This is a presentation from ITC 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. I T C L I M I T E D
Water Management @ ITC Limited, Munger
Presen tation for
CII - Nati onal Award for Excellence in Water Mana ge ment 2008
I T C L I M I T E D
Profile
• Celebrated its Ce nte nary Yea r on 6th November, 2007.
• Located in Bihar, 173 km from Patna
• Product : Package d Cigarette s
Key Achievements (2007- 2008)
• ISO 9001 : 2000 ; ISO 14001 : 2004 & OHSA S 18001 certified plant.
• National Award for excellence in Water Ma nageme nt 2007, CII – GB C.
• Natio nal Award for e nergy c onservation - inno vative project 2007, CII- GB C.
• First prize in eastern regio n Safety Healt h & Env ironment Award 2007, CII .
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2. I T C L I M I T E D
ability Re port
ITC’s Sust ain
I T C L I M I T E D
Water Management A pproach
• Establish Over all Wate r Bal ance
• Reduce at sour ce
• Reuse in other bene fici al applicati ons a fte r trea tmen t (lan d scaping,
toile t flushing, cooling towe r appli cati ons an d civil constructi on s etc.,)
• Recycle back to pr ocess appl icati ons a fter a ppr opr iate treatment
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3. I T C L I M I T E D
Water Consumptio n Trend
Water Consumption
800
750
700
650
KLD 600
550
500
450
400
0 1 02
- 02- 03 0 3-04 04- 05 05- 06 06- 07 07 -08
Ser ies1 775 712 682 526 463 467 5 08
Year
Please Note: Please Note: Water con sum pti on increased by 8.7 % as
producti on in crea sed by 15.0 % compare d to last year however the spe cifi c
water consumpti on is reduce d by 6 %.
I T C L I M I T E D
Specif ic Consumptio n
Specific Water Consumption
14.00
11.52
12.00
10.11
10.00 8.80
8.00
5.89
6.00 5.33 5.02
4.00
2.00
0.00
02- 03 03-04 04-05 05-06 06-07 07-08
Index kl/mnc
Please Note: Spe ci fic Wate r Con sumpti on ha s reduce d by 6 %
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4. I T C L I M I T E D
Spe cif ic Wa ste Wa ter Discharge
Qty Qty Qty
generated recycled discharged Volumes Specific water
Year (m3/day) (m3/day) (m3/day) (MNC) discharge (kL / mnc)
2004 - 2005 151.8 58 105 24 4.4
2005 - 2006 143.3 138 6 31 0.2
2006 - 2007 161.7 158 3 35 0.1
2007 - 2008 157.6 120 38 40.5 0.9
I T C L I M I T E D
Spe cif ic Wa ste Wa ter Discharge
4.5 4.24
4
3.5
3
2.5
2
1.5 0.9
1
0.2 0.1
0.5
0
'04 - '05 '05 - '06 '06 - '07 '07 - '08
Specific Water dis cha rge.
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5. I T C L I M I T E D
Perf or mance Index
Benchmark & Trend Setting
Benchmark ITC Munger
Wat er Index (Na tional) Wat er Index : 5.0 2 KL /Millon of
: 4 .88 KL/M illon of cig ar et tes** ciga rett es
Wat er Index (Int er nat ional) Target : August, 2009 (To achieve national
: 4.8 5 KL /Millon of c iga rett es* and International Bench mark).
* BAT’s S ocial Rep or t 200 7
** ITC’ s Ba ngal ore Fac to ry
I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
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6. I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
I T C L I M I T E D
Sustainability – People Involv eme nt
v Water Manager.
v Awareness Pr ogra mme s.
v Operatives train ing at OEMs.
v Water brigade forma tion.
v Water leakage Audit.
v SGA
v Suggestion to impl ementati on competi ti ons & Quizs.
v Lean-sigma appr oaches.
6

7. I T C L I M I T E D
Sustainabili ty – Re vie w & Moni torin g
Da ily
ü Water Analysis Repor t
ü Effluent Repor t
Monthly
ü Management Review (BM)
ü Report to Chi ef Engine er.
Yearly
ü Annual Water & EHS Rep or t
ü Director’s Re por t
ü Unit Achievement Rep or t
Bey ond Equipm ent P erf ormance….
