Water Management System at CCW · Venue :CII- Godrej GBC Hyderabad Date :16.12.2008 Name of the Presenter :A.K. Srivastava Head Plant Operations This report is solely for the internal

Water Management System at CCW

Venue :CII- Godrej GBC Hyderabad

Date :16.12.2008

Name of the Presenter :A.K. Srivastava

Head Plant Operations

This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization without prior written approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

Chaibasa Cement Works

Company Profile

Established in 1947.

Part of ACC/ Holcim, ati l d l b l l dnational and global leader

Expansion & modernizationin 2005.

1.2 MTPA integratedcement plant

Si d i “K lh iSituated in “Kolhan region– A hard core tribal belt” ,80 Km. from Jamshedpur.

QMS & EMS established asper IS/ISO 9001 & 14001.

OHSMS established as per

2

ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’

OHSMS established as perHolcim OH&S pyramid.Reliable and respected

Process Details

Highly sophisticated and modern plant with state of the art technology.

S i d ( t 23% i h d l f d i VRM)Raw material preparationRaw mat. extraction

Semi dry process (up to 23% enriched slurry feed in VRM)

Pyro processing

Raw meal preparation

3


Cement Grinding ShippingShipping

Roadmap for meeting the Environment goals

2008 2009 2010 2011

3030 30Stack emissions (mg/nm3) 50

650 602634 618Kg of CO2/ ton of Cementitious Material

(mg/nm )

20004000 3000Fugitive Emission SPM (µg/nm3) 5000

Environment

1 kilnCEMS Installation on Kiln Stack

-30% -10%-20% -15%Water Consumption

Tonnage of alternative fuels & raw mat. (tons) 222018400 14024 15150

Environment Road Map 88.7 82.286.4 84.3Power Consumption

KWh / ton

AFR InstallationCapex Rs. Cr 0.50.95 2.8 5.0

Thermal Substitution Rate (%) 1.990.53 1.43 1.62

4


Total GAV (Savings) Rs. Cr 5.890.29 3.47 4.30

Water Conservation Initiatives

Sl.No.

Water conservationinitiatives

Year ofImplementation

Annual Water Savings

Investment made Payback

period(months)R tation (months)

m3 Rs. Lakhs Rs. Lakhs

Strengthening of watermonitoring system by

1g y y

installation of watermeters at sourcepoints

2005-06 - - 2.22 -

Recycling of Effluent by

2

Recycling of Effluent byrerouting of reject pitdischarge toabandoned mine pit

2006-07 165000 4.85 2 5

ffl d h

3

Zero effluent dischargeby providingsedimentation tanksand reutilization offfl

2007-08 330000 9.7 12.1 15

5


effluent

Specific Water Consumption3 003 00

2.402.50

3.00

2.402.50

3.00

2.02

2.28

2.00

2.28

2.00 5 %

1.21

1.50

m3/M

T

1.50

m3/M

T

0.70

1.00

0.70

1.00

0.50

0 00 0 00

0.50

6


0.00

2004 – 05 2005 – 06 2006 – 07 2007 – 08 Benchmark

0.00 0.000.00

2004 – 05 2005 – 06 2006 – 07 2007 – 08 Benchmark

Road map to achieve global benchmarkObjective & targets Plan of Action Expected

Date ofCompletion

Technical justification

Strengthening of water Installation of Dec. 2009 Water recycled from reject pit ismonitoring system atuser end

water meters atuser end

collected in mines abandoned pit(A block) for further use inplant, this reutilized water isagain counted as fresh waterdue to lack of monitoringdue to lack of monitoringsystem.At present, water meters areinstalled only at sources and weare unable to take initiativesd t t idepartment wise.

To achieve specificwater consumption 700ltr./ MT of Clinker frompresent level of 1519

installation ofmodernizedFiltration FloatationPlant (FFP)

Dec. 2011 At present water consumption infloatation process is about 950ltr. per tonnes of clinker. Byimplementing this proposedpresent level of 1519

ltr./ MTof ClinkerPlant (FFP). implementing this proposed

project dry cake will be fed toVRM and 130 ltr. water pertonnes of clinker will beconsumed in this process.

7


Sustainability Indices

8


Environment Performance Index (PEP)

Systematic monitoring and evaluation of environmental performance

Identification of strengths and weaknesses (self-assessment)

Supporting tool in (environmental) business planning

Environmental programs, CAPEX projects, budgeting etc.

