I T C L I M I T E D
Water Management @ ITC Limited, Munger
Presen tation for
CII - Nati onal Award for Excellence in Water Mana ge ment 2008
I T C L I M I T E D
Profile
• Celebrated its Ce nte nary Yea r on 6th November, 2007.
• Located in Bihar, 173 km from Patna
• Product : Package d Cigarette s
Key Achievements (2007- 2008)
• ISO 9001 : 2000 ; ISO 14001 : 2004 & OHSA S 18001 certified plant.
• National Award for excellence in Water Ma nageme nt 2007, CII – GB C.
• Natio nal Award for e nergy c onservation - inno vative project 2007, CII- GB C.
• First prize in eastern regio n Safety Healt h & Env ironment Award 2007, CII .
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I T C L I M I T E D
ability Re port
ITC’s Sust ain
I T C L I M I T E D
Water Management A pproach
• Establish Over all Wate r Bal ance
• Reduce at sour ce
• Reuse in other bene fici al applicati ons a fte r trea tmen t (lan d scaping,
toile t flushing, cooling towe r appli cati ons an d civil constructi on s etc.,)
• Recycle back to pr ocess appl icati ons a fter a ppr opr iate treatment
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I T C L I M I T E D
Water Consumptio n Trend
Water Consumption
800
750
700
650
KLD 600
550
500
450
400
0 1 02
- 02- 03 0 3-04 04- 05 05- 06 06- 07 07 -08
Ser ies1 775 712 682 526 463 467 5 08
Year
Please Note: Please Note: Water con sum pti on increased by 8.7 % as
producti on in crea sed by 15.0 % compare d to last year however the spe cifi c
water consumpti on is reduce d by 6 %.
I T C L I M I T E D
Specif ic Consumptio n
Specific Water Consumption
14.00
11.52
12.00
10.11
10.00 8.80
8.00
5.89
6.00 5.33 5.02
4.00
2.00
0.00
02- 03 03-04 04-05 05-06 06-07 07-08
Index kl/mnc
Please Note: Spe ci fic Wate r Con sumpti on ha s reduce d by 6 %
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I T C L I M I T E D
Spe cif ic Wa ste Wa ter Discharge
Qty Qty Qty
generated recycled discharged Volumes Specific water
Year (m3/day) (m3/day) (m3/day) (MNC) discharge (kL / mnc)
2004 - 2005 151.8 58 105 24 4.4
2005 - 2006 143.3 138 6 31 0.2
2006 - 2007 161.7 158 3 35 0.1
2007 - 2008 157.6 120 38 40.5 0.9
I T C L I M I T E D
Spe cif ic Wa ste Wa ter Discharge
4.5 4.24
4
3.5
3
2.5
2
1.5 0.9
1
0.2 0.1
0.5
0
'04 - '05 '05 - '06 '06 - '07 '07 - '08
Specific Water dis cha rge.
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I T C L I M I T E D
Perf or mance Index
Benchmark & Trend Setting
Benchmark ITC Munger
Wat er Index (Na tional) Wat er Index : 5.0 2 KL /Millon of
: 4 .88 KL/M illon of cig ar et tes** ciga rett es
Wat er Index (Int er nat ional) Target : August, 2009 (To achieve national
: 4.8 5 KL /Millon of c iga rett es* and International Bench mark).
* BAT’s S ocial Rep or t 200 7
** ITC’ s Ba ngal ore Fac to ry
I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
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I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
6

I T C L I M I T E D
Sustainabili ty – Re vie w & Moni torin g
Da ily
ü Water Analysis Repor t
ü Effluent Repor t
Monthly
ü Management Review (BM)
ü Report to Chi ef Engine er.
Yearly
ü Annual Water & EHS Rep or t
ü Director’s Re por t
ü Unit Achievement Rep or t
Bey ond Equipm ent P erf ormance….
ü Performance appraisal of M anagers
I T C L I M I T E D
Water Conserv ation Projects
• CII Water Audit carried out in 2005-06. The following savi ngs po tentials
were identifi ed:
Effluen t discharge (200 5 – 2006 ) 160 m3 /day
Reducti on thr ough re cy cle of MGF /IRF b/w water 30 m3 /day
Reducti on in dome sti c water con sumpti on 15 m3 /day
RO product for CT make-up 50 m3 /day
RO reject for garde ning & Toi let fl ashing s 65 m3 /day
Total 160 m3 /day
• Earlier Treated Disc harge Water is b eing us ed b y
•Local farmers for irrigation
•Small scale gardeni ng i nside fact ory
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I T C L I M I T E D
Proposal # 1 : Recycle of Backwash Water
Raw water
MGF IRF Soft
tank Soften er
Water
– pH – 7.2-7.3
– TSS – 15-20 ppm
– TH – 500-550 ppm – pH – 7.2-7.3
Backwash
– TDS – 800-1000 ppm – TSS – 40-50 ppm
Water
– TH – 500-525 ppm
– TDS – 900-1000 ppm
Impl em ent ed
Existing
MF IRF
Raw wate r tank
By gra vit y
( TSS <20 mg/l)
Slu dge
Backwash water To dis posal
31 m3/day
I T C L I M I T E D
Proposal # 1 A cco mplished
Tube Settle r Pla nt
Savings: 30 m3 /day (10500 m3 /day annually )
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I T C L I M I T E D
Proposal # 2 : Reduction in domestic Water
• Dual Flash
• e- Flash
