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Water Conservation through re-cycle and re-use, presented by ACC Limited Damodhar Cement Works
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Water Conservation through re-cycle and re-use, presented by ACC Limited Damodhar Cement Works

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This is a presentation from ACC Limited Damodhar Cement Works, one of the finalists at the 5th CII-GBC National …

This is a presentation from ACC Limited Damodhar Cement Works, 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, Technology, Business
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  • 1. Excellence Through Teamwork Water conservation through recycle and reuse Presented By ACC Limited Damodhar Cement Works Dam odh ar Ce men t Works Damodhar at a glance …. • DCSL comme nce d commercial production in October 1990 as a joint ve nture project of WBID C a nd Ce me nt C orporation of I ndia Ltd • In Se pte mber 1996 A CC Ltd. took ov er the ma na ge me nt of the Company a nd it be ca me a Subsidiary of the A CC Ltd. With WBIDC as a partner • Capa city e nhance ment from 2.70 to 5.25 LTPA of Portland Sla g Cement in the y ear 1998 was taken up by A CC • A n ISO 9001 : 2000 and I SO 14001:2004 certified unit Dam odh ar Ce men t Works
  • 2. Our Strategic Vision Dam odh ar Ce men t Works Our Environmental Policy Dam odh ar Ce men t Works
  • 3. Cement Manufacturing Process Wet Slag sto rage at Ropewa y Loading Ball Mill-2 Station 16 T/H Cove red Ropewa y 2.6 KM, storag e H all Ball Mill-3 Capa city 13 5 TPH 15 TPH Clinker 180 00T Dry Sl ag Open Wet Slag Clinker 500 0T Storag e And Ce ment Sto rage Silo Capa city 35 KT Gypsum Gypsum 2 x 3 80 0 T 800 0T Slag Dr ye r Wagon Tippler 600 TPH Ball Mill-1 Bagging 60TP H 49 TPH 100 T C ap. 2 nos Roto Pac ke r Coal Coal Mill Storag e 3 TPH 800 MT Dam odh ar Ce men t Works Drinking Water Consumption Water consumption in Water Consumption in Factory Colony 300 300 262.39 Lit /Person /Day Lit /Person /Day 242.36 250 198.21 185.93 250 196.48 200.22 184 200 166.25 200 150 150 100 100 50 50 0 0 '04-'05 '05-'06 '06-'07 '07-'08 '04-'05 '05-'06 '06-'07 '07-'08 Year Year •2005-06 water con sumption high •2007-08 water con sumption high due to fly ash silo and cement silo due to new construction of quarters project Dam odh ar Ce men t Works
  • 4. Bench Marking 156.183 180 0.6 135.173 160 122.285 0.5 0.5 0.5 0.5 119.526 0.5 140 113.009 Consumption (K m3) Consumption (m3/T) Specific Water 93.233 120 0.4 91.962 0.28 0.28 78.734 0.28 0.28 100 0.3 80 43.174 40.791 41.94 60 30.323 0.2 0.081 0.085 0.078 40 0.06 0.1 20 0 0 '04-'05 '05-'06 '06-'07 '07-'08 '04-'05 '05 -'06 '06-'07 '07-'08 Yea r Year Industrial DCW Drinking/Domestic Use National Benchmark Total International Benthmark Dam odh ar Ce men t Works Water Flow Diagram Damodhar Riv er FM FM Process Drinking Water Water FM Process w ater Plant Colony Village Ta nk Drinking Water Over Head Tan k Drinking Water Process Reserv oir Plant Water Dam odh ar Ce men t Works
  • 5. Sewage Treatment Plant SWE AGE COLLECTIO N SUMP OXIDIZATIO N PLANT BACK CIRCULAR WASH TANK WATE R TANK FILTE R TRE ATE D SUPPLY WATE R FOR RESERVOIR IRRIG ATIO N Dam odh ar Ce men t Works Monitoring & Reporting System • Applying Analog Flow Meter for accuracy • Maintain daily log sheet to feed the readings • Weekly report to Chief Manager Engg., Plant operation head & Director Plant Dam odh ar Ce men t Works
  • 6. Project -1 : Reuse of Domestic Waste Water The previous system of domestic waste water treatment having following demerits : • The Dome stic Wa ste water including the kitche n a nd washroom dischar ge is trea te d at sew age trea tme nt pla nt • A fter the pla nt expa nsion, filtration ca pa city of STP was not suffi cie nt to take the increase of waste water day to day due to incre ase of population a nd quarters in colony Idea Generation • Disconne ction of Kitche n a nd ba throom line of A-Block & Hutme nt buildings from main STP line • Wa ste water from kitche n a nd bathroom colle ct in a pond after gravitation f iltration proce ss and this w ater use f or garde ning and bre eding fish Dam odh ar Ce men t Works Project - 1 : Reuse of domestic waste water Kitche n and Was hroom Water Collecte d into Pond Plantati on at Col ony Dam odh ar Ce men t Works
