This is a presentation from Hindustan Zinc Limited, 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.

1. National Award for “Excellence in Water Management
Ou r Approach…
“ The difficulty lies, not in the new ideas of water management and
conse rvation,
but in escaping the old ones”
ENDURING
VALUE
THROUGH
VALUES
Hindustan Zinc Limited
Chanderiya Lead Zic Smelter
2008
About Hindustan Zinc Ltd.
HZL w as created from the erstw hile Metal Cor pora tion of I ndia
(MCI) i n 1966 as a Public Sector Under taking.
In April 2002, became a part of S terlite gr oup
HZL - India’s leading base me tal producer and w orld’s III Largest
producer.
1

2. Hydromet Route of Zinc Production
Efflue nt Efflue nt
Treatm ent
Dis pos al to S ecur e L an d Fil l
Jarofi x Po nd
Tank Hous e
Our Approach to Sustainable Development
in Smelter
n Adoption of 5 R waste management principles
n Adoption of su stainability framework by International Council of
Mines & metals
n Benchmarking with World’s be st in all operating parameters
n Focu sed environmental initiatives for effective water management,
wa ste minimization and recycling, reducing air emissions, energy
conse rvation and su stainable development drivers.
n Comprehensive G RI G3 guidline based online data management
sy stem to capture all Triple Bottom Lime dimensions
n Implementation of British Safety Council ‘s safety management
sy stem
2

3. Our Implementation Methodology
n An integrated and structured approach -- comprising of Involvement of
executives and contract labors like Water S tewards nominated for
each Plant, further report to Water Mana gers and Unit Head for Water
Con servation activities
n Discu ssion of underlying factors behind the trends of HSE key
performance indicators by top management during the monthly HSE
review meetings.
n Training - an efficient tool to improve the KPIs by motivating employees.
q Frequent training programs for external environment, safety and
health, supervised by the HR head. The CEO u sually take s feedback
from Environment head and external faculty members who conduct
the training program.
Specific Water Consumption Figures
Specific
Annual Water consum pti on
Water
Year Quanti ty (m3)
Consum pti on
(Apr-Mar)
Indus trial Domes tic Source m3 / MT
Captive
2005 – 06 1407000 142.9 21.87
dam
Captive
2006 – 07 1755000 131.2 12.99
dam
Captive
2007 – 08 1867670 93.1 dam 11.72
3

4. Maintaining Zero Discharge… Pragmatically
Quanti ty Quanti ty Quanti ty
Year
generated recycled discharged
(Apr - Mar)
(m3) (m3) (m3)
2005 – 06 74325 74325 0
2006 – 07
62358 62358 0
2007 – 08
52928 52928 0
Beyond Benchmarks/ Global Norms…
Specific Water Conservation vs Bench mark
25
21.87
20
Hydro I
15 12.98
m3/MT
14 14 14
11.72
10 Bench mark- US
Clarksville
5
0
2005-06 2006-07 2007-08
4

5. Water Saving project implemented
Annu al Water Invest.
Savings Made Payback
Sl Title of Water Sa ving Year of
Period
No project impleme nted Implementation Rs. Rs.
M3 (Mont hs)
Lakhs Lakhs
1 ETP treated water to 05 - 06 339190 25.43 215 55
RO-I plant (88 m3/hr)
2. P rocess optimization of 06 - 07 29200 2.19 Nil Nil
DM plant operation to
reduce regeneration by
increasing the OBR
3. Reduction in 06 - 07 27375 2.05 Nil Nil
evaporation by
optimization of C T fan
operation according to
the heat load
Contd..
Annu al Water Invest.
Savings Made Payback
Sl Title of Water Sa ving Year of
Period
No project impleme nted Implementation Rs. Rs.
M3 (Mont hs)
Lakhs Lakhs
4. Recirculation of vacuu m 07 - 08 36500 2.73 4.63 21
pumps seal cooling
water To C T as Make
up water
5. Recirculation of stea m 07 - 08 73000 5.47 3.46 8
Condensate fro m
Leaching & purification
to CT as make up water
6. RO treated water 07 - 08 27375 2.05 0.20 1
directly taken to Filter
water storage tank,
reduced P SF backwash
fr equency
7. Recirculation of Boiler 07 - 08 87600 6.57 0.72 1.5
blow down water to CT
as Make up water
5

6. Annu al Water Invest.
Savings Made Payback
Title of Water Sa ving Year of
Sl No Period
project impleme nted Implementation
(Mont hs
8. Optimization of CT 07 - 08 154395 11.58 Nil Nil
water circulation rate
by switching on/off
pump as & when
require under six
sigma project
9 Optimization of COC at 07 - 08
CT by chemical
treatment & continuous
monitoring under six
sigma project
10. P roviding Level probe 07 – 08
in all CT to avoid
overflow under six
sigma project
11 ETP treated water to 07 - 08 192720 14.45 135 61
RO-II plant (50 m3/hr)
Total 901655 72.52 359.01
D M A I C
Reduction of Specific Water
Consumption in Hydro –I
CASE STUDY
6

