sustainability case tata power

Bombay Chapter of Commerce

Sustainability Case Study

MET Institute of Management ,Mumbai

Team: Blaze

Shruti Railkar [email protected] +91 9969004297

Kunal Thakur [email protected] +91 8879118457

First time Bottom Ash used in Bricksby

QC Team TATA Power

Philanthropy without scale and sustainability is like any other bad business that will simply wither and die on the vine.-Naveen Jain

2

Our Approach

Company Analysis

PDCA Cycle

Benefits

Future Plans

3

Company Analysis

PDCA Cycle

Benefits

Future Plans

4

Company Analysis

PDCA Cycle

Benefits

Future Plans

5

Company Analysis

PDCA Cycle

Benefits

Future Plans

6

VISION

• To be the most admired and responsible Integrated Power Company with international footprint, delivering sustainable value to all stakeholder.

MISSION

• We will become the most admired and responsible Power Company delivering sustainable value by:• Operating our assets at benchmark levels• Executing projects safely, with predictable benchmark quality, cost and time• Growing the Tata Power businesses, be it across the value chain or across geographies, and also in allied or new businesses• Driving Organizational Transformation that will make us have the conviction and capabilities to deliver on our strategic intent• Achieving our sustainability intent of ‘Leadership with Care’, by having leading and best practices on Care for the Environment, Care for the Community,

Care for the Customers and Shareholders, and Care for the People

Company PDCA Cycle Benefits Future Plan

7

TOTAL GENERATION CAPACITY 6999MW

8

Company PDCA Cycle Benefits Future Plans

QUALITY CIRCLE TEAM

QC TEAM

9


PROBLEM SOLVING CONTENTS

Company PDCA Cycle Benefits Future plans

10

STEP 1: Identification of problemBRAINSTORMING

TOTAL NO OF PROBLEMS

IDENTIFIED=60*

*List of problems provided in appendix


11

STEP 2: Selection of Problem


12

Selection Of Problem

The problems were categorized in A,B,C categories (A,B,C analysis)

A category-Which can be solved by QC circle

B category-Which can be solved by other department

C category-problems which require management approvalA

68%

B17%

C15%

Percentage

Category A = 41Category B = 10Category C = 9


13

Selection Of Problem QC TEAM DECIDED -CATEGORY A STRATIFICATION

A CATEGORY

Environment : 4

Safety/Health :

13

Cost:6

Moral:6

Quality :12

Selection Of theme

Sustainability/environment was selected since plant is located in heart of Mumbai city which is densely populated

Directly linked to MISSION statement

• Slide 2 of 59

Environment

Company PDCA Cycle Watch Industry Cost analysis

14

STEP 3: DEFINING THE PROBLEM


15

Defining The Problem

Reason• In Trombay Thermal Power Station, Coal is used as major

fuel for Power generation .• Ash is a byproduct

Type• Fly Ash-which is total burnt coal and which resale to

Cement construction company • Bottom Ash –No resale value. Therefore we have to

dispose it off.

% Content • The total % of Ash is divided in to two parts i.e. around 80% Fly Ash & 20% Bottom Ash

Requirement • Coal requirement for Trombay is around 9000 MT per day.

Company PDCA Cycle Watch Industry Marketing strategy Cost analysis


16

Defining The Problem Ash • They are using good quality Imported Indonesian

coal, it contains around 1-2% of ash content.

Content • Bottom Ash Generated: 7500 MT/yr. (625 MT/month)• Fly Ash generates: 37500 MT/year.

Future • After conversion of U#6 from Oil to coal, Bottom ash generation may increase by 5000 MT/year


17



18



19

Environment pollution

Huge amount disposable bottom ash 625 T/month(65trucks)

Disposable at the distance of 30KM

People have to work at night since transportation is at night.

Expenses Incurred on transportation 3,00,000/- month

Lack of space for storage Bottom ash.

Affect Green Manufacturing Index(GMI)4

IMPACT OF PROBLEM (Bottom Ash)


20


21

Impact of problem (Bottom ash)-StorageAs per Central Electricity Authority of India ‟Per Megawatt(MW) area calculation required for imported coal is:0.47Acre/MW

But our plant is running/installed at the ratio of :0.27Acre/MW (Situated in Mumbai (Metro city)

Already they are running their plant with lesser area.

Cleanness/healthiness or up keeping of the plant area got affected due continues storage of the Bottom within plant area.

