water audit in industry – cii’s perspective june 22 2011 pranab dasgupta

© Confederation of Indian Industry

Water Audit in Industry – CII’s

PerspectiveJune 22 2011

Pranab Dasgupta

National Seminar on “Standards for Quality and Empowerment”

Directorate of StandardizationMOD

Dept of Defense ProductionNew Delhi


Agenda for today’s presentation

Water Audit – Introduction & key drivers Standardization and Benchmarking Approach and Methodology supported with case

study Water Audit in building Monitoring & Reporting Typical Scope of Water Savings Report Card – CII Water Audit Program How to scale up Water Audit Introduction to CII Triveni Water Institute Business Communication


8 Keys to Successful Water Management -water audit being a core

component 1. Integrated Approach

2. Address both Technical + Human side

3 Accurate baseline data

4 Logical sequence –implementation in phases

5 Not only how much water but how it is used

6 Quality versus Application matching

7 Considering True Cost of Water

8 Understanding Life Cycle Cost

WATEWATER R

AUDIT AUDIT reqd reqd Steps Steps 3-83-8


Water Audit – Core Element of Water Management Program

A Water Audit is a “Systematic Approach

of Identifying, Measuring, Monitoring

and Reducing the Water Consumption by

various activities in an Industry”

Why Water Audit ? One should know exactly how the water is

being used in his premises prior to planning

any water management program.


Key Drivers of Water Audit

Legal Requirement

AP, TN, Karnataka, Gujarat, Maharashtra

CREP (Corporate Responsibility for

Environmental Protection) – 17 industry sec

Water stress regions – Availability / Quality

Corporate image

Business risk involved - Sustainability

Payback options in places of high water

tariff for industry


Standardization and Benchmarking

Industry are continuously minimizing their water footprint thus setting standards for SPECIFIC

WATER CONSUMPTION in their units.

Objective is to match National and International Benchmarks established in each of the sector


Examples on Specific Water Consumption

Pursuing to match or even parallel with

national and international

benchmarks


Binani Cement


Binani Cement - continue


Vehicles Manufacturing – 2007-08


Paper industry - Sripathi Sivakasi 2007-08


JK Tyre & Industries Ltd 2007-08


Steel industry - Vizak Steel 2007-08


Chemicals – TATA Chemicals


Approach to Water Audit in Industry

1. Starts with Training and Awareness

2. Inculcating water saving thoughts within the employees

3. Establishment of Water Balance within the premises

4. Application of 3 R’s principle – Reduce, Reuse and Recycle

5. Monitoring & Reporting to Sustain the Benefits


Water Loss One drop/secondHourly loss 0.5 litresAnnual loss 5 m3

Min. Annual water only cost Rs. 7.5

Union

Flange

Water Loss 0.1 litres/minuteHourly loss 6 litresAnnual loss 53 m3

Min. Annual water only cost Rs. 80Valve

Pump shaft seal

Water Loss 0 - 4 litres/minuteHourly loss 0 - 240 litresAnnual loss 0 - 2100 m3

Min. Annual water only cost Rs. 0 - 3150

Training and Awareness – sample sheet


Water Mass Balance


Borewell Pumps – 3800 kLD

Fire Hydrant

Drinking/ Process Water

Drinking Water

ProcessWater

Ad

min

– 1

4

Ca

nte

en

– 1

80

SM

D T

oil

ets

–

11

3P

MD

To

ile

ts –

1

20

co

lon

y –

41

1

Un

me

tere

d –

32

7

DM PlantSoftener

Va

c P

um

p,

Blo

we

r &

Air

C

om

p –

33

Air

Wa

sh

er

SM

D –

10

5

Air

Wa

sh

er

CT

S –

35

9

Bo

ile

r -

PM

D H

um

idu

ct

AC

Co

oli

ng

To

we

r –

46

5

DG

Co

oli

ng

To

we

r –

53

3

Domestic – 1340 kLD

838 1730 270327

PM

D C

lea

nin

g –

11

0

Du

st

& O

do

r –

20

2

PM

D P

roc

es

s –

37

3

450

Sand Filter

Industrial Cooling/ Process – 2450 kLD

Ba

ck

wa

sh

– 5

0

175

3790 kLD


Example: M&M Nashik Plant


Water Management Approach # 4

Reduce at Source(How much water is really

required?)


