Sterlite Industries Ltd, Silvassa

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This is a presentation from Sterlite Industries Ltd, 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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Sterlite Industries Ltd, Silvassa

  1. 1. National Awar d for Excellence in Wa ter Manageme nt 2008:CII Sterlite Industries India Ltd- Silvassa Excellence i n Water Ma nage me nt 2008 OVERVIEW STRUCTURE p A leading producer of ke y Aluminium commodities Co p p er n Group turno ver FY 07 -08 $ 8.2 bn Zinc Iron p Listed on the London Stock Exchange Copper Zinc Aluminum Iron p 30,000+ Employees p US$ 2.2bn pipeline of bro wn – and greenfield projects Sterlite Vedanta KCM HZL Balco Sesa Goa Alum ina (Copper) (Copper) (Zinc ) (Aluminium) (Iron) (Alumina) Malco (Aluminium) Excellence i n Water Ma nage me nt 2008
  2. 2. REFINERY CC ROD ANODE ELET RO REFI NIN G CAST ING ROLLI NG CAT HODE CC R OD COIL Excellence i n Water Ma nage me nt 2008 PROJECTS WITH ZERO INVESTMENTS: q Modification in Thermoshypon cooling water arrangement. Savings : 4380 m3 : Rs. 1.4 Lacs. q Condensate Re covery of RVD fo r Filter Pre ss Backwa shing. Savings : 1284 m3 : Rs. 0.41Lacs q Reu se of collected condensate water generated by anode casting cooling water. Savings : 655 m3 : Rs. 0.21 Lacs Excellence i n Water Ma nage me nt 2008
  3. 3. PROJECTS WITH INVESTMENTS: q Rain water harve sting. Savings : Year - Water Sav ings 2005 - 4178 m3 (Rs. 1.25 Lacs) 2006 - 6225 m3 (Rs. 1.86 Lacs) 2007 - 9475 m3 (Rs. 2.84 Lacs) 2008 - 3560 m3 (Rs. 1.13 Lacs) Total - 23438 m3 (Rs. 7.08 Lac s) Investment : Rs. 10 Lacs Payback Pe riod : 67 months Excellence i n Water Ma nage me nt 2008 PROJECTS WITH INVESTMENTS: q Conv ersion of Gland Packing Pumps into Mechanical Seal Savings : 1728 m3 Water (Rs. 0.55 Lacs) Investment : Rs. 3.0 Lacs Payback Period : 65 months q Prov ision of Electrolytic Cell cov ers in Refinery Savings : 3703 m3 Water (Rs. 1.18 Lacs) Investment : Rs. 1.0 Lacs Payback Period : 14 months q Control v alve prov ision in FO storage tank steam line Savings : 1501 m3 Water (Rs. 0.5 Lacs) Investment : Rs. 0.98 Lacs Payback Period : 24 months q Installation of v acuum pump in Rotory Vaccum Drier Savings : 444 m3 Water (Rs. 0.41 Lacs) Investment : Rs. 0.48 Lac Payback Period : 39 months Excellence i n Water Ma nage me nt 2008
  4. 4. PROJECTS WITH INVESTMENTS: q Modification i n CSM for cathode washin g Savings : 1027 m3 Water (Rs. 0.34 Lacs) Investment : Rs. 0.49 Lacs Payback Period : 17 months q Special Nozzles for ASWM washing Savings : 148 m3 Water (Rs. 0.05 Lacs) Investment : Rs. 0.05 Lacs Payback Period : 12 months q Bosch tank renovation Savings : 375 m3 Water (Rs. 0.12 Lacs) Investment : Rs. 2.45 Lacs Payback Period : 233 months q Leaching process alteration for steam reduction Savings : 555 m3 Water (Rs. 0.186 Lacs) Investment : Rs. 0.9 Lacs Payback Period : 58 months Excellence i n Water Ma nage me nt 2008 WATER CONSERVATION PROJECTS - SUMMARY: Total no of projects implemented = 13 ü Projects implemented without investments = 3 ü Projects implemented with investments = 10 Savings : 42015 m3 Water Total Inv estments made : Rs 20.85 Lacs Total Sav ings Ac hiev ed : Rs 13.05 Lacs Excellence i n Water Ma nage me nt 2008
  5. 5. WATER SHARE - SILVASSA 2% 2% 20% 18% 58% RFNY CCRC CCRP PMP ACP Excellence i n Water Ma nage me nt 2008 WATER CONSUMPTION (M3/MT) 0.67 0.70 0. 54 0.4 9 0. 46 0.60 0.50 Sp. Water Consumption 0.40 0.30 0.20 0.10 0.00 2004-05 2005-06 2006-07 200 7-08 Fi sca l Ye a r Reduc tion in Specific Wa ter Consumption = 31.34 % Excellence i n Water Ma nage me nt 2008
