1. RIL-DMD Presentation For National Award inExcellence in Water Management-2008 TO Reliance Industries LimitedDahej Manufacturing DivisionTeam: Mr. Dipak Mehta Mr. Muthukumaran Mr. Yusuf Husain1

2. RIL-DMD Our Mission To Continually offer value added and innovative petrochemicals products as raw materials for global and domestic customers, maintaining a Constant customer focus and an enduring concern for the environment and for stakeholder needs and valuesOur Vision Our ValueVisionary Leadership Customer Focus Agility Integrity Innovation We at RIL-DMD shall continue to Data Based Management contribute to Reliance Industries Social ResponsibilityLimited in sustaining its market Organizational and Personalleadership position in India. Learning Valuing Human Resources Focus on Results and CreatingValues System Perspective2 3. RIL-DMD Unit Profile Total Area of 700 hectares having 300 hectares Green beltCaptive jetty- capacity for 6000 DWT vesselManufacturing facilities of Ethylene, Propylene,EO/EG,HDPE, PVC, VCM, Caustic & ChlorineOnly Petrochemical complex in the country where PVCmanufacturing facility is backed by Captive Chlor Alkali PlantCaptive Power generation capacity 155 MWCaptive steam generation 540 MT/HrFuel for power and steam generation is totally gas9 MGD of water pumped from River Narmada (45 KM)3 4. RIL-DMD Product Flow DiagramCaustic Soda Chlor-AlkaliIndia's Only Salt to PVCFlakes/PrillsSaltPlant(50 KTA) Integrated PlantCl2Caustic SodaLyeEthylene VCM (165 KTA)from BarodaPlant30% HClComplex (15 KTA)Imported PVC REON PropanePlant (150KTA)RELENESemi-Rich HDPE(250 KTA)Gas C2H4Gas fromC2C3PlantGAIL EPRU Cracker MEG at GandharPlant(188KTA) & HaziraEO-EG Plant EO(10 KTA)Lean PropyleneGas to GAIL (100 KTA)Raw MaterialPlantsProducts 4 5. RIL-DMD JOURNEY OF RIL, DMD GROWTH IS LIFE2008-IMC Ramakrishna BajajNational Quality Award Application2008: CII Excellence in 2008: CIIEnergy Conservation Award Excellence in Energy Management Award 2007: Five Star Rating of BSC Audit2008: Excellence Award in 22ndNational Convention on Quality Circles 2007: Highest Five Star Rating of BSC Audit for2006: Certificate of merit by BEE Excellence in Health, Safety & Environment 2006: CII Award of Excellence for being Energy Efficient Unit 2006:: CIIAward of of Excellencebeing Energy Efficiency2006 CII Award Excellence for in Energy EfficientUnit 2005::Three Star Rating of BSC Audit2006 CII Award of Excellence in Water Management2005: Three Star Rating of BSC Audit for Excellence inHealth, Safety & Environment 2005: 1st Prize in BEE National Energy Conservation Award2005:National Energy Conservation Award- 1st Prize in Petrochemicals 2005: IMS 2004: GAIL Certification ( ISOConservation & OHSAS 18001 ) Award for Gas 9001, ISO 14001 2004: GAIL Award for Gas Conservation in Petrochemical Sector 2003:2003: 9001:2000, ISO 14001:2004, OSHAS 18001:1900 Certificationfor ISO Gujarat Safety Council and Factory Inspectorate Appreciation Awardaccident free 3 million operating hours. 