  • 7. Project - 1 : Reuse of domestic waste water 600 Volume (Lit.) RESULTS : Discharge water (KL) –Recycling of waste water and optimum usage of resource 0 0 0 0 –Smooth and efficient '03-'04 '04-'05 '05-'06 '06-'07 '07-'08 operation of STP –Ensure ZERO discharge Year Dam odh ar Ce men t Works Project – 2 : Reduction of river water usage The previous water supply system (sur face water from Damodar river) had the fo llo wing demerits : • Unhy gie nic w ater quality specially during monsoon. • During summer and w inter, 10 nos. la bor use d daily for channeling the wa ter to the pumping point • 18 KW pumps use d for lif ting the wa ter a nd 7.5 KW pump use d f or pressure f iltration • High trea tme nt cost of Rs. 4000.00 per month The Cost of production was Rs. 5.50 per KL . Dam odh ar Ce men t Works
  • 8. Project – 2 : Reduction of river water usage IDEA GENERA TION : • Elimination of the surface w ater supply a nd associa te d filtration syste m by installation of a dee p bore we ll pumping unit a t middle of riv er be d • Drawing the subsoil wa ter w hich is much more hy gie nic and av aila ble throughout the ye ar Dam odh ar Ce men t Works Project – 2 : Reduction of river water usage A ctions I mple mente d ü 40 feet deep bore well pump has be en installe d ü Wa ter treatment pla nt operation ha s bee n stoppe d Dam odh ar Ce men t Works
  • 9. Project – 2 : Reduction of river water usage RESULTS: • Continuous supply of good quality drinking water even in rainy season • Operation and maintenance cost have been reduced to Rs. 1.20 per KL Rs. • Hence annual saving is Rs. 2.40 Lakhs Rs. Dam odh ar Ce men t Works Project – 3 : Close circuiting of process water Previous water supply system : • Cooling water supplied to the machines was not recirculated and reused • High water loss • High amount of water cess paid by the company Idea Generation All the return water lines have been connected to the main return water pipe. Dam odh ar Ce men t Works
  • 10. Project – 3 : Close circuiting of process water Result : • Reduction if water consumption as well as discharge by 8% • Reduction in pump house power consumption by 6% Dam odh ar Ce men t Works Awareness • DCW sent repre se nta tive to De lhi for training on Wa ter Manage me nt syste m • Mass aw areness of taking hygienic water through distribution of leafle ts & ele ctronic me dia a mong the ne arby community & colony inhabita nts • Providing hy gienic w ater to the ne arby v illa gers • Periodic che cking of qua lity of w ater by internal a s w ell a s exter nal authority • Distribution of leaf lets for a wareness towards w ater borne diseases • A rrange draw ing competition on ‘Conservation Of Na tura l resour ces’ a mong the colony & ne arby inha bita nts’ childre n ces’ nts’ • ‘Suggestion Sche me’ for new idea ge neration me’ • Envir onmental Q uiz C ompetition conducte d by DC W club Dam odh ar Ce men t Works
  • 11. Sustainable Development • Rain Water Harvesting: C onstructed earthen pond a t Colony & concrete reservoir inside pla nt • Use of Treate d water from Se wa ge Treatme nt plant for pla nt & colony pla ntation & garde ning • Reserve shower & kitche n water into pond for pla nta tion • Complete Looping of proce ss w ater f or recirculation • Optimizing the water distribution cycle freque ncy towards colony & near by inhabita nts • Installation of floa t valv es to a ll the water reserv oirs (ta nks) a t all the colony buildings Dam odh ar Ce men t Works Our Future Plan…….. Plan…….. • Integration with OSHAS 18001 • Annual external audits through authorized auditing agencies • Involvement of people through small group activities • Developing In-house expertise for audits In- • Installation of flow meter at consumption points for better monitoring • Zero water leakage • Arrangements for collecting storm water from roof shed and collecting in the earthen ponds Dam odh ar Ce men t Works
  • 12. We can do no great things ; only small things with great love. - Mother Teresa Dam odh ar Ce men t Works Dam odh ar Ce men t Works

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