• e- Ta p
I T C L I M I T E D
Proposal # 2 A cco mplished
Dome stic Wa ter Sav ing s
E-Taps
Foam- Taps
People Awa reness
Dual Flash
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I T C L I M I T E D
Proposal # 3 Accom plished
Loca l Usage
Toilet Usage
Landscaping
Usage: 65 -70 m3 /day
I T C L I M I T E D
Proposal # 3 : RO Pla nt for Trea te d Efflue nt
vSegregate High T DS stream and dir ectly pum p to Final eff luent tank
ØAvoid the unnecessary TDS load to Ae ration
ØHelp improve the Aeratio n tank performance
vTreat the fina l effluent through RO – 11 5 m3 /day
Ø50 m3 /day output as Cooling Tower M ake-up
Ø65 m3 /day reje ct to garde n use, toilet flush
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I T C L I M I T E D
Proposal # 3 : RO Pla nt for Trea te d Efflue nt
110 m3/day
Treated Inter mediate
effluent tank Inter mediate
MGF
tank UF tank
Filter f eed
Existing pump
Existing TDS < 150 ppm TDS < 150 ppm
TDS – 1200 ppm
TH – 700 ppm TH < 50 ppm TH < 100 ppm
RO
Treated wate r-50 m3/day Softene r module
for CT make up
Reject
For garde ning,
Toilet flush
Note: TDS < 2100 ppm
MGF - Multi gr ade filte r COD < 250 ppm
MF - Micron fil ter BOD < 75 ppm
UF - Ultra filtra tion
RO - Reve rse Osm osis
I T C L I M I T E D
Proposal # 3 A cco mplished
Effluent Recy cling Scheme
Saving pote ntial: 50 m3 /day (17500 m3 /day annually)
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I T C L I M I T E D
Proposal # 3 Accom plished
Loca l Usage
Toilet Usage
Landscaping
Usage: 65 -70 m3 /day
I T C L I M I T E D
Other Initiatives
Remo te Radiator/T able Cooler
v ITC Mung er has proc ured a Rotary
UPS : A world class technology that has
a mec hanical stor eho us e of ener gy
coupled wit h a Diesel Engi ne
vIn place of a conventional Co oling
Tower, we hav e gone for a Table Co oler
which is an Air Co oling Remot e
Radiator
vHig h o n Cost
vBut sav es o ver 400 KL
water annually
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I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
v Parallel Plat e Separator post chemical treat ment
vOrganic Waste r emo ved as sludg e
vSludge Dewat ering /Filter Press
vFor Bett er Sludg e handling
vOil Catc h Pits
vTo arrest oil from enteri ng ET P Process Parallel Plate Separator
Filter Press Oil Cat ch Pits
I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
vETP A uto mation
• 8 Lev el Sensors
• 14 Aut o valv es Con tr olled from
• 6 NRVs HMI
• 5 parameter s ens ors
On line mo nitoring of D O, pH, T urbidity, Fr ee Chlorine
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I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
vRes ults
100
90
80
70
60
60
Mg / L
48
50 36
40
40 36
30 32
30
20
May
August
June
'07 - '08
July
Sept
April
I T C L I M I T E D
Initiatives in Residential Colony
Rain Wa ter Harve sting
Rec harge Struct ures :
• Roof T op Water – Aquifer Recharge Str uct ures
• Rec harge Tre nc h
• Onl ine Rec harge Pit
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I T C L I M I T E D
Impact of Recharging -
Depth to Wa te r Level (mb sl)
IT C Pa rk , Mun ger
Hydro graph Stati on Year Total Ju ne Ju ly Aug Sept.
1 Borewe ll n ear 2006 19.00 17. 00 16. 25 14.50
Bird’s eye 2007 15.60 14. 40 13. 82 13.80
Increment 3.40 2. 60 2.43 0.70
2 Borewe ll n ear 2006 18.00 16. 00 15. 50 13.00
Bank Hal l 2007 15.50 14. 30 13. 65 12.65
Increment 2.50 1. 70 1.85 0.35
3 Borewe ll n ear 2006 17.25 16. 50 16. 25 16.00
Near W are House I 2007 17.13 16. 00 15. 80 15.80
Increment 0.12 0. 50 0.45 0.20
4 Borewe ll n ear 2006 18.00 17. 00 16. 00 14.70
Near W are House II 2007 16.13 16. 00 15. 80 15.80
Increment 1.87 1. 00 0.20 -1.10
Rai nfall (mm)
2006 916 13 284 416 203
2007 1109 250 246 142 471
I T C L I M I T E D
Impact of Recharging -
Ground Water Level- Borewell-Bi rd' s E ye Ground Wat er Level- Borewell -Bank Hall
-1 0
-10
-1 1 Jun e July August Septem ber
-11 June July A ugus t Sept ember
Meter below Ground Lvl
Meter below Ground Lvl
-1 2 -12
-1 3 -13
-1 4 -14
-1 5 -15 6
-1 6 -16
-1 7 -17
-1 8 -18
-1 9 -19
-2 0
Ground Water Level- Borewell -W/H-1 Ground Water Level- Borewell-W/H-2
-1 0 - 10
Ju ne July August Se ptem ber Jun e July Au gu st Sept emb er
-1 1 - 11
Meter below Ground Lvl
- 12
Meter below Ground Lvl
-1 2
- 13
-1 3
- 14
-1 4
- 15
-1 5 - 16
-1 6 - 17
-1 7 - 18
-1 8 - 19
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I T C L I M I T E D
We understand the worth of water,
Even when the well is full of water.
Thank You
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