Kankroli Tyre Plant(KTP), A unit of JK Tyre & Industries Limited

  • 5,734 views
Uploaded on

This is a presentation from Kankroli Tyre Plant, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 …

This is a presentation from Kankroli Tyre Plant, 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 like this
No Downloads

Views

Total Views
5,734
On Slideshare
0
From Embeds
0
Number of Embeds
0

Actions

Shares
Downloads
65
Comments
1
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. CII - Sohrabji Godrej Green Business Centre, National Award for ” Excellence in Water Management – 2008” 2008” Presentation By Kankroli Tyre Plant (KTP) A UNIT OF I Team Members Mr. DR Pai Mr. A K Pamecha Mr. M P Sharma Special Guidance Mr. A K Makkar (Unit H ead ) Slide No . 1 UNIT PROFILE JK TYRE AND INDUSTRIES Banm ore (MP ) Kankroli (Raj asthan) Vikrant Tyres, Mys ore KANKROLI TYRE PLANT KTP – MISSION • Established at Kankr oli - 1976 • Initial capacity – 55 Ton/ Day, KANKRO LI TY RE PLANT • Curre nt capacity – 210 Ton/ Da y TO BE • Water Demand – 1200m3 (Max) ZERO LEAK P LANT Slide No . 2 1
  • 2. PROCESS OUTLINE Duri ng ma nufacturi ng, w e use Compressed Air, Steam, Water & Oil at v arious applications of pr ocesses. At KTP w e thought for a consolida te policy and pr ogram for identi fication and c orrection of leaks, Zero Drai n and Water Pr ocess efficienc y impr ov ement, Zero Leak mission w as started in J un -2008 Slide No . 3 Industry Benchmark 3T n m/ o Avg. – 8.4 Our Plant 3.04 2 nd Best – 4.8 C nu pi n o s m to Wtr ae Data Source : CII Study, Conducted by : Forbes Marshal Future Plans to “BETTER THE BEST” Slide No . 4 2
  • 3. WATER CONSERVATION STRATEGIES WATER CONSERVATION STRATEGIES 1. Work for ZERO Discharge 2. Develop Hydrophobia for water in unwanted places 3. Eliminate all open drains 4. Optimize and load cooling towers to their 100% capacity to reduce evaporation losses 5. Reduce evaporative cooling to the extent possible. 6. Explore radiator / air cooling 7. Recover / remove heat to the extent possible from water before sending it to cooling tower 8. Eliminate Flash losses in steam usage 9. Identify wastage and eliminate them. 10. Deploy concepts of Multiple recycling / recovery and reuse Slide No . 5 Initiatives Ø Prize for water efficient family block (8 quarters). Ø Prize for every received sugge stion, 15 No s/month Accepted sugge stions, Every implemented sugge stion for water con servation / Leak. Ø Solar Water Heater For Canteen Ø Solar Water heater for Ca rbon area Workmen bath Ø Water con se rvation by recycled water for Air Wa sher in Plant Ø FRP Sheet s for abundant daylight utilization Ø Push cock water tapings. Ø Dist rict Level Children Poster competition Ø Steering committee formed comprising of Unit Head, BU/SSU Head s, Asset Managers & Workmen. Ø Health Check up & Medical add to surrounding residing. Slide No . 6 3
