itc limited, munger
DESCRIPTION
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.TRANSCRIPT
1
I T C L I M I T E D
Presen tation forCII - National Award for Excellence in Water Manage ment 2008
Water Management @ ITC Limited, Munger
I T C L I M I T E D
Profile
• Celebrated its Centenary Year on 6th November, 2007.
• Located in Bihar, 173 km from Patna
Key Achievements (2007- 2008)
• ISO 9001 : 2000 ; ISO 14001 : 2004 & OHSAS 18001 certified plant.
• National Award for excellence in Water Ma nageme nt 2007, CII – GBC.
• National Award for e nergy conservation - innovative project 2007, CII- GBC.
• Product : Packaged Cigarettes
• First prize in eastern region Safety Health & Environment Award 2007, CII .
2
I T C L I M I T E D
ITC’s Sustainabil ity Report
I T C L I M I T E D
Water Management Approach
• Establish Overall Water Bal ance
• Reduce at source
• Reuse in other beneficial applications after treatment (land scaping,
toile t flushing, cooling tower applications and civil constructi ons etc.,)
• Recycle back to process appl ications after appropriate treatment
3
I T C L I M I T E D
Water Consumptio n Trend
Please Note: Please Note: Water consumption increased by 8.7 % as production increased by 15.0 % compared to last year however the specific water consumption is reduced by 6 %.
400
450
500
550
600
650
700
750
800
KLD
Year
Water Consumption
Ser ies1 775 712 682 526 463 467 5 08
0 1- 02 02- 03 0 3-04 04- 05 05- 06 06- 07 07 -08
I T C L I M I T E D
Specif ic Consumptio n
Please Note: Speci fic Water Consumption has reduced by 6 %
Specific Water Consumption
11.5210.11
8.80
5.89 5.33 5.02
0.00
2.00
4.00
6.00
8.00
10.00
12.00
14.00
02- 03 03-04 04-05 05-06 06-07 07-08
Index kl/mnc
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I T C L I M I T E D
Specif ic Waste Water Discharge
Year
Qty generated (m3/day)
Qty recycled (m3/day)
Qty discharged (m3/day)
Volumes (MNC)
Specific water discharge (kL / mnc)
2004 - 2005 151.8 58 105 24 4.42005 - 2006 143.3 138 6 31 0.22006 - 2007 161.7 158 3 35 0.12007 - 2008 157.6 120 38 40.5 0.9
I T C L I M I T E D
Specif ic Waste Water Discharge
4.24
0.2 0.1
0.9
00.5
11.5
22.5
33.5
44.5
'04 - '05 '05 - '06 '06 - '07 '07 - '08
Specific Water discharge.
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I T C L I M I T E D
Water Index : 5.02 KL/Millon of cigarettes
Target : August, 2009 (To achieve national and International Bench mark).
Performance Index
Benchmark & Trend Setting
Benchmark ITC Munger
Water Index (National): 4 .88 KL/M illon of cigarettes**
Water Index (International): 4.85 KL/Millon of c igarettes*
* BAT’s S ocial Report 2007** ITC’ s Bangal ore Fac tory
I T C L I M I T E D
Sustainability – People Involv ement
v Water Manager.v Awareness Programmes.v Operatives training at OEMs.v Water brigade formation.v Water leakage Audit.v SGAv Suggestion to implementation competi tions & Quizs.v Lean-sigma approaches.
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I T C L I M I T E D
Sustainability – People Involv ement
v Water Manager.v Awareness Programmes.v Operatives training at OEMs.v Water brigade formation.v Water leakage Audit.v SGAv Suggestion to implementation competi tions & Quizs.v Lean-sigma approaches.
I T C L I M I T E D
Sustainability – People Involv ement
v Water Manager.v Awareness Programmes.v Operatives training at OEMs.v Water brigade formation.v Water leakage Audit.v SGAv Suggestion to implementation competi tions & Quizs.v Lean-sigma approaches.
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I T C L I M I T E D
Sustainabili ty – Review & Moni torin g
Daily ü Water Analysis Report ü Effluent Report
Monthly
ü Management Review (BM)ü Report to Chief Engineer.
Yearlyü Annual Water & EHS Reportü Director’s Reportü Unit Achievement Report
Beyond Equipm ent Performance….