Reduction at Source

Better operating controls

Installation of water saving devices

Change of device/ equipment

Process modification

Few case studies are discussed herewith


Suggested action plan Immediately avoid use of hydrant water for other

applications

Safety aspects

Mandatory requirement

Create awareness amongst

Plant personnel

Contractors & suppliers

Introduce Work permit system for FH water usage

Continuous monitoring required

Good potential to save process water Atleast 50 m3/h or 1200 m3/day

Case Study 1 Avoid use of fire hydrant system for miscellaneous applications


Before

To ETP To ETP

Fresh

WaterFresh Water

Fresh Water Consumption = 70 m3/day

Case Study 2 Water use in rinsing section

30 m3/daypH -5.0, TDS-900

30 m3/daypH -6.5, TDS-100

Excellent potential to reuse 2nd stage rinse water in 1st stage rinsing

Components


After

Fresh Water Saving = 30 m3/day

To ETP

Fresh

Water

Reuse 2nd stage rinse as I rinse

Components


Benefits

Water Saving

9000 m3/yr

Annual savings = Rs.1.50 Lakhs Investment = Nil Payback period = Immediate


Case Study 3 Optimize pump gland seal water consumption in the plant

Approach for optimization Throttle the individual valves

Alternatively, further reduce the line size

As a long term option Install a closed loop seal water circulation system

Provide dedicated cooling towers Individual plants – Can be combined where feasible

Industry best practice For mechanical seals

“Smartflow” intelligent control system – Safematic Inc.

Allows water only when cooling is required


Case Study 3 -continue

Water Savings = 4,95,000 m3/yr

Annual savings = Rs.9.90 lakhsInvestment reqd = Nil

Benefits Atleast 15% fresh water savings in gland seals

Fresh water savings ~ 1500 m3/day

Continuous awareness and monitoring

required Sustain the benefits achieved



Recycle and Reuse


USES OF RECYCLED WATERUSES OF RECYCLED WATER

LOW END APPLICATIONS

Toilet flushing

Gardening

Floor washing

HIGH END APPLICATIONS

Boiler feed

Cooling water make-up

Process water


Recommendations

WTP Filtration Cycle

Collect filter back wash only

In Chamber (in Man hole)

Install tube settler

Treat & recycle

In Raw Water Tank

STP Filtration Cycle

Collect all Back wash water in a collection sump

MGF

ACF

Sand Filters (2 Nos)

Input as feed to R.O

Use for Beneficial applications - CT Make up / Gardening

Case Study 1 Reuse of Filter Backwash Water in Beneficial Application


Benefits

WTP Filtration Cycle Water Saving

50 m3/day

Annual Water Savings - 18250 m3 /annum

Annual Cost Savings - Rs. 6.0 lakhs

Investment - Rs. 3 Lakhs

Payback - 6 months

STP Filtration Cycle Water Saving

40 m3/day

Annual Water Savings - 14600 m3 /annum


Seal water consumption 11 vacuum pumps ~ 50 m3/h

Seal water drained to ETP

Fresh water being used for refiner seal 8 refiners ~ 40 m3/h

Both water drained to ETP Equivalent fresh water consumed

Case Study 2 Install a cooling tower for vacuum pump seal water and refiner

seal water in paper machine


Case study 2 - continue

Clarified water tank

Vacuum Pump seal

water 11 nos.

Refiner seal water – 8

nos.

Fresh water header

Cooling tower

Fresh water

makeup

M/c backwater


Drained seal water quality tested in lab Vacuum pump - Same as inlet fresh water

Refiner - Same as inlet fresh water

Lab tests conducted by plant team Oil & grease ~ BDL

Good potential to install a cooling tower system for seal water Recirculate after cooling

