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ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
ITC Limited, Tribeni
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ITC Limited, Tribeni

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This is a presentation from ITC Limited, Tribeni, 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, Tribeni, 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, Business, Technology
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  • 1. ITC Limited Pape rboards & Specialty Papers Division Unit – Tribeni WATER MANAGEMENT CII–SO HRABJI GO DREJ GR EEN BUSINESS C ENTRE 16th – 17th Decemb er 2008 Unit Profile • A Specialty Paper Mill • Three Paper Machines • Production 2007-08: 23387 MT • Annual Turnover = Rs. 1937 Million • Certified ISO 9001, 14001 and OHSAS 18001 1
  • 2. Organisation Structure Vice Pre side nt Tribe ni O pe rations HOD DG M Finance Operations HOD HOD HOD Ma terials Engineering Produ cti on (Was te & Haz.ch em HOD IS (Mech. ) IS (PM 3&4 ) Mg r) Techni cal MR ISO HOD CS IS (Elect .) IS (PM 1) HOD Safety HOD IT IS (Instmn. ) IS (FH) MR OHSAS HOD HR IS (E & U) CMO IS (Secu rity) TEM Water & Bio Med Fire Co-o rd Coo rdinator Energy Mg r Waste Mg r & Afforestn. Source of Water f17 Nos. of Borewells located within Mill and Estate Area fSink Depth of 600 ft below ground level fTapping is done at a depth of 350-550 ft 2
  • 3. Water Balance Area Quantity m3/day Average daily 5959 consumption Paper Machine 1 1311 Paper Machine 3 2169 Paper Machine 4 1740 DM Plant 345 DIW & ETP 110 Chemical Kitchen 120 Mill Drinking Water 164 Fresh Water Consumption ( April – Q uantity , m3 Produ ction in Specific water March ) Tonnes consu mption, m3/ MT Industrial Do mes ti c 2004-05 25323 51 13216 8 23667 107 2005-06 25161 96 12696 74 24024 105 2006-07 23953 56 11507 34 24250 99 2007-08 21148 30 11315 97 23387 90 3
  • 4. Fresh Water Consumption Specific Fresh Water Consumption (kL/t) 230 213 178 180 128 130 107 105 99 90 80 2001- 2002- 2003- 2004- 2005- 2006- 2007- 2002 2003 2004 2005 2006 2007 2008 With con tinuous efforts and several fresh water saving initiativ es impl emen ted, we have reach ed this position. Fresh Water Consumption Cumulative % reduction in Fresh Water intake w.r.t 2001-02 60 57 49 50 53 50 39 40 % reduction 30 20 16 10 0 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 4
  • 5. Fresh Water Consumption Benchmarking Tribeni Mill National Internation CPCB Benchmark al Norms Benchmark 90 m3/T Not 100 m3/T 150 m3/T Available (w.r.t waste wate r norms of 120) Best Availabl e Ref erences of European Countries fro m th e "BREF Pulp and Pap er", el ectronic ad aptation of the Eu ropean ref erence docu ment on Best Availabl e Techniques (in the slant of redu cing th e agg res sions to man and environment) in the Pulp and Paper manufa ctu ring industry. Implemented Projects 07-08 Scheme-1: Recirculation of Fresh Water from Overhead Tank for Compressor cooling 5
  • 6. Implemented Projects 07-08 Scheme 1 Old System: New System: F/water r equir ement 30 m3/hr . F/water r equir ement 30 m3/hr . Water sent back to Over head Tank : Nill Water sent back to Over head Tank : 30 m3/hr Actual cooling Water consumed : 30m 3/hr Actual cooling Water consume d : Nil Savings : 237600 m3 / year Investment Rs.0.2 Lakhs Implemented Projects 07-08 Scheme-2: Reduction of sealing water in Couch of PM4 by use of Anti friction bearing Savings : 31680 m3 / year Investment Rs. 9 Lakhs 6