7. Establish
D Project & Business Synergy CTQ
0 Char ac teris tics
1
Who is the
M customer in
2 What is the
3 your project? Customer
CTQ? What is the
A
4 n Hydro -I Project
5
6 n Conservation CTQ?
of Natural
I Resources n Reduction of
7
8
Specific
9 Water
Consumption
C
10 in Hydro-I
11
12
D Defining a Project
0
T heme Selection Matrix
1
Departme Al ignmen Cust omer Financia l Priori ty
Stre am SN Theme Name Cus tomer CTQ Inte rnal CTQ/CB P Sat isf act i Eff ort s** Se lec tion
nt t t o CBP Be ne fit s* Score
on
M Misce llane
o us
1
R edu ctio n o f
Sp ecif ic Wa ter
Con ser vat ion of
Natu ra l Con ser va tion of Wat er 9 9 1 3 2 43 Yes
C ons up tion Reso ur ces
2 R edu ctio n o f S/S Red uct o n of
i Red uct ion of Mn O2 in L eac hing &
2 in Ca lcine COP Impr ove me nt of Cell Ho use Op er atio n 9 9 3 3 7 29 Yes
3 R edu ctio n o f
Ro aste r
Au xiliar y Powe r Cust omer 's
3 Cos t Re duc tion 8 3 3 3 2 16 Yes
C ons umptio n in Satisf actio n
Ac id Plan t
R edu ctio n o f
A 4 W ate r S lub le
o
Zin c in Jer ros ite
Red uct o n of
COP
i
Rec ove ry I mp ro vemen t 9 9 3 3 7 29 Yes
4 Le ach ing C ake
R edu ctio n o f Zn
Red uct o n of
i To Re du ce c ons ummable s
5 5 D ust in COP Con sump tion
9 9 3 3 7 29 Yes
p ur ifica tion
6 imp rov emen t of
6 a vaila bility o f Red uct o n oin
i OEE Imp rov emen t 9 9 3 3 7 29 Yes
C astin g M/C in COP
Hydr o C ell Ho use .
I mp ro vemen t o f
I Cell
Ho use
7 C ell Ho use
R atin g
Red uct o n oin
COP
i Powe r Sa ving 9 9 9 1 7 29 Yes
I mp ro vemen t o f
7 Eq uip me nts Red uct o n oin
i
8 Impr ove me nt of OEE 9 9 3 3 7 29 Yes
8 a vaila bilty i
C ellHo use
n COP
9 R edu ctio n o f
Au xillar y Powe r Red uct o n of
i
9 Red eu ction of Powe r c on sumptio n 9 9 9 1 7 29 Yes
C ons umptio n in COP
C PP
C CPP
10
R edu ctio n o f Co al
C ons umptio n in
Red uct o n of
COP
i
Cus tomer 's Sat isfac tion 9 9 9 1 7 29 Yes
Po wer pla nt.
10
I mp ro vemen t o f Cust omer s
11 11
Mills Ava ilab iit y
l Satisf actio n
Qu ality I mp ro vemen t 3 9 3 3 2 43 No
12 R edu ctio n o f SO2
Envir onme nta l
12 Emissio n f ro m Red uct ion of S x
o 3 1 1 3 9 No
Prot ect i n
o
C PP
7

8. Defi ne
D a
0 Project Scoping Proj ect
1
M Longitudinal Scope
2
3 n It start from Raw Water Pond at DM Outside Scope
Plant at Hydro-I and ends at ETP
A Period when
4 there is
5
6
continuous
Lateral Scope heavy rains
I When any of
7
n Water saving at each SBU’s at Hydro I
SBU is not
8
9 in operation
on a
C particular
10
11
day for more
12 than 8 hrs.
D Loss - Gain Matrix
0
1
Gains Loss
M
2
3 Redu ced wat er C onsumption. ETP tr eat m ent co st will b e
high
Short
Maint en ance of z ero discharge W ater cess will b e h igh
A Term
4 Lo wer efflu ent g en er ation
5 Sust ain ab le gro wth Vio lation of zero d isch arg e
6 condit ion s
Long Cost r edu ctio n During dr aught years
I Term continu it y of op er atio ns
7 may suffer
8
9 Leaning & sat isf act ion of t eam
memb er s
C Better image within st akeho lders
10
11
12
8