Database for communication purposes

Group and Group company internal benchmarking

7 3

8 0

7 5 7 67 5

8 0

8 5 Atmospheric Emission: PMEnval Performance Indicator

6 2

6 6

6 0

6 5

7 0

EP

I (%

)

5 0

5 5

2 0 0 5 2 0 0 6 2 0 0 7 2 0 0 8 2 0 0 7 2 0 0 6

Y e a r

9


CCW Performance CCW Target

ACC Avg. Performance HOLCIM Avg. Performance

Commitment towards reduction in GHG Emission

Our objective is to reduce by the year 2010 the averagespecific net CO2 emission by 20 % from the reference year1990 l l d WBCSD CO l

900 075 0

1990, calculated per WBCSD CO2 protocol.

Clinker Factor Specific Net CO2 Emission

876.0

840.0

860.0

880.0

900.0

Cem

. M

at.

69.5

73

65 0

70.0

75.0

804.0 800.0

781.0

760.0

780.0

800.0

820.0

. C

O2

/ M

T o

f

60.3

55.955.0 55.0

55.0

60.0

65.0

%

720.0

740.0

2005 2006 2007 2008

Year

Kg

.

50.02005 2006 2007 2008 2007 2006

Year

10


CCW Performance CCW TargetCCW Performance CCW Target

ACC Avg. Performance HOLCIM Avg. Performance

Commitment towards reduction in GHG EmissionThis reduction will be achieved through improving the four key eco-efficiency parameters:

clinker factorspecific thermal energy consumption

1050 0

specific thermal energy consumptionspecific electrical energy consumptionthermal substitution rate

Specific Electrical Energy ConsumptionSpecific Thermal Energy Consumption

106

100.0

105.0

110.0

Cem

en

t

995.0

876900.0

950.0

1000.0

1050.0

Cli

nker

91.9

89.0

85 6 85 0

91.42

90.0

95.0

100.0

kW

h/

MT o

f

755.0 750.0 748.8 751

700 0

750.0

800.0

850.0

KC

al/

Kg

. o

f C

85.6 85.0

80.0

85.0

2005 2006 2007 2008 2007 2006

Yea

600.0

650.0

700.0

2005 2006 2007 2008 2007 2006Year

K

11


Year Year

CCW Performance CCW Target ACC Avg. Performance HOLCIM Avg. Performance

Water Conservation Initiatives

Phase 1st :Strengthening of water monitoring system

Phase 2nd :Recycling of Effluent

Phase 3rd :Zero effluent discharge

12



Objectives

Compliance with environmental legal requirements

To improve Environmental Performance Indicator (EPI) of the plantTo improve Environmental Performance Indicator (EPI) of the plant

Regular monitoring of water consumption

Conservation of natural resources

Project Mission

Installation of water meters at source level

Project Organization

Client: Mr. A. Roy Choudhary, Vice President

Project Manager: Mr. A.K. Srivastava, Manager Engineering

Project Member: Mr S K Mazumdar HOD Water SupplyProject Member: Mr. S.K. Mazumdar, HOD Water Supply

Mr. Pradeep Singh, HOD Environment

Mr. P.K. Bhattacharya, Asst. Officer, WS

13



Identified Risks in planning phase

Sr. No.

Identified Risks Remedial Actions

1. Unavailability of layout drawings (plant established in the year 1947)

Study and develop water line layout

2. Procurement of the water meters in the time frame Adherence with delivery schedule.

Att ib t & A ti l

Sr. No. Activity Accomplished

byPlanned date of commencement

Actual date of commencement

Planned date of

completion

Actual date of

completion

Attributes & Action plan

1.Study of existing lay out and generate requirement for water meters

HOD: Water Supply 05.04.2005 05.04.2005 15.04.2005 10.04.2005

2. Procurement of water meters HOD: Purchase 15.04.2005 10.04.2005 30.06.2005 10.08.2005meters

3. Installation of water meters

HOD: Water Supply 01.07.2005 12.08.2005 31.07.2005 25.09.2005

4Establishment of system for daily water Mgr Engee 01 08 2005 01 10 2005 Cont Cont

14


4. for daily water consumption monitoring

Mgr. Engee. 01.08.2005 01.10.2005 Cont. Cont.


Out come of Team WorkMonitoring of water consumption started on daily basis.Monitored water consumption was double than derived from formula on monthly production basis.

Abandoned Quarry

Source End user

monthly production basis.

Quarry Pit (G Block)

Active Quarry Pit

Clinkerisation Plant

C i P

M

MQuarry Pit

Check Dam(River)

Captive Power Plant

Floatation Plant

M

M

Abandoned Quarry Pit (A Block)

Plant

Cement Grinding &

Packing Plant

M

15


Domestic


Objectives

To improve life of reject pit

To improve stability of reject pitTo improve stability of reject pit

To improve Environmental Performance Indicator (EPI) of the plant

Conservation of natural resources

Project Mission

Recycling of Effluent by rerouting of reject pit discharge to abandoned mine pit


Client: Mr. A.K. Srivastava, GM (Tech.)