  • 7. Implemented Projects 07-08 Scheme3: Refurbishing of PM4 steam & condenser circuit Implemented Projects 07-08 Scheme3: Refurbishing of PM4 steam & condenser circuit Old System: New System: Steam r equir ement : 110 TPD Steam r equir ement : 80 TP D Condensate r ecover y : 39 TP D Condensate r ecover y : 56 TP D Water r equir ement : 21 TPD Water r equir ement : 7 1 TPDr Water saving : 50 TP D ( This saving would come in DM wa ter ) Savings : 49500 m3 / year ( DM water) Investment Rs. 120 Lakhs 7
  • 8. Implemented Projects 07-08 Scheme5: Se quencing of Coloure d Laminating Grade making on PM4 Grade change in Colour laminating grades is associated with lot of water for cleaning & flushing the system. T PM team has come together to reorganize making schedule with in-depth R& D inputs to avoid water usage during many grade changes Savings : 12000 m3 / year Investment : Nil Implemented Projects 07-08 Scheme 6: Use of New Generation CentriCleaner system on PM1 Picture before modification Picture after modification Water requirement : 6m3/hr Water requirement : 4m3/hr Savings 15840 m3 / year Investment Rs.28 Lakhs 8
  • 9. Implemented Projects 07-08 Scheme 7: Reduction of leakage of Gland sealing water through use of Mechanical seals Savings : 15840 m3 / year Investment Rs. 24 Lakhs Implemented Projects 07-08 Scheme 8: Use of highly efficient imported Vacuum Pumps requiring less sealing water Before Modernisation After Modernisation Savings : 23760 m3 / year Investment Rs.57 Lakhs 9
  • 10. Implemented Projects 07-08 Scheme 9: Reduction in consumption of Make up water in Cooling Tower by improving COC Implemented Projects 07-08 Scheme 9: Reduction in consumption of Make up water in Cooling Tower by improving COC Old System: New System: For TG2 For TG2 Evaporation loss: 1 1 m3/hr Evaporation loss: 1 1 m3/hr Blow down : 27. 5 m3/hrl Blow down : 5.5 m3/ hrl Total mak e up water : 38.5 m3/hr Total mak e up water : 16.5 m3/hr For TG3 For TG3 Evaporation loss: 14.7 m3/ hr Evaporation loss: 14.7 m3/ hr Blow down : 36. 7 m3/hrl Blow down : 7.4 m3/hrl Total mak e up water : 51.4 m3/hr Total mak e up wate r : 22 m3/h r Total mak e up water reqd.: 89.9 m3/ hr Total mak e up water reqd.: 38.5 m3/ hr Savings : 50 m3 / hour Investment Rs. 40 Lakhs 10
  • 11. Implemented Projects 07-08 Scheme 10: Introduction of Reverse Osmosis system in PM1 Savings : 39600 m3 / year Investment Rs.40 Lakhs Waste Water Discharge Specific Waste Water Discharge (kL/t) 11 0 80.7 69.3 63 61.5 60 2004-2005 2005-200 6 2006-2007 2007-2008 With con tinuous efforts in max imising pro cess wa ter recy cling we hav e redu ced belo w 50 % of CPCB norms. 11
  • 12. Waste Water Discharge Waste Water Discharge - Benchmarking Tribeni Mill National International CPCB Norms Benchmark Benchmark 61.5 m3/T Not Available 60 m3/T 120 m3/T Best Availabl e References of Europ ean Countries fro m th e "BRE F Pulp and Paper", el ectronic ad apta tion of the Eu rop ean reference do cument on B es t Availabl e Techniques (in the sl ant of reducing the aggressions to man and environment) in the Pulp and Paper manufactu ring industry. The Road Map towards Zero Discharge 3-step process: • Implementation of Future Fresh Water Conservation Projects • Closing the Water Loop with reuse of Mill Treated Water • Continuous Monitoring and Control to sustain the System 12
  • 13. Monitoring f All fresh water consuming areas are provided with water flow meters connected to DCS system. f Daily, weekly and monthly MIS reports contain the fresh water consumption figures. f Monitoring is done online, by the respective utilities and paper machine shift incharges. f Specific Key Focus Areas are predefined for respective managers as a part of their annual appraisal system for Water Conservation Measures and Monitoring 13

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