  • 4. E.M.S. INITIATIVES AT KTP Ø Discharge Elimination Ø Leakage Elimination Ø Air Emission Reduction Ø Effluent Discharge Reduction Ø Adoption of clean Processes Ø Energy Conservation Ø Optimization of Fuels and Oils Ø Recycling, recovery and reuse Ø Process Waste reduction Ø Enhancing Green Belt Ø Resource Conservation Slide No . 7 Water Conservation Efforts Water Conservation Efforts VISI ON, M ISSI ON & GUIDANCE Recycle & Rain Water Waste Harvesting Apex Apex Treatme nt ING Level RE Lev el E-U CL - S Cooling Unit Level Water CY Towers Unit L evel Q uantificatio n E E Eliminatio n RE Business Uni t Level Busin ess Unit Lev el Sav ing Sewerage Task For ce / Small Gr oup s Droplets Recycling SG Projects RECOVERY Slide No . 8 4
  • 5. Water Conservation Projects By Employees A THEMES Pro jects Im lemente d p T eam Maintain in g ZERO Disch arg e M CS E lo y ees awa rene ss impro v ement p ro grammes mp M CS Pu sh co ck in place o f n o rm l tap es a M CS B THEMES Toilet flu sh water v olume red uc tio n b y inse rtin g M CS brick P rojects Implemented Team Twin ty p e T oile t flu sh water tan k in trod u ctionall cooling water lines Clos e looping of M CS MCS Reco very In creas e in plant & colo ny was te water & Use o f b ack wa sh water in Air recycling g Sy stems M CS Han dlin MCS Tren ch water recov ery Boiler b low-d own re du ction by con d uc tiv it y M CS Improve s team co ndensate recovery MCS MCS C THEMES con tro l o f DM Wat er Coo lin g to wers elimin ation andRain po ration lo ss eva water harves ting us ing natural Pro ject s Implof Terrain gradian t emen te d MCS Team M CS Emp loy ye inv o lve men t t hrou gh sp ecific s ug ges tio ns fo r w ate redu ctio n Wo rk men & St aff co n serv at ion Dra in co rrec tio n s an d maint ain ing s water harves ting Rain torm wa ter us ing Plant roof water collection MCS M CS Drin kin g w ater su pp ly pressu re red u ctio n Wo rk men & St aff drain s d ry Red uc tio n in n umbe r o f w ater t aps Wo rk men & St aff Us e of radiator cooling (A CF C) inplace of cooling towers MCS 24 x 4 Leak mon ito rin g sys tem 2 Wo rk men & St aff Us e o f b ack wash wat er fo r Flo or & Road cle anin g Wo rk men & St aff Cooling to wer recons truction for efficiency Stea m re du cti on in bo iler de -aerat or by wa y o f p re - W at er for improvements MCS Wo rk men & St aff h eat ing u sing wa ste hea t A CILOL Chemical s prayning in neig hbouring st eam i nst ead of lea vin g in o pe n a tmo sp he re Us