump seal cooling 250 m3 Vacuum pump cooling 300 m3 300 m3 320 m3 400 m3 ETP 11
  12. 12. Monitoring & Reporting Systems DAILY W A TER CONSU MP TION D A TA S HEE T DA TE: / / Ti me : A. M. Initial Final Cons. Remar Description Reading Reading (m³) k 1 Raw wate r to Cla rifier (X 10 m ³) 2 CT Ma ke up 3 DM wate r to CST 4 SW to Service wate r tan k 5 Raw wate r to Fire H ydra nt tan k (X 10 m ³) 6 Potable water to Pota ble water t ank Activities for aw areness on w ater conservation in Plant n We celebrate “Worl d Env ironment Day ” on June 5 ev ery y ear n CH ANGE: Challenge for How to Acknowledge the Green Education was organi ze d in May , 08 as One day awareness workshop on Water Conse rv ation. n One week was f ully dedicated and Declare d as WATER WE EK f rom 5TH June to 11th June, 08 in Colony as water conserv ation and capacity building initiativ e. n Green Em ploy ee of the Month Scheme is in practice to recogni ze the eff orts of plant person al towa rds Water Conserv ation Activ ities. n We also publish qu arterly magazine o n HSE titled “Saath Sa ath” n Posters on water conserv ation are displ ay ed at v arious locations of the plant n In-house intra net based web -site titled ‘Apna HSE Web P ortal” n Promotion of use of treated sewage water f or lawns & plantation in resp ectiv e househo lds n Rain water h arv esting thereby recharging old bor e wel ls at Township ad opted 12

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