ITC Limited, PSPD, Unit - Kovai

  • 2,430 views
Uploaded on

This is a presentation from ITC Limited, PSPD, Unit - Kovai, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 …

This is a presentation from ITC Limited, PSPD, Unit - Kovai, 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.

  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Be the first to comment
    Be the first to like this
No Downloads

Views

Total Views
2,430
On Slideshare
0
From Embeds
0
Number of Embeds
0

Actions

Shares
Downloads
53
Comments
0
Likes
0

Embeds 0

No embeds

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
    No notes for slide

Transcript

  • 1. PSPD, KOVAI CII National Award 2008 “Excellence In Water Management” 16 & 17 Dec 2008 ITC Limited, PSPD, Unit - Kovai Company Profile: PSPD, KOVAI ITC Limi ted , PSPD Unit:Kov ai • ITC Ltd is a multi business Co rpo rat e with En viron mental Philoso phy o f Trusteeship rel ated to soci al & envi ronment al resources, aligned to the purs uit o f economic obj ectives. • PSPD is the Paperboard & Specialty P apers Di vision, 1500 crore busin ess having 4 manufacturing Units • Unit: Kov ai is On e o f th e units, locat ed 42 k m north o f Coimb ato re, Tamil Nadu. - Acquired from B IPCO in M arch 20 04 - Production capacity o f 9 0000 t/ y ear ( from 55,000 t / year) - Manu facture Du plex Board from 10 0 % recycl ed fi ber - ISO 9001, ISO 14 001 & OS HAS 1 8001 certi fi ed 1
  • 2. Process Flow - Block diagram Fuels Emission: SPM <50ppm PSPD, KOVAI Water Water Treatment from River Powe r: 8 m w DM Sp. Water: 13.4 m3/t Boiler Plant White Con dens ate Cutti ngs recovery Steam Screen +3 Hot Pulper centricl Dis TL wire eaner per ser. D Screen Coaters Sheeter Press: e + Hot Suction Top : : 2& Pulper centricl Dis FL wire Dryers, Blade+ godown s + bi nip Rewin& Reel der eaner per Temsec MG, Rod Rewinder : 3 p ONP + ser. Calender Back : a Mag Blade t Screen +3 c Pulper BL wire centricl Finishing h eaner House Board machi ne Waste Paper Stock Storage Preparation Petax Sp. Effluent filter ETP Treated Effluent Discharge – 9.33 for Irrigation m3/ton Certifications & Awards: Unit - Kovai PSPD, KOVAI Certifications: • ISO 9001 : 2000 • ISO 14001 : 2004 • OSHAS 18001 : 1999 • British Safety Counc il Award 2007 : Rating • British Safety Counc il Award 2008 : Rating Awards: • “ Excellent Water Efficient Unit” – CII National awar d for Excellence in Water Management 2007 2
  • 3. Preservation of Environment: PSPD, KOVAI • Priority for Conse rvation of Re sources • Wate r & Ene rgy Conse rvation - Recyclin g & redu cing us ag e : Inv ested Rs 3.0 cr in new tech nologi es. - Invested Rs 55 cr in Energy cons erv ation. - Evaluatio n & improv em ents th roug h regul ar audits • Re cycling of solid waste : - 100 % fly ash from boiler, ETP sludge, Dein king slud ge & Pl astics fro m wast e p ap er are recy cl ed • Facilitie s & Proce sses are e nvironment frie ndly: - Onlin e stack monit orin g – SPM, SOx, NOx and continu ous AAQS to improv e environm ent al stand ards • CDM Proje ct: - Predo min antly using wast e biomass in boil er as fu el, 96,000 tons o f CO2 red ucti on per annum Preservation of Environment by Using PSPD, KOVAI Treated Effluent: Tre e Population Gree n Belt De velopment: 14 000 0 • 245 acre und er cultiv ation usin g 1 200 00 treated effl uent. 12 000 0 10 000 0 • 1,20,000 trees o f variou s species No of trees 805 00 8 000 0 5 500 0 • Long t erm tie u p with Tamilnadu 6 000 0 Agri cultural Universit y to monitor and stud y the imp act o f treat ed 4 000 0 efflu ent on soil & gro und wat er. 20 000 2 000 0 0 2 004 - 05 200 5 - 0 6 2006 - 0 7 200 7 - 08 3
  • 4. Mill water Balance: Intake from river : 3000 to 3800 m3/day PSPD, KOVAI Effluent Discharge : 2200 to 2600 m3/day From Ri ver Water Treatment Water meters 3800 500 700 Stock Preparation 1650 4600 3000 2575 Board 1900 3500 500 KRO FTA Petax Machine 2600 1350 ETP 1415 Steam 690 Boiler & 175 Utility 15 10 Irrigation Domestic Specific Water Consumption: PSPD, KOVAI 25 22 20 cu.m / ton of paper board 15.26 58% 15 13.31 reductio n 13.2 9.31 10 5 0 2004 - Q1 2004 - 05 2005 - 06 2006 - 07 2007 - 08 after ITC 4