e o f Flash world Wo rk men & St aff MCS famous Lake RA JSA MA ND for evoporation wat er u sag eatio n sp ra y b y use of b ack-wash Sto p fre sh minimis in co al Wo rk men & St aff wa ter Us e o f au to st op v alve s wit h time s fo r sto pp in g w ate r Wo rk men & St aff circu lat ion in idle m/ cs Ferrul es in sertio n fo r wa ter co nse rv ati on Wo rk men & St aff Sto pp ag e o f se con d circ ula tio n p u mps in cert ain pl aces Wo rk men & St aff Slide No . 9 SUSTAINING : LEAK FREE PLANT Awareness Among People Leakage is Direct Loss of Resources gok i k cpk l s cpr k /ku , uh us •NEW TAG DES IGNED FOR c<rk m i knu [ k' k j gr k eu! R q THIS MISSION. d gr dch l q sH l k/kk , j uk kbZ s • THE TAG HAS 3 FOLDS: ok i kuh dk l c fey ck/k ! "i s Wks • 1ST FOLD TO TIE ON LEAK gok i k dk ugh d k Zeky uh b s s • 2ND TO CORRECTING gj l e; dsfy ; s ; sgs vueks ! y AGENC Y COST OF LEAK: AIR@6KG/CM2 IN 3/8PIPE=Rs:2.6 0/Min • 3RD FOR REGISTRATION / OIL=ONE DROP /PER Day =Rs:6.85 MONITOR ING Ac tive P ersons • ANY PERSON CAN 11 98 IDENTIF Y ANY LEAK AT 112 ANY PLACE. Ar ea Identified Corrected % Correction 350 300 306 320 BU1 208 173 83% 250 233 2 6 4 BU2 173 146 84% 200 89 150 92 BU3 363 259 71% 70 104 94 68 10 5 0 0 Warehouse 4 4 100% 0 St ea m Air Oi l w ter a Ut il ity 86 73 85% B U1 BU2 BU3 SSU1 WH Ident f ed i i Corre cte d Grand Total 834 655 79% Slide No . 10 5
  • 6. Pro ject – 1 : Co oling Tower Efficiency I mprov ement Cooling Tower # 3 & 4 Before After CT# 4 Compressors & VAM Chille r CT# 3 Cooling BU-1 Mills • Cooling Tow er#1 capacity enhanced from 600 m3/hr to 1000 m3/hr, Cr oss Flow , Less drift loss (< 0.05%), more efficient . • Sav ings: Water @ 22 KL/ Day, Electrici ty 12 kW/Hr. • Cooling Tow er # 3 & 4 Eliminated Slide No . 11 Wo rk Project-2 : Cooling Tower # 2 & 5 (PCW + Tren ch) Addition al PHE pro vid ed Trenc h Trenc h for Heat utilization o f CB D CB D tren ch wat er Tank Tank ACFC cap acity in creas ed Pump Trench No . 1 Trench No . 2 Trench No . 3 Trench No . 4 Trench No . 5 25 HP for d elta 1 5 deg ree C, X3 from wat er cool ed to ai r cool ed type. PHE PHE Filter I II ACFC Curing Curing Pump CB D CB D 125 HP PC W / H ydraulic Supply Storage Storage Tank Tank After GAIN : Saving of Water= 11.5 KL/Day Slide No . 12 6
  • 7. Pro ject – 3 : Sewag e Trea tmen t Plant Water R ecycled to Process K L/Da yy Water R ecycled to Process K L/Da Key Acti on Taken 282 1. STP installed to treat w ater for 167 recycling to process 139 120 148 2. Repair a nd prov iding of bottom 03-04 04-05 05-06 06-07 07-08 lining to prev ent seepage from tanks. Recycling Yield in % Recycling Yield in % 3 Treat and rec ycle plant domestic 4 8.6 2 w aste w ater for process use. 5 4 2.1 3 Cantee n & domes tic plant w aste div erted to S TP. 34 .81 05-06 06-07 07-08 Trad eeEfflu ent Gener ation Trad Efflu ent Gener ation 249 253 193 63 61 03-04 04-05 05-06 06-07 07-08 Slide No . 