  6. 6. Waste Water Details : Industrial 10308 12000 8260 Waste Generated ( M3 ) 10000 8000 5544 5300 6000 4000 2000 0 2004-05 2005-06 2006-07 2007-08 Fisca l Year Excellence i n Water Ma nage me nt 2008 Waste Water Details : Domestic 7093 7054 8000 5838 5808 7000 Quantity Generated (M3) 6000 5000 4000 3000 2000 1000 0 2004-05 2005-06 2006-07 2007-08 Fiscal Year Excellence i n Water Ma nage me nt 2008
  7. 7. BENCHMARKING q Our ultimate objectiv e of our plant is to be 0.4 m3/MT of copper cathode. q We are continuously committed towards natur al resources conserv ation and water conserv ation is our prime f ocus. This we are achiev ing by TQM methodolo gy , PEP and internal proj ects . q To sustain as a ZERO discharge plant in copp er industry . ROAD MAP FOR THE FUTURE q Regular Water Aud its & Identif ication of new projects. q SPC techniques in Water Monitorin g. q Utilization of waste condensate water. q Conv ersion of all gland seal pumps into mechanical seals. q Exploring the possibility of Air Cooled heat exchangers in place of normal coolin g towe rs. Excellence i n Water Ma nage me nt 2008 TQM PROJECT 1: WATER FUL I MPLE MENTATION KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION Problem Statement : Reduction of water & steam in Cathode Stripping Machine from 10000 M3 to 7000 M3 per annum of cathode production. Mission Statement : Increase in washing effectiveness in CSM & thereby conservation of water & a saving of approx Rs 1.0 Lac per year. Excellence i n Water Ma nage me nt 2008
  8. 8. TQM PROJECT 1: WATER CONSUMPTION REDUCTION Cause And E ffect Diagra m based on Brai n Storming : PUMP TANK Leakages Ev aporation Tank Los s es High / low No calibration of ov erf low Seepage to pres sure pres sure gauge Leakages ground HIGH STEAM CONSUMPTION c hoke-up leakages Les s Mai tenanc e n Improper improper laggin g & Ins uf f icient angle Insuf fic ient cladding w idt h Number PIPELINES NOZZLES Excellence i n Water Ma nage me nt 2008 TQM PROJECT 1: WATER FUL I MPLE MENTATION KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION Formulation of Theories q Overflow and leakages of tan k q Evaporation losse s in CSM q Cho ke-up of Nozzle s. q High or low pressu re in wa shing line. q Pump & Pipeline leakages Excellence i n Water Ma nage me nt 2008
  9. 9. TQM PROJECT 1: WATER FUL I MPLE MENTATION KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION Results & Benefits 900 Water Consumption 850 850 845 819.8 3 809.08 804.6 7 804 839.0 8 802 (M3) 835 800 808.83 800.1 7 801.9 2 750 751.7 5 Af ter TQM Bef ore TQ M 700 20 06-7 May-07 Jul-07 Sep- 07 Nov-07 Jan-08 Mar-08 Month Reduc tion in Water Consum pti on : 4.7 % ( Rs. 0.34 Lacs ) Excellence i n Water Ma nage me nt 2008 TQM PROJEFACTOR FOR SUCES S FUL I MPLE MENTATIONN IN KE Y CT 2 : WATER CO NSUMP TION RE DUCTIO ACP Contr ol v alv e prov ision in Steam Readings in MT FO stora ge tank s team line Proble m Sta teme nt : 10 Reduction of steam for F O hea ting from 8 8 8.1 T onnes/day to 4 T onnes/day. 7.9 6 Be fore TQM Afte r TQM 5.6 Missi on S tate me nt : 4.1 4 4.2 4 4.1 Effective utilisation of Steam for F O 3.6 3.6 heating and there by a saving of 2 Rs.50,000 per an num. 0 Me th od olo g y o f Im ple mentati on : Dec-07 Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul -08 Aug-08 § Analytical study of Steam re quirement. Month 07-08 § Installation of Steam Control Valve. § Continuous monitoring o f the s ystem and data analysis. Excellence i n Water Ma nage me nt 2008