Fresh water only for cooling tower make-up

Good potential to reduce fresh water consumption ~ 80 m3/h or 1920 m3/day

Case study 2 - continue


Water savings = 6,33,600 m3/yr

Annual Savings = Rs.12.67 lakhs

Investment reqd. = Rs.8.00 lakhs

Simple payback = 8 months

Case study 2 - Install a cooling tower for vacuum pump seal water and refiner

seal water in paper machine


Case Study 3 Treated Domestic Water Reuse

Colony domestic wastewater

Generation - 1000 m3/day

Discharged outside after treatment

Treated domestic water characteristic

Treated domestic water

pH – 7.2

Conductivity - 500 ppm

Turbidity – 10 NTU

BOD < 10 ppm

COD < 50 ppm

Process water

pH – 7.4

Conductivity - 400 ppm

Turbidity < 15 NTU

COD < 50 ppm

Good Potential for reuse as DM Plant feed


Treated Sewage Reuse Scheme

Bar Screen

Chamber

SewageCollection

Tank

ChlorineDosing

Garden /

DM Plant

Clarifier

Raw Sewage

Air Blower

Sludge drying Beds

Aeration tank

Tube settler

Additional treatment scheme

Existing treatment scheme


Collectionsump

ClarifiedWaterTank

ChlorineDosing

Treated wastewater

to process

SecondaryClarifier

SC1

Sludge re-circulation pumps

Filter Feed Pumps

Paper stream Inlet

Aeration tank

PressureSandfilter

Activated CarbonFilter

MicronFilter

High Pressure pump

RO

Case study 4 -Treated Wastewater Reuse Scheme

PrimaryClarifier

PC2

pH-7.2TSS < 700 ppmCOD < 1000 ppmTDS < 800 ppm

pH-7.5TSS < 60 ppmCOD < 80 ppmTDS < 800 ppm

pH-6.8-7.2TSS < NilCOD < 30 ppmTDS < 50 ppm


Benefits

Water Saving 1000 m3/day

3,30,000 m3/annum

Annual Savings - Rs 6.60 Lakhs

Investment - Rs 15.00 Lakhs

Payback - 27 months


Case Study 4 Blow Down Optimization in Boiler

Soda Recovery Boiler Operating at ~ 90 TPH, 63.5 ata & 450oC

Online Conductivity meter installed

30 mS maintained in boiler drum

Present blow down ~ 4.5% Low conductivity maintained

Recommend to increase conductivity in steps Maintain 80 mS in line with CFB

DM Water Saving ~ 1.8 m3/h


Water Audit in building On-site survey and assessment of

Water using hardware, fixtures, equipment, landscaping

To develop recommendations for improving water use efficiency

Typical Water Consumption Pattern in Building Cooling tower 30%

Leakages 25%

Domestic 40%

Others 5% -(Irrigation & landscaping /Vehicle cleaning)


Electronic wash system

Electronic hand wash

Saves up to 70% water in hand

wash

Handles high TDS up to 1800 ppm

Foam spray taps

Saves up to 40% water in

handwash


Electronic flush system

Electronic urinal flush

Saves up to 40% water in flush

Handles high TDS up to 1800 ppm

Flush System


Water less Urinals

100% Water Savings


Rain Water Harvesting


Grey Water Recycling

140 lit/day of fresh water For Washing and Cleaning



Monitoring and Reporting


MONITORING

Monitor daily, monthly, yearly

Institute specific format

Introduce as a part of log sheet


Ashok Leyland – Monitoring and Reporting System


Typical Scope of Water Savings – Ex: Hindustan National Glass & Industries Limited, Nashik

Water Saving Activity Annual Water Saving

m3

Blow down water from cooling tower is

treated in STP and used in gardening -2009 31025

Reusing treated water from STP in Cullet

washing 7200

All underground lines were replaced with

overhead lines to minimize unidentified

losses

91250

Recirculation of glass gob cooling water 21900New pit for collection and recirculation to and

from cullet washers 29200

Installation of cooling tower to eliminate

fresh water usage for the hot cullet scraper

during heavy draining of gobs

11880


Report Card – CII Water AuditWater audits & Training

45 audits and training till

date2 companies facilitated for

‘Zero Water Discharge’Godrej Industries Ltd, ValiaITC Ltd, Munger

Annual Water Savings

(m3/year)

Equivalent Annual Cost Savings

(Rs Lakhs/year)

Identified 18 million 1255.00

Achieved*

(till date)4.0 million 150.00

* Balance under implementation


What Next ? Scaling up of Water Audit !!

1.Water Foot Printing in

Industry

2.Blue Rating of

products / organizations


CII – Triveni Water Institute The first of its kind in the world (Government, Industry,

Civil Society coming together)

Jaipur, Rajasthan

Jaipur, Rajasthan

BangaloreBangalore

New DelhiNew Delhi

PunePune


National & International Partners

National State and Central

Government

International Partners Water Industry Alliance,

South Australia

Cleantech, Switzerland

IFC, USAID,

Netherlands, Israel –

Expressed interest


CII Water Activities

Events & Award Programs

Information Dissemination Centre including Publications Education & Training

CII TriveniWater Institute

AdvisoryServices


Business Communication

S Raghupathy - Executive Director

Email: [email protected]

K S Venkatagiri – Principal Counsellor


Pranab Dasgupta – Senior Counsellor


THANK YOU

water audit in industry – cii’s perspective june 22 2011 pranab dasgupta

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