13 Ongoing Project : Curing Main Trench L ea k Co rrection We are correcti ng all the headers / return lines of 135 m long curing main trenc h for leak, heat insula tion a nd fl oor for eas y identificati on and maintenance of all the pipe lines. It w ill help us to sav e w ater up-to 50KL/Da y. BEFORE AFTER Slide No . 14 7
  • 8. Water Consumption Per Capita Consumption Ltrs./Kg. Ltrs./Kg. 7.36 6.96 7.22 6.56 6.63 6.44 216 213 205 219 5.37 206 201 196 199 3.59 Ind ustrial water co nsumption 142 2.806 2.547 C olony water consumptio n 123 03-04 04-05 05-06 06-07 07-08 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 Oct-08 Power Cons umptio n (Kwh. /Kg .) Air Consumption ( m3 /Kg.) 0 .851 0.69 0.686 0.689 0.823 0 .676 0.816 0 .795 0.776 0.651 0.764 02-03 0.644 03-04 04-05 05-06 06-07 07-08 02-03 03-04 04-05 05-06 06-07 07-08 Slide No . 15 RAINWATER HARVESTING (KL) 70000 66349 62747 60000 50000 40000 36588 30000 20000 20000 10000 10000 10000 199 0 2002 2003 2004 2005 2006 2007 2008 Slide No . 16 8
  • 9. • • • • • • 285 00 0.0 295 00 0.0 305 00 0.0 315 00 0.0 325 00 0.0 335 00 0.0 345 00 0.0 289, 189 300,058 Shift Head Repor t 305, 722 85-90% survival rate Plants 309, 722 Planta tio n Cu m ulativ e Nos. Preside nt Re vie w 319,902 (Mon thly) Among 3 (VD O Conferen cing 337,267 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 Target Setting,/ 98.74 Revi e wing &/ Re vision Sectional Re vie w (Dail y) About 45-50% of land area as green area,. Key Acti ons Taken Vacant Area The region suffering from acute water shortage N Wa W A S S C P Ut T F T T C T B P a a t u a i t y y o u l o o u te il r e r p r t e r r t i a w t a i h e a a b e e a l p r- it i m n (Daily) t e r m l d l e c ( g h In - ( i r y u G a E S n l c ) x ) a g r s T T C C T T T T C G I S F F F C C C C q o o a o o n u r a a u o o o o u y y t t b t t s b b r e r m m m m r r r a a r a a u W r r e e e p p p p e e e o l l i l l l i i d n d o v P P o o o d P P c T T a F c c u e r r S r r T u u u S S t y y l n n o o c o o c c e r r n n n u a d c c r Pa c c r r d e e p d d d b F S e e a e e B rt a a 18 19 20 21 22 23 L L L a e s s p c s s e p p b ic - u u u s s r s s a - - r S S T m m m ul S S a i d B B c c o c c c p p p p U U ar r r t r r Lt Lt Lt M3 K K MT Kg K MT K MT MT MT MT MT 2 1 y y y Feb-07 a r/ p MT a r/ p r/ /K g a / p K a p g / K /M g / K 22 a W l H - - - s Kg Kg - - / g T U g g g Mar-07 21 K g n i Scanty rainfall for several consecutive years in past. t 0 20 40 60 80 Feb-07 Apr-07 21 Unit Head Re vie w Mar-07 49.97 May-07 % V a % K 21 % K % K % V a % K % K % K % K % K % K % K % K % K % K % K % K g g g g g g g g g g g g g g g l l Jun-07 u 43.5820 s s s u s s s s s s s s s s s s ENVIRONME NTAL IMP ROVEMENTS 0 Apr-07 53 86 20 19 Un 19 20 40 60 80 e e .3 2. 