  • 5. Water Conservation Projects: PSPD, KOVAI Under Waste Water Reuse: S Projects Inv estm ent Impl emented Water No in Lak hs year savings (m3/year) 1 Krim a sealing wat er o utlet 0.8 Sep 200 6 13,200 reused in proces s 2 Using boil er blo w down for 0.7 Jan 20 07 11,550 cooling tower m ake up 3 Petax Filter accept us ed for 0.5 Jan 20 07 33,000 filt er b ack was h instead o f fresh wat er 4 Top liner silo 2 ex cess back 1.4 Feb 200 7 29,700 wat er us ed for pul ping Water Conservation Projects: PSPD, KOVAI Under Waste Water Reuse: S Projects Inv estm ent Impl emented Water No in Lak hs year savings (m3/year) 5 Sealin g water reci rculation for 6.2 Mar 2007 1,15,500 vacuum p umps 6 Reus e of foam t ank overflow 1.0 May 2 007 33,000 to fill er pul per 7 Top liner tray water divert ed to 0.15 Mar 2008 11,880 top liner silo 5
  • 6. Water Conservation Projects PSPD, KOVAI Unde r Waste Wate r Re cycle : S Project Inv estm ent Impl emented Water No in lakhs Year Savings m3/year 1 Petax filt er inst alled fo r 200 April 20 05 9,90,000 recy cling o f pro cess water 2 Recycling dei nking wast e 1.0 Dec 200 6 90,750 wat er in th e top liner 3 Kro ft a Clari fied water used 0.5 Oct 20 07 47,520 in Broke Thickener 4. Stock Preparation rej ect 12 Dec 200 7 79,200 thick ening for recy cling o f back water Water Conservation Projects PSPD, KOVAI Under Water Reduction: S Project Inv estm ent Implem ent ed Water savi ngs No in lakhs Year m3/year 1 Top LP Shower worn 2.0 March 2006 24,750 out nozzl e change 2 Felt lubri cation nozzl e 2.0 Sep 200 6 33,000 changed to wid e angl e 3 Using Pet ax wat er in 0.5 Feb 200 7 66,000 fill er lin er d andy shower 4 Reduction o f P ump and 1.0 April 20 07 1,58,400 agitat or s ealing water 5 Optimi zation o f booster Nil June 2 007 63,360 pump 6 Redu ction o f R aw water 4.0 Aug 20 07 33,000 head er p ress ure 6
  • 7. Water Conservation Projects PSPD, KOVAI Under Water Reduction: contd S Project Inv estm ent Implem ent ed Water savi ngs No in lakhs Year m3/year 7 Lev el control for white 0.28 Jan 20 08 33,000 back, back wat er chest 8 Lev el Cont rol fo r Top 0.38 Jan 20 08 15,840 liner back water chest 9 Optimi zatio n o f b ack 0.15 Jan 20 08 15,840 liner wire ed ge cleanin g shower 10 Optimi zatio n o f 4 Nil Jan 20 08 79,200 numb er o f P ress part LP shower 11 Temperat ure control loop 1.75 Feb 200 8 95,040 for v acuum s eal pit m ake up fresh wat er Innovative Project 1 – Thickening of Stock PSPD, KOVAI preparation tertiary screen rejects • Past S cenario : Vibrating s creen and Side Hill s creen were us ed to thick en th e tertiary screen rejects, the out put co nsistency of sludg e was 2 to 4 % and th e filtrate collect ed was us ed in the syst em • Pres ent Scena rio: – Vibrating s creen and Side hill screen were replaced by two hydras creen. – Hyd ras creen consist o f s crew co nv eyo r en clos ed by a screen, which helped to avoid jam ming prevailing in old syst em – The consist en cy o f th e rej ects in creased from 2% to 20 % which increas ed the filt rat e qu antity by 10 cu.m/h r • Project Summary: – Fresh wat er s avings per annum – 79,200 m3 – Inv estm ent cost – 12 lacs – Payback Peri od – 26 months 7