9. Identif y
D Vari ati on
0 List of X’s Chosen for Screening Sourc es
1
M
2
3 Sl. No. Name of ‘X’ Description of ‘X’
Cycle of c oncentr ati on i.e TD S i n
A X1 COC circul ati on water to TD S i n M ake U p
4 water is to be mai ntai ned > 7
5
6
X2 Water Level Pr obe Probes at all the C T’s were opti miz ed
I
7
8 Filter water use at H BF cake was hing as
X3 Stoppage of Us e of Filter well as at cloth was hing reduced and
9
Water for replaced with recy cled water.
HBF washi ng
C
10
11
12
Identif y
D Vari ati on
0 List of X’s Chosen for Screening Sourc es
1
M
2
3 Sl. No. Name of ‘X’ Description of ‘X’
Condensate tanks li ne earlier c onnected wit h
A X4
Transfer of C ondens ate to
Cooli ng T ower
CT3, Now s hifted to CT1 & 2 for r educ tion i n
4 makeup water.
5
6
Frequent Cl eani ng of Sc hedule has been made and being foll owed
X5
Cooli ng T ower Nozzles for cl eani ng of nozzl es at all CT’s
I
7
8 Opti mization of Cooli ng Circulation r ate of CT pumps are opti miz ed
9 X6
Tower Circul ati on based on r equirement at end us e.
C
10
11
12
9

10. Water Saving & Financial Impact in terms of Monthly Saving:-
Wat er Consumpt ion M3/M T of
Cathode
Financial S avings
Water Conservation (Rs)
Water
Linear (Wat er Consumpti on
Consumpt Fi nancial M3/MT of Cat hode)
Mont h ion Savings
M3/M T of (Rs) 16 800000
Cat hode
700000
Base Line 14. 79 15
SST 14. 25 141762
Water M3/MT of Cathode 600000
PT 13. 75 273023 14
Financial Saving
500000
June, 07 13. 05 432400
Jul y,07 11. 83 748007 13 400000
A ugust ,07 12. 57 570289
300000
S ept, 07 11. 82 715241 12
Oct ,07 11. 65 752124 200000
11
100000
10 0
PT
SST
July,07
Oct,07
June,07
Sept,07
August,07
Base Line
Month
Present effluent flow at DM plant
DM plant CT blow down CT SSF back PSF bac k
regeneration 250 m3/day wash wash
110 m3/day 100 m3.day 100 m3/day
N- Pit of 200 m3 capacity
Pumped to ETP
ETP
10

11. PROPOSED PROJECT
Proposed recycling
DM plant CT blow down CT SSF back PSF back
regeneration 250 m3/day wash wash
110 m3/day 100 m3.day 100 m3/day
New Pit of 75 m3 capacity N- Pit of 200 m3 capacity
Pumped to ETP Pumped to
Roaster water Mixing in boiler WGP & any
injection blow down for excess to RO
ETP 250 m3/day cooling directly
100 m3/day
Water Circuit Hydro I
Raw water clari fier RO treated water
3500-3000 m3 2000-2500 m3
W ater treatment
5500 m3
Roaster & Aci d DM plant Cool ing Tower L& P Cell house & Melting
400 m3 1500 m3 2500 m3 600 m3 500 m3
Boiler Blow down Regeneration Blow down Mg Bleeding Anode & Cathod washing
ACF & PSF
GCP area back wash Vacuum pump cooli ng Pump seal cooling
250 m3 Vacuum pump cooling
300 m3 300 m3
320 m3 400 m3
ETP
11

12. Monitoring & Reporting Systems
DAILY W A TER CONSU MP TION D A TA S HEE T
DA TE: / / Ti me : A. M.
Initial Final Cons. Remar
Description
Reading Reading (m³) k
1 Raw wate r to Cla rifier (X 10 m ³)
2 CT Ma ke up
3 DM wate r to CST
4 SW to Service wate r tan k
5 Raw wate r to Fire H ydra nt tan k (X 10 m ³)
6 Potable water to Pota ble water t ank
Activities for aw areness on w ater conservation in Plant
n We celebrate “Worl d Env ironment Day ” on June 5 ev ery y ear
n CH ANGE: Challenge for How to Acknowledge the Green Education was
organi ze d in May , 08 as One day awareness workshop on Water Conse rv ation.
n One week was f ully dedicated and Declare d as WATER WE EK f rom 5TH June to
11th June, 08 in Colony as water conserv ation and capacity building initiativ e.
n Green Em ploy ee of the Month Scheme is in practice to recogni ze the eff orts of
plant person al towa rds Water Conserv ation Activ ities.
n We also publish qu arterly magazine o n HSE titled “Saath Sa ath”
n Posters on water conserv ation are displ ay ed at v arious locations of the plant
n In-house intra net based web -site titled ‘Apna HSE Web P ortal”
n Promotion of use of treated sewage water f or lawns & plantation in resp ectiv e
househo lds
n Rain water h arv esting thereby recharging old bor e wel ls at Township ad opted
12