2. 2. 4. it Feb-07 12 6. 5. 0. 2. 2. 15 0. 0. 1. 8. Pl May-07 Jul-07 .0 0 35.40 55 0 21 75 0 67 5 45 0 60 0 64 6 3. 0 42 0 66 75 0 91 51 89 51 51 an Mar-07 Jun-07 01-Aug 48.1745.03 21 40 40 50 50 50 6 8 2 4 Apr-07 Jul-07 41.9432.77 02-Aug 21 May-07 32.83 0 8 0 8 1 1 1 0 5 0 5 0 0 0 0 0 3 0 2 0 0 1 0 1 0 Pl T Feb- 01-Aug 527 03-Aug 5 . 1 2 4 45.48 . 4 4 4 21 . 1 3 2 . 2 0 3 6 . 7 3 . 2 2 . 9 0 . 1 47 0 . 2 16 2 . 0 7 . 1 7 4 . 3 0 4 . 9 0 . 4 20 0 5 . 0 . 5 19 0 an 1 19 A o d Jun-07 43.33 4 4 9 1 1 . 0 . 0 8 4 . 6 7 3 2. 2 7 7 5 8 2. 1 9 7. 7 8 2. . 2 7 6 6 3 . 0 0 6 9 3 5. 7 1. 9 9. 7 1 5. 7 2. c t a y Mar- 512 04-Aug 58 22 . 6 6 5 3 . 7 4 9 0 3 4 0 0 0 0 0 0 0 0 0 0 0 31 32 49 13 00 05 63 01 42 u 9 7 7 9 7 3 8 02-Aug Jul-07 30.73 7 8 6 7 6 0 7 a l 03-Aug 36 Apr- 01-Aug 516 05-Aug 21 04-Aug 41.94 62 T May- 512 06-Aug 0 7 0 21 0 1 0 5 0 0 0 0 0 0 0 0 0 0 0 0 A o 02-Aug 3 . 8 4 53 . 6 1 3 . 1 2 8 . 1 4 9 . 8 3 . 5 2 . 3 0 . 2 5 0 . 2 2 . 8 . 1 5 . 4 5 . 3 0 . 4 0 . 0 . 0 . 0 c t d Jun- 05-Aug 488 07-Aug 9 0 -2 8 35 . 2 6 21 . 0 2 2 3 0. 3 4 0. 0 6 2 1 7 0. 7 1 0 0 1 -9 4 0. 9 9 9. 2 2 -0 6 8 0 6 2. 0 0 -0 0 0 0. 0 0 2. u 0 a y -0 Di 35 8 0 . 4 4 3 4 7 9 9 0 5 3 1 8 4 0 0 0 0 a 7 0 5 8 2 ff 08 14 28 04 07 73 24 50 .9 .0 .0 .0 .0 7 7 6 03-Aug l 06-Aug 08-Aug 55 7 2 22 4 5 5 4 1 9 Jul- 04-Aug 504 55 07-Aug 41 01- 05-Aug 500 09-Aug 21 08-Aug 31 0 1 42 0 1 0 -0 -0 - 0 0 0 5 0 -0 -0 -0 -0 0 1 0 D 02- 509 10-Aug 1 . 1 3 0 . 7 6 0 21 . 6 5 3 .0 -6 0 3 .0 2 0 . 2 0 . 6 2 0 . 1 -1 0 6 . 7 1 0 .1 0 .1 -3 83 .1 -9 0 .0 -9 -3 2 . 0 5 . 19 6 0 i 1 19 50 t t 4 4 2 . . . . . 5 . . 0 f 5 2 5 9 8 9 61 13 0 3 0 6 23 31 28 04 9 . 1 1 7 . .3 1. 1. 06-Aug 3 9 1. 8. Pl 11-Aug 55 21 . 5 7 6 4 6 3 4 7 1 0 5 7 1 1 0 5 0 5 0 1 f 51 87 an 82 56 56 0 5 5 7 5 0 . 2 5 . 09-Aug 7 03- 07-Aug 503 40 0 0 0 5 0 0 6 0 0 0 9 49 l e 10-Aug 04- 08-Aug 41 519 12-Aug 22 11-Aug 52 05- 09-Aug 497 13-Aug 2 54 22 1 12-Aug 3 0 47 0 2 1 4 1 34 5 0 0 1 0 26 0 5 0 7 0 5 0 86 0 75 0 11 0 42 0 0 42 0 4 Pl D 0 3 06- 10-Aug 513 14-Aug . 4 1 4 2 . 5 7 4 21 . 8 4 2 . 56 0 3 . 2 3 4 . 2 2 . 32 0 . 4 50 0 . 5 18 2 . 0 7 . 0 9 4 . 39 0 4 . 12 0 . 27 19 0 . 91 0 . 0 . 91 18 0 7 an 19 A M a e 48 2 7 W a e r o Boi e r KL/ a y 4 1 9 9 7 c 3 1 2 . . . . 2 . 9 0 0 6 3 7 5 1 7 2 6 0 6 9 0 9 1 T 1. 3. 8. 8. 3. 13-Aug 9 6 2. 3 5 2. 1. 9. t 15-Aug 48 21 . 1 1 6 4 . 