2002: United Nations Five Leaves Award for Environment Conservation 2002: UN Five Leaves Award to Chlor Alkali Plant2000: Gujarat Safety Council and Factory Inspectorate Appreciation Award for 1million Accident Free Operating hours Started1999: Commercial ProductionPhase - II 1999: Commercial Production started for MEG & HDPE ( Phase-II ) 1996: Commercial Production Started Phase - I ( Phase-I ) 51996: Commercial Production started for PVC & Caustic 6. RIL-DMD Care For EnvironmentFollow a Systematic approach to Environmental Management Plan in Order to achieve continual performance improvementPrevent pollution, Maximize recycle, reduce wastes, discharges and emissions. Conserve natural resources by their responsible and efficient use in all our operations. Emphasize every employees responsibility in environmental performance, ensure appropriate operating practices and training Promote awareness among contractors, suppliers and customers for shares responsibility towards environment protection 6 7. RIL-DMD MONITORING REPORTING SYSTEM Video Conference with Corporate Office Top Management. Site Water Balance, Monthly report, Utility Reconciliation. Making Action Plan, Comparison with Target/ Benchmark Trend AnalysisPlant performance & Complex Water consumption report generation & review by Sr. VP ( Technical Services)Plant-wise report & monitoring for utilitiesDaily Water Balance for ComplexOn-line monitoring tool IP-21(ASPEN PLUS) :Monitoring of Consumption and Distribution of Utilities 7 8. RIL-DMD Water Management StructureSTRATEGIC LEVELSite President TACTICAL LEVEL Sr. Vice PresidentSUPPORTING LEVEL Utility Cell AVP Utility Coordinators Utility Managers TLS Engineers ProcessTechnicianOperation Engineers Maint. Technician Major Functions : Major Functions :Major Functions :Set TargetsEvaluation of Identification ofProvide direction suggestion scheme schemeBenchmarking &Monitoring Specific Brainstorming &External Audits.implementation.Utility ConsumptionReview UtilitySuggestionconsumption trend Conceive new andSchemeimplement approvedReview status ofschemes EmployeeWater ConservationInvolvementschemes and Optimize utilitiesAwareness CreationAwarenessConsumption Programmes8 9. RIL-DMDPDCA Cycle Plan Obtain Insight (Audits) Nominate Champion Develop Programs Set Targets & MeasuresActDevelop Action Plan DoCorrect Deficiencies Implement ProjectReview Original Monitor ProgressWater Management P Lock In The GainsPolicies AReview Objectives & D Set New Targets CommunicateTargetsC ResultsReview ProgramsUpdate Action Plan Check Review Results Verify Effectiveness Examine Opportunities For Continual Improvement9 10. RIL-DMDMonitoring & Reporting SystemADDRESS: R-O&U-6.3-1 DAILY REPORTDAILY PLANT STATUS REPORT OF O&U ON5-Nov-08 ABC OF SAFETY MEANS ALWAYS BE CAREFUL REPORT PREPARATION DATE 6-Nov-08 AUTILITY SYSTEM1 Water withdrawl from Angaareshwar 8.494 MGD2 Cum water withdrawl for the month349.572MGD3 RW reservoirs level2.9 2.95/3.05Mts4 Fire Water reservoir levels 4.8 Mts5 Drinking Water reservoir level4.5 Mts6 DM Water Storage Tanks Level 9.2 9.90 Mts7 Emergency GOX Bullets Pr. ( ASP )34 Kg/cm28 LIN Production 15.5 MT9 LIN Sale/Stock transfer 17.72 MT 10 LIN Closing Stock113.41 MT 11 LIN STORAGE LEVELS( V1/V2/V12) 7800 6900 38 mm WC / mm WC / % BWATER CONSUMPTION IN THE COMPLEX1 Water pumping from Angareshwar38617 m3-2 Firewater make up in Header0 m3 -3 Filtered water to DM plant10850 m3-4 Filtered water to CT-01 59200 Cooling water make up5 Filtered water to CT-02 2081 m3 Cooling water make up6 Filtered water to CT-03 3354 m3 Cooling water make up7 Filtered water to CT-04 6852 m3 Cooling water make up8 Filtered water to CT-06516 m3 Cooling water make up9 Drinking