  10. 10. Employee & Comm uni ty I nv olv ement APPROACH T OP D OW N APPR OACH B OTT OM U P APPROACH CSR Activ ities Policy D ep lo ym ent PEP M echanism Continuou s Imp rovement W ater Month EDUCATION S A A P A EE H M A H TS A : H L LA R V S M O V w have sup por t d " Sh al e e a Daily Man ag em ent CSR Activities Pr avesh M oho st v - 0 07" under C R i ni i at ves at Vaso na Sch ool a 2 s S i o t i w e 250 new st ude nt hav et aken ad m ssi ni n cl ss 1 ( one) . er a Excellence i n Water Ma nage me nt 2008 SUGGESTION CATEGORY COP Reduction System Improvement 18% 17% Process Improvement Qua lity 14 % 10 % Wat er Conser vation 16% Safety Env ironment 2 5% Excellence i n Water Ma nage me nt 2008
  11. 11. Water Month Celebration q Celebrated Water Month on March 2008. q Celebrated World Water Da y on March 22 nd 2008. q Each year carrie s a particular theme on WWD like … 2008 : Theme 2008: Sanita tion 2007 : 2006 : Water and Culture 2005 : Water for Life 2004 : Water and Di sa sters 2003 : Water for the future etc…. q Organized various events related to water awarene ss. Excellence i n Water Ma nage me nt 2008 WATER MONITORING & REPORTING SYSTEMS: q Whole Plant is divided into 5 areas and Water Con sumption for each plant is monitored and action plans taking according to it. q Water norm s are fixed for all the equipments & any variation is alerted by DCS. q Water audits being done internally by water champions and remedial actions immediately taken. q Water report i s getting prepared by the Water Manager and is getting reviewed by the Head Operations in presence of Sectional Heads. q The Water report con sist s of Water Share, Specific Con sumption, Trend analysis, Internal & External Benchmarking, Concern s and Action plan for the next month. Excellence i n Water Ma nage me nt 2008
  12. 12. LIST OF MAJOR ENVIRONMENT IMPROVEMENTS KE Y FACTOR FOR SUCES S FUL I MPLE MENTATION q Rain water harvesting in the plant. (10 Lacs) q Zero Discharge Plant. q Reduction in air pollution by introducing scrubbers. (3.5 Lacs) q Installed Sewage Water Treatment facility. Treated water is being used for gardening purpose. (2.5 Lacs) q Installed air pre heater in the boiler to reduce fuel consumption. (5.5 Lacs) q Installed Acetylene Soot Collection System installed in CCR to improve working Environment. (5.6 Lacs) q Soil Correction Carried out in Refinery. (2.62 Lacs) q Installation of Air Ventilators in Refinery & CCR. (3.23 Lacs) q Conversion of FO fired boiler into Biomass fuel fired furnace. (11.4 Lacs ) Excellence i n Water Ma nage me nt 2008 AWARDS & CERTIFICATION KE Y FACTOR FOR SUCES S FUL I MPLE MENTATION q ISO 9001,ISO 14001 and OHSAS 18001 Certified by DNV qIEI Safety award by Gujarat State – 2007 qCII – Excellent Water Efficient Unit Award – 2007 qCII – Excellent Energy Efficient Unit Award – 2007 qIMEA-Platinum award for Metal Category by M/s Frost and Sullivan qRBNQA- Commendation Certificate qQualtech Innovation award – “Recovery of Nickel from Electrolyte Stream” qCorporate award “ Creative Workplace ”- Sept 2008 qFirst prize for best Suggestor Award@INSSAN- July 2007 qSecond prize for best Suggestor Award@INSSAN- July 2007 qUnique employee involvement practices – INSSAN May 2007 qGolden Peacock National Training award for 2007 Excellence i n Water Ma nage me nt 2008

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