Also as per MOEF (Ministry Of Environment & Forest ) notification we can store the Bottom Ash(solid waste) upto:3Months only



21

Defining The Problem To Improve:•Green Manufacturing Index (GMI) . (Directly linked to Companies “MISSION”)

To redu

ce

Environment

pollution

Storage & Transport

ation problem

Expenses incurred for disposable of bottom

ash

Working at night

shift


22

Defining Of Problem (Goal setting)

Disposing at present (MT/Month)

Planned disposal (MT/Month)

Bottom ash in MT

625 300

50

150

250

350

450

550

650

Bottom ash in MT

Bott

om a

sh In

MT

To reduce disposable of bottom ash from 625MT/Month to 300MT/Month


23

STEP 4: Analysis of Problem


24

ANALYSIS OF PROBLEM 5W & 1H TOOL

What? • 625MT/month-transportation• Around Rs.3.2 Lakhs per month expenses

Where?• Plant situated at trombay in Mumbai• Transported outside the plant area as permitted by

MPCB(Maharashtra pollution control board

When? • Ash generated 365 days of the year• Transportation in late hours

Who ? • Problem is irrespective of person –Process related

How?• Transported at late night by dumpers .• Spillage• Environmental pollution

Summery of SAP report

Year Bottom ash qty in MT/year

Amount spent for disposal in lakhs

2007-08 7000 35

2008-09 8600 44

2009-10 7500 40.5

2010-11 7350 37.5


25

Step 5: Identification of causes

26


Identification Of Causes

Environment

Person

System

Material

27


Identification Of Root Causes By Why-Why Analysis

Ash Content in

100% pure coal is not available

Available from natural mines

Why ?

Why ?

Coal

Economically & easily available than Oil & Gas

Why ?

Transportation By Road

Disposal yard is 30KM away from plant

Only MPCB approved dumping yard

Why ?

Why ?


28

Identification Of Root Causes By Why-Why Analysis

Space constraint

More generation in small space

Generation has been increased from 180MW to1580MW

Need for power

Industrial growth

Dumping

Environmental Constraint

Mumbai (Metro city)

Today TATA power have dumping permission but they are not sure about tomorrow

Why ?

Why ?

Why ?

Why ?

Why ?

Why ?

Why ?


29

STEP 6: DATA ANALYSIS

30


Data Analysis

Total amount spent

in last 4 years- 157 lakh

Avg amt spent till date-39.25 lakh/yr

Total Bottom Ash disposed-30450MT(FOR LAST 4 YRS)

Avg bottom ash disposed-7612 MT/yr

SAP REPORT


31

Data Analysis

Disposal area is far away from plant 30 km

• Bottom ash needs to be disposed at MPCB approved are

Ash Content in a Coal

• Indian coal has 30-40% ash content


32

STEP 7: DEVELOPING SOLUTION

33

Some of the solution listed down

Sr No Description Statement Remark

1Use of other fuels like gas/oil instead

of coal Coal is economical than other fuel Rejected

2 Transfer the plant at a remote location

Very costly. Not possible at this

momentRejected

3 Use of 100% pure coalGot the coal from

natural mines. 100% pure coal not

availableRejected


34

Developing SolutionPossible usage of bottom ash

Non structuring work like PCC, Plastering

Leveling Bed for Paver blocks

Molding of bricks

Paver blocks

Structural/Masonary work



35

STEP 8: TRIAL IMPLEMENTATION

36


Developing solution

Sr. No Solution Statement Remark

1 PCC and plastering work

We can replace bottom ash

instead of sand in the PCC & plaster

Selected

2 Bottom Ash Bricks As per result we can use it Bricks Selected

3 Leveling bed for paver block

We can use it for leveling of paver

blockSelected

4 For masonry work Ash can be used instead of sand Selected


37

TRIAL IMPLEMENTATAIONCompany PDCA Cycle Benefits Future Plans

38

TRAIL IMPLEMENTATAION

39


Trial Implementation Sample

NoRatio

(by volume)Proportion Weight

(KG)Strength

Cement Bottom Ash %(Kg/brick)

Fly Ash

StoneDust

MPA(N/mm2)