water to complex992 m3 - 10 Service water to complex3161 m3 - 11 DM water to CPP-I 2453 m3 DMWater consumption 12 DM water to CPP-II1537 m3 DMWater consumption 13 DM water to Process plants4690 m3 DMWater consumption 14 DM water to regeneration90 m3 DMWater consumption 15 CT-02 Cir. Rate313200 m3- 16 CT-03 Cir. Rate234900 m3- 17 CT-04 Cir. Rate460080 m3- FDMWP2 CHEMICAL STOCKPRESENT STOCK RECEIPT FROM aHCl (MT) -13 35 VCM PLANT 10 bNaOH (MT)8.5 16 CA PLANT 11. RIL-DMD Monitoring & Reporting SystemReliance Industries Limited Weekly report/ Water block/54/07- 08 TECHNOLOGY DEPARTMENT WEEKLY REPORT FOR WATER BLOCK Week no. 49 505152Sr.No. WEEK ENDS ON STD VALUE 11-Mar-08 18-Mar-08 25-Mar-08 1-Apr-081RAW WATERm3/day36160 35064.1 34795.033806.433487.7Raw Water Receipt from Reservoir to RWTP MGD 7.957.717.657.44 7.37Fire Water Make Upm3/day 1644 0.0 0.00.00.0Raw Water to Jatropha Plantationm3/day 1500 0.0 0.00.00.02 Filter waterActual Raw Water Receipt (Excl.Jat.&FW) m3/day--- 35064.1 34795.033806.433487.7RWTP Backwash water (FW)m3/day 675 610.7 610.7514.3514.3Total Filter Water Available for Distribution m3/day34453.4 34184.333292.132973.4(Excl.Backwash)MGD7.6 7.57.37.3Raw Water Treatment Plant CapacityUtilisation % 5042.942.5 41.3 40.9Service water m3/day25922988.03029.73004.4 2997.4Drinking waterm3/day 1022886.6 879.9 910.1 1020.7DM Water Plantm3/day11463 10396.4 10325.010267.910242.9Make up to cooling tower (Totaliser based)m3/day21364 19203.6 20323.418975.918827.3Make up to cooling tower (COC based)--18969.3 19412.519540.119303.2 Total consumption m3/day--- 33474.6 34558.033158.333088.3 m3/day-- 978.9 -373.7 133.9-114.9Un Accounted losses in Filter Water MGD--0.2 -0.1 0.0 -0.033Cooling Water System Make up CT- 01 m3/day 76426855.36963.16632.9 6180.1 CT- 02 m3/day 42002012.31950.31846.0 1980.7 CT- 03 m3/day 36002778.13233.43129.4 3170.7 CT- 04 m3/day 75986877.67516.76813.7 6905.6 CPP-2m3/day 559680.3 659.9 553.9590.1 3.1 COC of Cooling Towers CT-017.7 6.97.3 7.37.5 CT-027.7 6.67.2 7.37.4 P.O. CT-037.7 6.96.8 7.57.5 CT-047.7 6.77.2 7.07.7 CPP-2 CT 5.5 6.67.5 7.17.94DM Water Filter water receipt to DMWP m3/day11590 10396.410325.0 10267.910242.9 Waste Water Generation m3/day---646.4735.7 742.9700.0 Total Production m3/day10800 9750.0 9589.3 9525.0 9542.9 D.M Water Plant Capacity Utilisation100-110 90.388.888.288.4%ConsumptionDM water to CPP-1 m3/day 14301554.71602.61740.3 1656.3DM water to CPP-2 m3/day 18042494.42278.62209.3 2423.3DM water to process m3/day 52825138.15389.65099.1 5012.1DM water for regeneration m3/day4557.957.960.0 57.95 Break up of DM Water to Process PlantVCM m3/day 318263.7 233.5284.9 241.7PVC m3/day 22212207.62460.52156.22127.4CHLRO-ALKALIm3/day 11101071.71107.7986.3 1214.2C2-C3 m3/day32 21.0 20.019.020.3GAS CRACKER m3/day 487 1429.91104.51155.3960.8HDPEm3/day20 4.0 2.1 4.55.6EO-EG m3/day 279216.0 195.5246.0 228.1Specific water consumption per MT of116Production m3/MT6.3206.726.716.716.70 12. RIL-DMDSpecific Water Consumption17.5%17.5%Sp.Water Consumption ReductionReduction m3/MT fromfrom8.02004-052004-05 7.357.56.51 6.436.067.0 6.5 m3/ MT6.0 5.5 5.0 4.5 4.02004-052005-062006-07 2007-08 Year 12 13. RIL-DMD Specific Waste Water Discharge Sp. Waste Water Discharge M3 /MT 20.8% 20.8%1.1Reduction Reduction1.0 0.937 from from1.0 2004-05 2004-050.829 M / MT0.9 0.7710.80.742 