8 4 9 0 3 4 0 0 0 0 0 0 0 0 0 0 0 0 41 52 44 06 D 24 60 53 03 17 1 5 u 7 7 6 3 6 0 1 07- 11-Aug 509 50 3 0 2 7 4 3 3 a l 14-Aug 54 08- 16-Aug 531 46 22 W e 12-Aug 50 vt 15-Aug 09- 500 17-Aug 48 21 e F e d W t r Condi t i y 13-Aug 2 1 M Green Belt Area (Acres) 42 Regular plantation at the rate of more than 10000 trees per year 5 9 T 16-Aug 0 3 0 2 0 1 0 0 1 0 0 0 1 0 1 0 1 0 0 0 0 0 A 18-Aug 50 4 14-Aug . 8 5 5 . 1 4 4 22 . 3 1 8 . 25 0 . 8 4 8 . 6 3 . 34 0 . 6 1 0 . 7 -3 2 . 0 . 7 6 1 . 9 5 0 . 0 0 . 18 0 . 26 0 . 5 0 . 21 0 c 4 t D 10- 17-Aug 503 0 1 -0 9 0 . 5 3 . 6 4 1 77 0. 8 1 0. 4 5 5 5 6 80 0. 4 1 2 7 7 0. 2 -0 3 2 -8 0 3 -0 4 8 9 2 5 22 -3 1 07 -0 4 0 0. 0 03 -3 3 u 1. D 64 3 5 . 3 7 1 6 8 4 6 2 7 1 4 7 7 5 1 4 9 a 7 6 8 1 4 2 04 04 08 18 61 i t t 5 5 60 .7 .0 .6 .0 .4 .0 .5 8 8 9 15-Aug l 49 21 f 11- 509 19-Aug 3 0 8 4 4 5 6 2 7 3 DM a t r Condi v i y f 18-Aug 55 12- 16-Aug 40 517 20-Aug 21 60 Green Cove rage Done 19-Aug - - 21-Aug 60 21 i n 2 4 17-Aug -0 -0 - 0 0 -0 -0 - -0 -0 -0 -0 -0 - -0 - -0 0 2 0 13- 20-Aug 516 3 .0 3 45 2 .0 6 . 1 3 . 8 3 1 .0 6 4 .0 4 .0 -8 .0 -8 .0 -1 .3 .1 -2 3 .1 2 2 .0 5 -6 . 0 . 1 0 8 4 Di 18-Aug 22-Aug 8 19 0 54 6 48 8 22 3 3 4 7 1 84 1 4 84 0 16 48 5 02 9 07 01 74 12 6 37 5 7 37 0 95 4 0 7 5 ff 14- 21-Aug 504 4 9 7 7 9 0 6 1 . 6 19-Aug 55 45 15- 494 23-Aug 21 St a m Ge ne r a t o MT/ Da y 20-Aug 22-Aug 40 16- 40 518 24-Aug 21 23-Aug 35 25-Aug 44 21 82.77 21-Aug 17- 24-Aug 509 38 22-Aug 38 18- 25-Aug 524 26-Aug 20 23-Aug 33 43 19- 512 27-Aug 21 24-Aug 26-Aug 45 28-Aug 37 20 20- 510 40 SSU Head R evi e w (Daily) 27-Aug 25-Aug 29-Aug 40 20 21- 511 46 A special greening drive in the adjacent areas for one Lac plantation. 28-Aug 26-Aug 42 22- 29-Aug 522 30-Aug42 21 27-Aug 38 23- 503 31-Aug 20 44 40 MONITORING AND REPORTING SYSTEM 28-Aug 30-Aug 24- 29-Aug 31-Aug 500 39 36 25- 30-Aug 500 47 35 26- 491 31-Aug 34 27- 499 45 28- 484 SAMPLE DATA SHEE T 29- 489 Slide No . 18 Slide No . 17 30- 501 31- 484 9
  • 10. Environme ntal Projec ts- GREEN BELT Environme ntal Projec ts- RAINWATER HARVESTING Slide No . 19 FUTURE ACTIONS °Waste H eat reco very fro m Screw Co mpressors for Boiler FD Fan °Screw Compress ors I.p.o. Reciprocating Comp ressors °Energy & W ater efficient mono pumps o ver VT pumps °Steam consump tion reduction in Tyre Curing – Op eration 1.99 kg/ kg ° Colony roof water coll ection. ° Furth er condens ate recov ery. ° Mo re Air cool ed m/cs. ° Insulation of drinking wa ter lines for loss redu ction ° Use of recy cl ed wa ter for Stea m Gen erati on. ° Using municipal waste water for clear water gen erati on. ° Impro ving rain water tan ks. ° Cooling tower res tructuring for efficiency improvemen t ° Nitrogen Curing inpla ce of Hot W ater. Slide No . 20 10