1 1:4:6 7.5% 42.50%(1.35) 50% Nill 4 7.52

2 1:5:4 8.6% 51%(2.04) 40.4% Nil 4 15.64

3 1:6:3 8.6% 61.13(2.44) 30.29%

Nil 4 11.70

4 1:8:3 7.12% 67.71%(2.84) 25.16%

Nil 4.2 11.4

5 1:8:2 7.18% 73.91%(2.83) 18.31%

Nil 3.8 15.67

6 1:10:3 6.1% 72.4%(2.78) 21.5% Nil 3.84 6.24


Comparison Between Clay Brick & Bottom Ash Brick

Sr No Property Clay Brick Bottom Ash Brick

Remark

1 Compressive strength

5-6MPA 15-16MPA 3 time more

2 Density 1800-1900Kg/cm2

1900-2000Kg/cm2

Acceptable

3 Water Absorption

10-20% 10-20% Ok


STEP 9:REGULAR IMPLEMENTATIONCompany PDCA Cycle Benefits Future plans

42

REGULAR IMPLEMENTATION

• During trial implementation it was confirmed that we will continue with the proportion 1:8:2 having an un expected strength value of 15.67MPA.

• Decided, we will implement the trial proportion 1:8:2 on regular basis. • Consumption of Bottom Ash per Brick is 2.83KG. • 250 bricks per Day. • We have increased our brick molding from 250 bricks/day to 350 Bricks/day. • Utilizing 990KG Bottom Ash daily for molding of 350 Bricks. • Bottom Ash Consumed for PCC work per meter cube (M3) = 765KG

• (APPENDIX-84)


43

Regular Implementation

Bottom Ash Brick


44

TROMBAY PLANT AREA


45

TANGIBLE BENEFITS

Cost Benefit Analysis:• After installation of Pilot Brick plant Bottom Ash is used in making of Bricks, PCC (Plain cement

Concrete), Plaster & masonry work and curbing work for all new Gardens developed - total Bottom Ash Consumed within 6 and half month = 875 MT (Metric Ton)

• Saved the transportation cost for 875 MT

• Transportation and Disposal cost of Bottom Ash per Ton is Rs. 510.

• Direct saving in the transportation cost of Bottom Ash = 875 X 510 =4,46,250/-

• As we had replaced the natural sand by using Bottom ash, we saved the cost of procuring Natural Sand for 875 Metric Ton.

• Cost of 1 Ton sand = 2100/- (if easily available, but now a day‟s natural sand is not easily available)

• Cost of 875 Metric Ton Sand saved = 875 X 2100 = 18,37,500/- Saving due to utilization of Bottom Ash instead of Sand in Bricks and civil work i.e. if we had

purchased the sand for above work we would have to spend around: Rs. 18,37500/


46

47

INANGIBLE BENEFITS Care of Environment &contribution to wards sustainability:

• As in this project we are able to reduce the storage and disposal problem of Bottom Ash. • Reduction of pollution in transport of Bottom Ash • Reduction in fuel cost and saving precious resources (diesel) for the transport of Bottom Ash ,

Bricks & natural sand. • Reduction in carbon foot print of the company. • Fatigue of workers reduced in the transportation of Bottom Ash , Natural sand and Bricks. • Reduction in mining of natural sand • Reduce, Reuse and Recycle .Contribution to wards Greenolution . Reusing the Bottom Ash in Civil

work. • Team work Experience As a team we worked together to achieve our goal.

48

Company Pen Industry Benefits Future plans

FUTURE PLAN

49

Future PlanTo achieve our goal of reducing disposal of Bottom Ash from 625 MT/months to 300MT/month & zero disposal by 2020 following are the future plans:

•Taking Clearance for the Radioactivity test to use the Bottom Ash Bricks for Structural and in-house. work : Samples submitted on 12/10/12 to BRIT office (Department of Atomic Energy, Radio analytical laboratory , Govt. of India, Mumbai ) for testing . Waiting for the results.

•Installation of Large capacity Brick plant having the capacity around 2000 to 3000 numbers of bricks per day.

•Utilization of Bottom Ash for the structural use.

•Making of Paver blocks by using Bottom Ash.

•After successful implementation of above plans we can reduce our Bottom Ash disposal to 300MT/months within next two years.

•Horizontal Deployment all over the TATA POWER.(Already Started)

•100% Utilization by 2020.

•Will be one of the future economical and eco-friendly construction materials

Company Pen Industry Benefits Future Plan

49

Thank you!!

51

APPENDIX

52

Appendix60 problems

52

Contd….

53

Contd…

54

Selection of Problem-RATING METHOD

Problem 3 Problem 5 Problem 17

Problem 34

0102030405060

Rating

Rating

55

Appendix

56

sustainability case tata power

Business