30.80.70.70.62004-052005-062006-072007-08 Year13 14. RIL-DMDPer Capita Consumption (Industrial)Per Capita Consumption 64229.3% 29.3%650.0 Reduction Reductionfrom from 5572004-05 2004-05600.0Litres/person/day550.0478 500.0454450.0400.02004-05 2005-06 2006-07 2007-08 Year14 15. RIL-DMDPer Capita consumption (Colony)Per Capita consumption 6% Reduction6% Reduction from 2006-07from 2006-07 219217220.0 204210.0 m3/ MT200.0 190.0 180.02005-062006-07 2007-08 Year15 16. RIL-DMDWater Conservation Measures Water Saving Project ImplementedYearSaving km3 Rs. / annum (Lacs) Increase in cycle of concentration in all 2004-130 (RW)10.5Cooling towers from 5 COC to 7.5 COC 05 Cooling Tower Blow down of CT-2004-30(RW)2.2504 used as make up in Cooling05Tower -02 & 03. (Cascadingsystem) CPP-Continuous blow down from boiler2004-20.2(RW)1.5drum, recycled back to Cooling water 05return header. Cooling Water Supply pump bearing oil-2004- 14.4 (RW)0.93cooling water recycled to return header. 0516 17. RIL-DMD Water Conservation Measures Water Project ImplementedYear Saving km3 / Saving annumRs x106 CPP - Steam turbine generator bearing 2004- 5.02 (RW) 0.35cooling water diverted back to Cooling 05water return header. Gas Cracker Unit: Silica sample cooler 2004- 26.4 (DM) 1.98water recycled to cooling water return 05header.In house Steam trap and steam leak 2004- 17.5 (DM) 4.02survey for entire complex done,05leakages and faulty steam traps foundand attended.HDPE: Use of waste flash steam in 2004-2.47 (DM) 0.57VAR machine.0517 18. RIL-DMDWater Conservation Measures WaterSaving Rs Project Implemented YearSaving km3 / x106 annum Firewater network: Cooling2005-108.0 9.32 Tower Blow down water used as06(RW) a make up resulted in reduction in fresh make-up water.Raw water Plant: Filter bed backwash2005- 60.7 (RW)5.24 frequency increased from 20 hrs to 3206 hrs.100 nos. push back type valve 2005-12.5 (RW) 1.08 provision in Toilets 06 40 nos. Toilet photo sensors installed. 2005-8.7 (RW)0.7506 18 19. RIL-DMD Water Conservation MeasuresWater Saving Saving Project ImplementedYearkm3 / annumRs x106Ground Water Recharging In Saraswati 2005-Quality -- Township. 06 improvement.PVC: Utilization of Waste steam of CPP-2 2005-78.0 (DM) 17.9 in VAR (Vapor absorption) of PVC plant. 06 EOEG Plant: Installation of wastewater 2005-42.0 (DM) 9.66 recovery unit (PK-610) for recovery of06 wastewater for utilization in Process.EPRU Plant: Steam consumption2005-5.8 (DM)1.33 reduction in amine stripper by06 optimizing CO2 to steam ratio. (six- sigma project).19 20. RIL-DMD Water Conservation MeasuresWater Saving Saving36 Project Implemented Year km / annum Rs x10 CA Plant: Seal water from 4 20052.3 (DM)0.43 pumps in Secondary brine area is-06 rerouted to lean brine return lineHDPE Plant: DM water consumption2005- 73 (DM) 1.65 reduction by improvement in transport06 water system of Extruder. VCM plant: Condensate recovered from 2005- 0.50.33 Exchangers of Oxy reactors & returned 06 (Condensate) to VCM DM tankEOEG Plant: Increase in Cycle time of 2006- 46(DM)10.5 Ion exchange resins By improvement in 07 Influent quality20 21. RIL-DMDWater Conservation Measures WaterSaving Project ImplementedYear Saving km3 / Rs x106 annum PVC Plant: Cent rate water2007- 12.42 (DM) 2.84 utilization in place of DMW for K- 08 6701 Grade PVC in Line-1&2 Wet scrubbers.VCM Plant: Cooling water pH analyzer2007-08 