ü Performance appraisal of M anagers
I T C L I M I T E D
Water Conserv ation Projects
• CII Water Audit carried out in 2005-06. The following savi ngs po tentials
were identifi ed:
Effluen t discharge (200 5 – 2006 ) 160 m3 /day
Reducti on thr ough re cy cle of MGF /IRF b/w water 30 m3 /day
Reducti on in dome sti c water con sumpti on 15 m3 /day
RO product for CT make-up 50 m3 /day
RO reject for garde ning & Toi let fl ashing s 65 m3 /day
Total 160 m3 /day
• Earlier Treated Disc harge Water is b eing us ed b y
•Local farmers for irrigation
•Small scale gardeni ng i nside fact ory
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8. I T C L I M I T E D
Proposal # 1 : Recycle of Backwash Water
Raw water
MGF IRF Soft
tank Soften er
Water
– pH – 7.2-7.3
– TSS – 15-20 ppm
– TH – 500-550 ppm – pH – 7.2-7.3
Backwash
– TDS – 800-1000 ppm – TSS – 40-50 ppm
Water
– TH – 500-525 ppm
– TDS – 900-1000 ppm
Impl em ent ed
Existing
MF IRF
Raw wate r tank
By gra vit y
( TSS <20 mg/l)
Slu dge
Backwash water To dis posal
31 m3/day
I T C L I M I T E D
Proposal # 1 A cco mplished
Tube Settle r Pla nt
Savings: 30 m3 /day (10500 m3 /day annually )
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9. I T C L I M I T E D
Proposal # 2 : Reduction in domestic Water
• Dual Flash
• e- Flash
• e- Ta p
I T C L I M I T E D
Proposal # 2 A cco mplished
Dome stic Wa ter Sav ing s
E-Taps
Foam- Taps
People Awa reness
Dual Flash
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10. I T C L I M I T E D
Proposal # 3 Accom plished
Loca l Usage
Toilet Usage
Landscaping
Usage: 65 -70 m3 /day
I T C L I M I T E D
Proposal # 3 : RO Pla nt for Trea te d Efflue nt
vSegregate High T DS stream and dir ectly pum p to Final eff luent tank
ØAvoid the unnecessary TDS load to Ae ration
ØHelp improve the Aeratio n tank performance
vTreat the fina l effluent through RO – 11 5 m3 /day
Ø50 m3 /day output as Cooling Tower M ake-up
Ø65 m3 /day reje ct to garde n use, toilet flush
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11. I T C L I M I T E D
Proposal # 3 : RO Pla nt for Trea te d Efflue nt
110 m3/day
Treated Inter mediate
effluent tank Inter mediate
MGF
tank UF tank
Filter f eed
Existing pump
Existing TDS < 150 ppm TDS < 150 ppm
TDS – 1200 ppm
TH – 700 ppm TH < 50 ppm TH < 100 ppm
RO
Treated wate r-50 m3/day Softene r module
for CT make up
Reject
For garde ning,
Toilet flush
Note: TDS < 2100 ppm
MGF - Multi gr ade filte r COD < 250 ppm
MF - Micron fil ter BOD < 75 ppm
UF - Ultra filtra tion
RO - Reve rse Osm osis
I T C L I M I T E D
Proposal # 3 A cco mplished
Effluent Recy cling Scheme
Saving pote ntial: 50 m3 /day (17500 m3 /day annually)
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12. I T C L I M I T E D
Proposal # 3 Accom plished
Loca l Usage
Toilet Usage
Landscaping
Usage: 65 -70 m3 /day
I T C L I M I T E D
Other Initiatives
Remo te Radiator/T able Cooler
v ITC Mung er has proc ured a Rotary
UPS : A world class technology that has
a mec hanical stor eho us e of ener gy
coupled wit h a Diesel Engi ne
vIn place of a conventional Co oling
Tower, we hav e gone for a Table Co oler
which is an Air Co oling Remot e
Radiator
vHig h o n Cost
vBut sav es o ver 400 KL
water annually
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13. I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
v Parallel Plat e Separator post chemical treat ment
vOrganic Waste r emo ved as sludg e
vSludge Dewat ering /Filter Press
vFor Bett er Sludg e handling
vOil Catc h Pits
vTo arrest oil from enteri ng ET P Process Parallel Plate Separator
Filter Press Oil Cat ch Pits
I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
vETP A uto mation
• 8 Lev el Sensors
• 14 Aut o valv es Con tr olled from
• 6 NRVs HMI
• 5 parameter s ens ors
On line mo nitoring of D O, pH, T urbidity, Fr ee Chlorine
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14. I T C L I M I T E D
Other Initiatives
Better Efflue nt Handling
vRes ults
100
90
80
70
60
60
Mg / L
48
50 36
40
40 36
30 32
30
20
May
August
June
'07 - '08
July
Sept
April
I T C L I M I T E D
Initiatives in Residential Colony
Rain Wa ter Harve sting
Rec harge Struct ures :
• Roof T op Water – Aquifer Recharge Str uct ures
• Rec harge Tre nc h
• Onl ine Rec harge Pit
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15. I T C L I M I T E D
Impact of Recharging -
Depth to Wa te r Level (mb sl)
IT C Pa rk , Mun ger
Hydro graph Stati on Year Total Ju ne Ju ly Aug Sept.
1 Borewe ll n ear 2006 19.00 17. 00 16. 25 14.50
Bird’s eye 2007 15.60 14. 40 13. 82 13.80
Increment 3.40 2. 60 2.43 0.70
2 Borewe ll n ear 2006 18.00 16. 00 15. 50 13.00
Bank Hal l 2007 15.50 14. 30 13. 65 12.65
Increment 2.50 1. 70 1.85 0.35
3 Borewe ll n ear 2006 17.25 16. 50 16. 25 16.00
Near W are House I 2007 17.13 16. 00 15. 80 15.80
Increment 0.12 0. 50 0.45 0.20
4 Borewe ll n ear 2006 18.00 17. 00 16. 00 14.70
Near W are House II 2007 16.13 16. 00 15. 80 15.80
Increment 1.87 1. 00 0.20 -1.10
Rai nfall (mm)
2006 916 13 284 416 203
2007 1109 250 246 142 471
I T C L I M I T E D
Impact of Recharging -
Ground Water Level- Borewell-Bi rd' s E ye Ground Wat er Level- Borewell -Bank Hall
-1 0
-10
-1 1 Jun e July August Septem ber
-11 June July A ugus t Sept ember
Meter below Ground Lvl
Meter below Ground Lvl
-1 2 -12
-1 3 -13
-1 4 -14
-1 5 -15 6
-1 6 -16
-1 7 -17
-1 8 -18
-1 9 -19
-2 0
Ground Water Level- Borewell -W/H-1 Ground Water Level- Borewell-W/H-2
-1 0 - 10
Ju ne July August Se ptem ber Jun e July Au gu st Sept emb er
-1 1 - 11
Meter below Ground Lvl
- 12
Meter below Ground Lvl
-1 2
- 13
-1 3
- 14
-1 4
- 15
-1 5 - 16
-1 6 - 17
-1 7 - 18
-1 8 - 19
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16. I T C L I M I T E D
We understand the worth of water,
Even when the well is full of water.
Thank You
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