National Award for Excellence in W ater Management-2008
                  16 & 17 December 2008;
  CII – Sohrabji Godrej G...
Water Conservation Measures implemented
PSPD
BHADR AC H AL AM            2007-08
                                         ...
Water Conservation Measures implemented
PSPD
BHADR AC H AL AM         2007-08

     Reuse of P M-1,2 & 3 hydra ulic statio...
Production Vs Fresh water intake
PSPD
BHADR AC H AL AM




Even w hen production has more than doubled since last 10 years...
Global Benchmark
PSPD
BHADR AC H AL AM




So urce: N at ional Product iv ity Council, New Delhi
Final re port o n w at er...
Employee involvement through TPM
PSPD
BHADR AC H AL AM




                           Waste water discharge
PSPD
BHADR AC ...
Specific Waste Water Discharge - Standards
PSPD
BHADR AC H AL AM


                            Discharge
  Standard
      ...
Utilization of waste water
PSPD
BHADR AC H AL AM


     Utilization of treated effluent water for irrigation




  Source:...
Innovative project – 2
PSPD               Reuse of cooling tower blowdown
BHADR AC H AL AM

Trigg er:
- Once thro ugh seal...
Sustainability through Monitoring & Reporting
PSPD
BHADR AC H AL AM

Monitoring & Reporting:
4 Entire pla nt is DCS operat...
PSPD
BHADR AC H AL AM




                   Thank You
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ITC Limited, Bhadrachalam

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This is a presentation from ITC Limited, Bhadrachalam, 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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ITC Limited, Bhadrachalam