1.69 (RW)15.3 return diverted to cooling water return headerHDPE Plant: Modification in Wax 2007-08 2.3 (DM) 0.43 Collection system for improved recovery of DM water.Total699.9 98.86 21 22. PROJECT 1: Utilization of Backwash water for developing RIL-DMD Jatropha plantations Modification:This year we utilized amajor part of the Backwash water in our Jatrophaplantations. DuringOctober 2007 Jatrophaplantations was done in 56Original Scheme: acres. The plantation Raw Water Treatmentrequired 20 m3 per hectare plant generates of water. Installing a wastewater from Filter bed rerouting line in theBackwash and Backwash water line clarifloculator drains was provides this water. This resulted in a saving ofThis resulted in a saving of diverted to the Natural 246.0Km3 of raw water246.0Km3 of raw waterpond.that accounted to Rs.31.0that accounted to Rs.31.0 lacs savings perlacs savings per Annum.This was done atAnnum.This was done at an investment of Rs.10lacsan investment of Rs.10lacs with a Simple paybackwith a Simple payback period of 8 Months.period of 8 Months.22 23. RIL-DMD PROJECT 2: Waste Water Recovery Scheme in CPP-IIProject Cost Rs 13,00,000 Average Water Recovered- 200 m3/Day Savings Realized Rs 2800/ Day Annual Savings Rs 10,00,000.Project Started Date Target Completion Date Actual Completion Date23 24. RIL-DMDCertification & Benchmarking CertificationStandard.System Date ISO 9001 - 2000 23 rd May 2006 Quality Management System ISO 14001 - 200423 rd May 2006 Environment Management SystemOccupational Health and Safety OHSAS 18001 - 199923 rd May 2006Assessment SeriesBenchmarking Plant Year done by LevelRemarks Solomon,Ranked 3rd Quartile amongst the 30 GCU 2008GlobalUSA participating plantsRanked 2nd in Internal CPP 2007 Internal Group sitesBenchmarking of RIL Group SitesPDC Ranked 9th amongst MEG MEG 2007GlobalNetherlands industries in the world.PDC Ranked 4th position based on PVC 2007GlobalNetherlands energy consumption in world GPCB norms of discharge water for our complex is 15730 m3 /day, as against existing discharge rate of only 4990 m3 /day24 25. RIL-DMDFuture plans 2008 - 09 SchemePlantPotential Annual Investment TargetWater Savings (Rs. Lacs) Date Saving km3(Rs./ annumLacs) PerformanceAll CT s - --Mar 2009 Testing of Cooling Water Towers Replacement of All CT s -6790 Aug 2009 existing GRP fans to FRP fans in balance cooling tower Replacement of CT 04- 250 164 May 2009 inefficient CT 04 CW pumps (6 nos) 25 26. RIL-DMD Future plans 2008 - 09 Potential Annual Scheme PlantWater SavingsInvestment TargetSaving km3 / Rs. Lacs Rs. LacsDateannumReduce DM water MEG 227.27 50 -Underconsumption by Studyimproving DI unit /Aldehyde removalunit operation, andreducingregenerationReduction in WaterPVC3.210.7- Decto Monomer ratio 2008Zero Make up of Compl-4.38-UnderRaw Water in Fire ex StudyWater 26 27. RIL-DMDCommunity Awareness Providing Awareness on Importance of Conserving Water on Environment Celebration Day Introduction of Green School Project Installation of Dedicated Water Supply line to reduce the Water Wastage during transportation thru Road Tankers. Conducted Science fare at district level to motivate young students to think innovative for Natural resource 27 conservation 28. RIL-DMDFight Global WarmingEach one of us can make a difference !28 29. RIL-DMDRI EnrichingLivesLand EmpoweringDPeople MD 29