Project Manager: Mr. KRK Prusty, Manager Mining

Project Member: Mr. P.K. Nanda, Jt. Manager Mining

Mr. Rajesh Kumar, Jt. Manager Mining

Mr Y Kumar Dy Manager CSR

16


Mr. Y. Kumar, Dy. Manager CSR


Identified Risks in planning phase

Sr. No.

Identified Risks Remedial Actions

l d l d

1. During project bund may be collapsed and lead to flood in near by areas.

Strengthening of bund.

Dewatering of reject pit.





Planned date of

completion

Actual date of

completion

1. Strengthening of bund by dumping overburden soil Mgr. Mining 10.10.2006 07.10.2006 15.11.2006 23.11.2006dumping overburden soil g g

2. Dewatering of reject pit through diesel pump Mgr. Mining 15.11.2006 23.11.2006 30.11.2006 07.12.2006

Laying of pipe with valves

3.

y g p p& strainer in bund for regular dewatering of clean water through gravity.

Mgr. Mining 20.11.2006 27.11.2006 30.11.2006 05.12.2006

Development of natural

17


4.Development of natural drain for the recirculation of mine discharge water

Mgr. Mining 20.11.2006 29.11.2006 31.01.2007 20.02.2007


Quarry

Source End user

Abandoned Quarry Pit (G Block)

Active

Clinkerisation Plant

Q y

M

Active Quarry Pit

Check Dam(River)

Captive Power Plant

Floatation

M

MAbandoned Reject Evaporation/


oatat oPlant

Cement Grinding &

P ki Pl t

M

Mine Pitj p /

Natural seepage

Domestic

Packing Plant

18



Out come of Team Work

Pit life increased by 1 year.

Dewatering pump operation not required ( Rs 10 Lakhs/ annum)Dewatering pump operation not required ( Rs. 10 Lakhs/ annum).

Stability of bund increased.

Clean water is being recycled (approximately 2000 KL per day) in ‘A’ block pitfor reutilization in cement plantfor reutilization in cement plant.

Water

19


Silica


Objectives

Conservation of natural resources (water & energy)

Control of water pollutionControl of water pollution

To improve Environmental Performance Indicator (EPI) of the plant

Project Mission

To achieve ‘Zero effluent discharge’


Client: Mr. I.M. Sharma, Plant Head

Project Manager: Mr. A.K. Srivastava, GM (Tech)

Project Member: Mr. P Singh, Asst. Manager Environment

Mr J N Prasad Jt Manager CivilMr. J N Prasad, Jt. Manager Civil

Mr. Y Singh, Dy. Manager CR-RM

Mr. M Singh, Asst. Engineer CR-RM

20


Mr. P K Bhattacharya, Asst. Officer WS





Planned date of

completion

Actual date of

completion


y completion completion

1. Initial Cleaning &Arresting leakages

Dy. Manager & Asst. Engr. CR-RM, Asst. Mgr Env.

12.09.2007 12.09.2007 30.09.2007 25.09.2007

2.

Construction of effluentcollection sump(1mX1mX1m) to collectcompressor cooling water& pump installation

Jt. Mgr. CivilAsst. OfficerWS

12.09.2007 12.09.2007 30.09.2007 25.09.2007

3.

Revamping of old settlingtank and procurement &installation of recyclepump.

Dy. Manager & CR-RM, Jt. Mgr. Civil

01.10.2007 26.09.2007 31.01.2008 31.01.2008

Minimising water Asst Officer4.

Minimising waterconsumption in Wetgrinding & thickening.

Asst. OfficerWS, Asst. Engr.CR-RM

12.09.2007 12.09.2007 30.09.2007 30.09.2008

5.

Recycling effluent in wetgrinding & stopping riverwater consumption in the

Asst. Mgr Env.,Asst. Officer 01.02.2008 01.02.2008 15.02.2008 15.02.2008

21


water consumption in thesame. WS


Source End user

Abandoned Quarry Pit (G Block) Clinkerisation

Plant

Quarry

M

Active Quarry Pit

Check Dam(Ri )

Captive Power Plant

M

M L

F

F

E

ST

(River)


Floatation Plant

Cement Grinding &

M

M N

E

U

LST

ST( )

Domestic

Grinding & Packing Plant T

ST

22



Out come of Team Work

Conservation of water (approx. 1000 KL per day)

Conservation of energyConservation of energy.

Control of pollution

23


Pumping facility installed to recycle effluent.Pump installed to recycle effluent.

HAND IN HAND - TOGETHER EACH ACHIEVE MORE

Thank you for your benign presence & support

24


y y g p pp

Documents

Water Management System at CCW · Venue :CII- Godrej GBC Hyderabad Date :16.12.2008 Name of the Presenter :A.K. Srivastava Head Plant Operations This report is solely for the internal