  1. 1. National Award for Excellence in W ater Management-2008 16 & 17 December 2008; CII – Sohrabji Godrej Green Business centre, Hyderabad A. Padmanabhan, General Manager (Projects) M/s ITC Limited – Paperboards & Specialty Papers Division, Unit Bhadrachalam PSPD Company profile BHADR AC H AL AM n PSP D, a Division of ITC Ltd, formed in Apr 2002, by merging group businesses i n Paperboards & Spe cia lty Papers. n PSP D co nsist of Unit Bha dra chalam , Unit Kovai, Unit Tribeni, Unit Bollaram , w ith turnover of Rs.2364 Crores duri ng 2007-08. Bhadra chalam tur nover more than is Rs.1200 Cr n Unit Bhadra chalam is India’s la rgest single lo cation integrated paperboard compa ny of capa city 4.0 lac TPA. n 98% self sufficie ncy in pow er requirement through co-ge neration. n ISO 9001:2000, ISO 14001-2004 and OSH AS18001 certification fo r Unit Bhadra chalam are a p roof of Qua lity, Environme nt, Health and Sa fety Systems.
  2. 2. Water Conservation Measures implemented PSPD BHADR AC H AL AM 2007-08 An nual W at er I nvest Payback Tit le of W at er Saving project Savings S.N Year Period implement ed 3 m Rs .Lakhs Rs . Lakhs (Months) Reduct ion by ins t allat ion of pus h t ype 1 but t ons at t oilets t o re du ce 300m 3/d of 2007-08109500 2.74 0.50 2.2 dom es t ic w at er cons um pt ion. Reus e of C aus t icizing CD filt er, 2 com pres s or and pump s ealing w at er 2007-08264000 6.60 11.30 20.5 for log w as hing t o s ave 900m3/d Reus ing of PM -5 lean t ank ex ces s back w at er f or t ow er dilut ion at 3 2007-08 82500 2.06 11.30 65.7 ble ach e d t ow er s uct ion t o s ave 250m 3/d I nst alled Dis c filt er for PM -5 t op l ayer t o 4 re cycle t he back w at er t o s ave 2007-08 36300 9.08 105.00 138.80 1100m3/d. Reus e of SRB-3 HBL t ank pum ps s ealing 5 w at er as Evaporat or - 3 c oolin g t ow er 2007-08 33000 0.83 1.60 23.3 make u p t o s ave100m3/d. Water Conservation Measures implemented PSPD BHADR AC H AL AM 2007-08 Reuse of Eff luen t secondary cla rif ier ou t le t 6 water for floor clea ning o f Evaporator 3 & 2007-08 66000 1.65 2.45 17.8 Caustciz ing p lan t to save 200m3 /d Reuse of Pu lp sheeting mac hine backwater 7 for pulper s lus hing at St-A &B to save 2007-08 49500 1.24 1.85 17.9 150m3/d Reuse of sand f ilter blow down wa ter from 8 TG 5, as make up for TG5 Cooling tower to 2007-08 33000 0.83 0.65 9.5 save 100m3/d Rectif ication of 20 numbers of leakages 9 thro ugh on -line wa ter leaks arresting 2007-08 82500 2.06 0.87 5.1 method in the mill to save 250m3 /d Reuse of Evapara tor-4 Pumps sealing wa ter 10 as make up for cooling tower to save 2007-08 148500 3.71 3.50 11.3 450m3/d.
  3. 3. Water Conservation Measures implemented PSPD BHADR AC H AL AM 2007-08 Reuse of P M-1,2 & 3 hydra ulic stations , & vacuum condenser cooling wa ter for PM-2 11 2007-08 66000 1.65 3.78 27.5 & 3 h igh pressu re showers to save 200m3 /d of fresh wa ter Recycling of LimeK iln-2 vaccum p ump 12 sealing wa ter throug h cooling tower to 2007-08 148500 3.71 4.50 14.5 save 450m3/d Recycling of SR B4 spou t cooling w ater, 13 SWA S pa nel ccoling water to raw w ater 2007-08 82500 2.06 2.50 14.5 clarif ies to save 250m3/d Reuse of cooling tower blowdow n wa ter 14 for Evap- 3 &4 vaccum pp sealing wa ter 2007-08 165000 4.13 5.00 14.5 purpose to 500m3/d Reuse of excess pulp s heeting machine 15 backwater for D1 d ilution screw a t N FL-1 to 2007-08 58800 1.47 4.50 36.7 save 700m3/d for 7 days in a mon th TOTA L 1752300 43.81 159.3 43.60 Summary of Water Conservation PSPD BHADR AC H AL AM Water savings Savings Investment Payback Year (m3) (Rs. Lakhs) (Rs. Lakhs) (Months) 2004-05 579150 5 5 12 2005-06 2175690 49 237 58 2006-07 1136800 49 52.2 13 2007-08 1752300 44 159.3 43.6
  4. 4. Production Vs Fresh water intake PSPD BHADR AC H AL AM Even w hen production has more than doubled since last 10 years, fresh w ater intake has increased by only 9% . Achieved majorly by reduction, reuse and recy cli ng appro ach throug h in-ho use efforts and technology route. Specific water consumption PSPD BHADR AC H AL AM Cubic m et er pe r t onne of product ion Consist ent effort s for water conservat ion over a decade t hrough 3R has r esult ed in 51.2% r educt ion in specifi c wat er consumpt ion for decade a nd 21.33% reduct ion in last four years.
  5. 5. Global Benchmark PSPD BHADR AC H AL AM So urce: N at ional Product iv ity Council, New Delhi Final re port o n w at er conserv at ion i n pulp and paper sect or. Table 14: Re gio n/ Co unt ry specific av erage w at er cons umpt ion i n l arge scale w ood base d pulp and paper mills, (Page 48/ 115) Roadmap towards Global benchmark PSPD BHADR AC H AL AM (A) Capacity utilization - to reduce specific water consumption - to reduce water usage for non productive purpose (B) Technology up gradation - to reduce fresh water consumption, waste water generation & improve quality of waste water - to built-in water reuse and recycling facilities (C) Employee participation and water audits - water & process mapping to identify opportunities - to reduce wastage and losses - to create awareness & update with latest water conservation techniques and products