  • 8. Innovative Project 2 – Temperature control PSPD, KOVAI loop for vacuum seal pit make up water • Past S cenario : Temperat ure o f s ealin g water is criti cal for v acuum pu mp effi ciency, the tem perat ure was co ntroll ed m anu ally using v alv e • Pres ent Scena rio: – A new tem perat ure co ntrol loo p pro vided fo r co ntrol – Temperat ure set poi nt given and th e flo w o f wat er v ari ed autom atically to maintai n the temp erature – This has increas ed reliability in temperature control and reducti on in fresh wat er m ake up • Project Summary: – Fresh wat er s avings per annum – 95,040 m3 – Inv estm ent cost – 1.75 lacs – Payback Peri od – 4 months Innovative Project 3 – Krofta clarified water for PSPD, KOVAI broke thickener shower • Past S cenario : Fresh wat er was used in brok e thickener sho wer with th e no zzl e size o f 2 mm fo r cl eani ng the thi ck en er m esh • Pres ent Scena rio: – Kro ft a clari fi ed wat er with 150 ppm o f TSS is chosen as replacement o f fresh wat er – Since the nozzl e size is 2 mm and the m aximum p arti cl e size in the Kroft a clari fi ed wat er is less th an 75 mi cron, the jammi ng tendency is too less – This helped us to stop fresh wat er compl etel y an d res ulted in s avings of 6 cu.m/hr • Project Summary: – Fresh wat er s avings per annum – 47,520 m3 – Inv estm ent cost – 0.5 lacs – Payback Peri od – 2 months 8
  • 9. Bench Mark – Specific water consumption PSPD, KOVAI Without Dei nking & CPP Road Map towards International B ench Mark: 10 9.31 • Reus e o f Pro cess Efflu ent by lo calized 9 treatm ent cu.m / ton of paper board 9 - Treat efflu ent from Stock p rep aration sep arat ely witho ut sendi ng to ETP, necess ary 8 facilities are plan ned an d to be install ed in 2007 - 08 Bench Mark - NPC 2008 - 09 With Deinki ng & CPP • Reus e o f treated efflu ent in the p ro cess 22 19 - Inv estm ent in secon dary treatment plant is 18 plann ed in 20 09 -10 cu.m/ ton of paper 13.4 board 14 10 • Impl ementatio n o f rain wat er h arv estin g inside 6 the plant 2009 - 10 20 07 - 0 8 Bench Mark - NPC Specific Waste Water Discharge: PSPD, KOVAI With Deinking & CPP 50 50 cu.m / ton of Paper Board 40 30 50 20 15 m3 /t 9.3 10 15 m3/t 9.3 m3/t 0 CPCB Norm Bench Mark - NPC Un it - Kovai 9
  • 10. Pe r capita Domestic wate r consumption: PSPD, KOVAI 18 17 17 Ltrs/person/day 16 15.57 15 14.19 14 13 2005 -2006 200 6 - 2007 2007 - 08 Review : Sustenance & Improvements PSPD, KOVAI • Consumpti on at all consuming points are captured in DCS - Hourly rep ort is generat ed for mo re th an 30 p oints - Automati c al arms d urin g variatio ns • Daily area wis e fresh wat er cons umptions are monito red • Water consumpti ons revi ewed, vari ances analyzed & corrective actions planned in - Dail y AET’s meetings - Weekly Producti on Pillar m eetin g - Monthly P erformance revi ew by Unit Steerin g Board. - Designated Wat er M anager facilitat es the revi ews. • Impl ementatio n status o f s ugg estions fro m PACT memb ers ( wo rkm en ) are revi ewed in mont hly perform an ce reviews. 10
  • 11. Real time MIS report from DCS: PSPD, KOVAI ITC PSPD KOVAI R eport Duration : SHIFT WAT ER REPORT Operator : SHIFT 1 6am 7am 8am Engg M ax Min Avg Sr. No. Description Time Time - - - Units Value Value V alue 7am 8am 9am 20 Fresh water flow m3/hr 283.50 11:23 65.47 6:51 97.19 82.66 135.69 109.37 21 Raw water pressure bar 4.40 12:15 1.71 7:47 3.80 3.33 2.71 3.66 22 Krofta feed flow rate m3/hr 5999.15 7:27 5605.15 11:37 5768.15 5868.73 5910.60 5805.96 23 Krofta feed line valve opening % 100.00 6:01 100.00 6:01 100.00 100 100 100 24 Main cooling tower level % 87.02 6:10 74.35 8:09 78.32 85.16 79.43 75.42 25 P etax running time in A shift mins 436.00 14:00 0.00 6:01 217.07 29.50 86.65 130.50 26 P etax running time in B shift mins 357.00 6:01 357.00 6:01 357.00 357 357 357 27 P etax running time in C shift mins 443.00 6:01 443.00 6:01 443.00 443 443 443 28 fresh water totalizer for A shift m3 779.70 14:00 1.22 6:01 408.70 43.06 144.60 276.77 Water Conservation in Local community PSPD, KOVAI • Awareness program in loca l society - Involving local community in World Environment & farmer’s Day celebrations. - Distribution of saplings. • Drinking water supply to local village s (2500 people) • Rain water harvesting facilities - Check dam s : 7 nos - De-silting of ponds : 19 nos - Beneficiaries Recharged Open wells : 160 nos Recharged Bore wells : 99 nos 11
  • 12. PSPD, KOVAI THANK YOU 12