ü Performance appraisal of M anagers
I T C L I M I T E D
Water Conserv ation Projects
160 m3/dayTotal
65 m3/dayRO reject for gardening & Toi let flashing s
50 m3/dayRO product for CT make-up15 m3/dayReduction in domestic water consumption
30 m3/dayReduction through recy cle of MGF /IRF b/w water160 m3/dayEffluen t discharge (2005 – 2006)
• Earlier Treated Discharge Water is being us ed by
•Local farmers for irrigation
•Small scale gardeni ng i nside factory
• CII Water Audit carried out in 2005-06. The following savi ngs potentials were identifi ed:
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I T C L I M I T E D
Proposal # 1 : Recycle of Backwash Water
Raw watertank Soft
Water
– pH – 7.2-7.3– TSS – 15-20 ppm– TH – 500-550 ppm– TDS – 800-1000 ppm Backwash
Water
MGF IRF Soften er
– pH – 7.2-7.3– TSS – 40-50 ppm– TH – 500-525 ppm– TDS – 900-1000 ppm
Backwash water31 m3/day
SludgeTo dis posal
ExistingRaw wate r tankBy gra vit y( TSS <20 mg/l)
MF IRF
Impl emented
I T C L I M I T E D
Proposal # 1 Acco mplished
Tube Settler Plant
Savings: 30 m3/day (10500 m3/day annually )
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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 Acco mplished
Domestic Water Sav ing s
E-Taps
People Awa reness
Dual Flash
Foam- Taps
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I T C L I M I T E D
Proposal # 3 Accomplished
Local Usage
Usage: 65-70 m3/day
Toilet Usage
Landscaping
I T C L I M I T E D
Proposal # 3 : RO Plant for Treated Effluent
vSegregate High T DS stream and directly pump to Final eff luent tank
ØAvoid the unnecessary TDS load to Aeration
ØHelp improve the Aeratio n tank performance
vTreat the final effluent through RO – 115 m3/day
Ø50 m3/day output as Cooling Tower Make-up
Ø65 m3/day reject to garden use, toilet flush
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I T C L I M I T E D
Proposal # 3 : RO Plant for Treated Effluent
UF
110 m3/day
Treatedeffluent
tankMGF
Note:MGF - Multi grade filte rMF - Micron fil terUF - Ultra filtra tionRO - Reve rse Osmosis
Filter feedpump
Intermediatetank Intermediate
tank
RO module
RejectFor garde ning,Toilet flush
Treated wate r-50 m3/day for CT make up
ExistingExisting
Softene r
TDS – 1200 ppmTH – 700 ppm
TDS < 2100 ppmCOD < 250 ppmBOD < 75 ppm
TDS < 150 ppmTH < 100 ppm
TDS < 150 ppmTH < 50 ppm
I T C L I M I T E D
Proposal # 3 Acco mplished
Effluent Recy cling Scheme
Saving potential: 50 m3/day (17500 m3/day annually)
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I T C L I M I T E D
Proposal # 3 Accomplished
Local Usage
Usage: 65-70 m3/day
Toilet Usage
Landscaping
I T C L I M I T E D
Other Initiatives
Remo te Radiator/T able Cooler
v ITC Munger has procured a Rotary UPS : A world class technology that has a mechanical stor ehous e of ener gy coupled with a Diesel Engi ne
vIn place of a conventional Cooling Tower, we have gone for a Table Cooler which is an Air Cooling Remote Radiator
vHigh on Cost
vBut saves over 400 KL water annually
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I T C L I M I T E D
Other Initiatives
Better Effluent Handling
v Parallel Plate Separator post chemical treatment
vOrganic Waste r emoved as sludge
vSludge Dewatering/Filter Press
vFor Better Sludge handling
vOil Catch Pits
vTo arrest oil from enteri ng ET P Process
Filter Press Oil Catch Pits
Parallel Plate Separator
I T C L I M I T E D
Other Initiatives
Better Effluent Handling
vETP Automation
• 8 Level Sensors• 14 Auto valves• 6 NRVs• 5 parameter s ens ors
Controlled from HMI
On line monitoring of DO, pH, T urbidity, Fr ee Chlorine
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I T C L I M I T E D
Other Initiatives
Better Effluent Handling
vRes ults
60
3036
36
32
40
48
20
30
40
50
60
70
80
90
100
Mg
/ L
'07
- '0
8
Apr
il
May
June
July
Aug
ust
Sept
I T C L I M I T E D
Initiatives in Residential Colony
Recharge Structures :
• Roof Top Water – Aquifer Recharge Str uctures
• Recharge Tre nch
• Online Recharge Pit
Rain Water Harvesting
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I T C L I M I T E D
Impact of Recharging -
Year Total Ju ne Ju ly Aug Sept.
1 Borewe ll n ear 2006 19.00 17.00 16.25 14.50Bird’s eye 2007 15.60 14.40 13.82 13.80Increment 3.40 2.60 2.43 0.70
2 Borewe ll n ear 2006 18.00 16.00 15.50 13.00Bank Hal l 2007 15.50 14.30 13.65 12.65Increment 2.50 1.70 1.85 0.35
3 Borewe ll n ear 2006 17.25 16.50 16.25 16.00Near W are House I 2007 17.13 16.00 15.80 15.80Increment 0.12 0.50 0.45 0.20
4 Borewe ll n ear 2006 18.00 17.00 16.00 14.70Near W are House II 2007 16.13 16.00 15.80 15.80Increment 1.87 1.00 0.20 -1.10
2006 916 13 284 416 2032007 1109 250 246 142 471
Depth to Wate r Level (mbsl)IT C Park , Mun ger
Hydrograph Stati on
Rai nfall (mm)
I T C L I M I T E D
Impact of Recharging -Ground Water Level- Borewell-Bi rd' s E ye
-2 0-1 9
-1 8-1 7-1 6-1 5
-1 4-1 3-1 2-1 1
-1 0Jun e July August Septem ber
Met
er b
elow
Gro
und
Lvl
Ground Water Level- Borewell -Bank Hall
-19-18-17-16-15-14-13-12-11-10
June July A ugus t Sept ember
Met
er b
elow
Gro
und
Lvl
6
Ground Water Level- Borewell -W/H-1
-1 8
-1 7
-1 6
-1 5
-1 4
-1 3
-1 2
-1 1
-1 0Ju ne July August Se ptem ber
Met
er b
elow
Gro
und
Lvl
Ground Water Level- Borewell-W/H-2
-19
-18-17
-16
-15-14
-13
-12-11
-10June July August Sept ember
Met
er b
elow
Gro
und
Lvl
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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