  6. 6. Employee involvement through TPM PSPD BHADR AC H AL AM Waste water discharge PSPD BHADR AC H AL AM (Kiloliter per tonne) As per CRE P (Corporat e Res po nsibility for Env ironme nt al Prot ect ion) propose d by MoEF and CPCB max imum li mit is 10 0 kiloliter per tonne
  7. 7. Specific Waste Water Discharge - Standards PSPD BHADR AC H AL AM Discharge Standard (KL/MT) CREP 100 Benchmark * 50 Best 53 Achievable * Relaxed Standard * 63 Bhadrachalam 53.9 CREP: Corporat e Res pons ibilit y for Environment Prot ect ion ( CREP) by M oEF, * Nat ional Product ivit y Council, New Delhi Quality of Waste Water PSPD BHADR AC H AL AM Adsorbable Organic AOX (Kg/ Tonn e) Halides (AOX) in the Bhadrachalam Mill 0.011 treated waste water Indian 0.46-0.8 hav e been reduced Paper/Paperboards Mills* to 0.011 Kg/ton of European Paper 0.03 production during Industrie s# 2007-08 World Bank 0.2 Standard** *Average as per C ompreh ensi ve I ndust ry Document for Large S cal e P aper M ills, st udy con du ct ed by Cent ral Pulp & P aper R ese arch I nst it ut e, 2007 I # CEPI ( Confeder at ion of European P aper I ndust ries,) Sust ainabilit y Report 2007 I **W orld Bank Gui deline f or New Paper M ills.
  8. 8. Utilization of waste water PSPD BHADR AC H AL AM Utilization of treated effluent water for irrigation Source: ITC Sustainability Report 2008 Innovative project – 1 PSPD BHADR AC H AL AM Ozone bleaching for Fiberline Trigger: - Water consum ption per ton of blea ched pulp is 25m3/t ( cooking & fiberline only) is high compared to international stand ards. - Color in pulp mill efflue nt - M ax imize utilization of effl uent w ater for irrigation Ana lysis: - Ozone b leaching is effe ctive at high(35% - 40%) consistency presses Action: First installation in India w ith O2 generation plant, Ben efits: - Guara nteed w ater consumption is 15m3/t - Reduction in color of p ulp mill effluent by 50%. - Reduction in AOX to 0.1 to 0.01kg/ton. - ClO2 co nsumption reduced by 50%
  9. 9. Innovative project – 2 PSPD Reuse of cooling tower blowdown BHADR AC H AL AM Trigg er: - Once thro ugh seal ing w ater for evaporator vacuum pumps d ue to fouling of seali ng w ater - Evaporator cooling tow er blow dow n is drained to control COC Ana lysis: Blow dow n w ater is not fit for reuse in vacuum p umps seali ng purpose due to high TDS. Need for chemi ca l treatment for blow dow n w ater to pass through va cuum pumps for se aling p urpose Ben efit: -Chemical treatment of blow dow n w ater at inlet of vacuum pumps and dra ining after usage - Reduction of 500m3/d of fresh w ater consumption fo r sealing. Innovative project – 3 PSPD Recycling through CD Filter for PM5 BHADR AC H AL AM Trigg er: - Sp w ater consumption is hig h for paper machine due to variation in product mix - Backw ater not fit for reuse due to high fiber a nd filler co ntent Ana lysis: -ClariDis c filter fo und s uitable for recycling of b a ck w ater for reuse in machine . - Filter produces super clear, cle ar and cloudy filtrate to be used for specific a pplication. Ben efit: - Recy cling o f 1000m3/d of ba ck w ater (capa city is 3000m3/d) - Recovery of fiber by using cloudy filtrate at tow er dilution purpose
  10. 10. Sustainability through Monitoring & Reporting PSPD BHADR AC H AL AM Monitoring & Reporting: 4 Entire pla nt is DCS operated for control a nd consistent operation. 4 M onitoring of w ater and energy cons umption on real time basis. 4 Norms for w ater consumption; p lant w ise and process w ise. 4 EC Cell to monitor cons umption daily basis agai nst norm and report back a ny deviation seeking rea sons from HO D. 4 Metering facility over entire plant integrated w ith DCS. 4 Total employee participation thro ugh mill w ide TPM initiative to promote w ater conservation. 4 Water conservation a s KRA for ma nagers i n their annual a pprais als. 4 Capital s cheme for w ater conservation w ith 5-7 year payback is implemented. Sustainability through Monitoring & Reporting PSPD BHADR AC H AL AM M onitoring & Reporting: 4 M onitoring on shift basis , pro cess pla nt drains le ading to ETP to monitor discharge of efflue nt w ater and chara cteristics. 4 Water audits are carried out annually through ex perts. 4 Water balance carried out on mo nthly basis , department w ise. 4 Capital and revenue b udget to for audits and im plementation of proposals. 4 Water flow meters at w ater intake and dis cha rge are regul arly calibrated as per ISO s che dule 4 IMIS reports for daily and monthly cons umption and dis cha rge. 4 M onthly review against the norms for improvement
  11. 11. PSPD BHADR AC H AL AM Thank You

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