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Transcript of © Confederation of Indian Industry Water Audit in Industry – CII’s Perspective June 22 2011...
© 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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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.
© Confederation of Indian Industry
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
© Confederation of Indian 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
© Confederation of Indian Industry
Examples on Specific Water Consumption
Pursuing to match or even parallel with
national and international
benchmarks
© Confederation of Indian Industry
Binani Cement
© Confederation of Indian Industry
Binani Cement - continue
© Confederation of Indian Industry
Vehicles Manufacturing – 2007-08
© Confederation of Indian Industry
Paper industry - Sripathi Sivakasi 2007-08
© Confederation of Indian Industry
JK Tyre & Industries Ltd 2007-08
© Confederation of Indian Industry
Steel industry - Vizak Steel 2007-08
© Confederation of Indian Industry
Chemicals – TATA Chemicals
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
Water Mass Balance
© Confederation of Indian Industry
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
© Confederation of Indian Industry
Example: M&M Nashik Plant
© Confederation of Indian Industry
Water Management Approach # 4
Reduce at Source(How much water is really
required?)
© Confederation of Indian Industry
Reduction at Source
Better operating controls
Installation of water saving devices
Change of device/ equipment
Process modification
Few case studies are discussed herewith
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
After
Fresh Water Saving = 30 m3/day
To ETP
Fresh
Water
Reuse 2nd stage rinse as I rinse
Components
© Confederation of Indian Industry
Benefits
Water Saving
9000 m3/yr
Annual savings = Rs.1.50 Lakhs Investment = Nil Payback period = Immediate
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
Water Management Approach # 5
Recycle and Reuse
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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)
© Confederation of Indian Industry
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
© Confederation of Indian Industry
Electronic flush system
Electronic urinal flush
Saves up to 40% water in flush
Handles high TDS up to 1800 ppm
Flush System
© Confederation of Indian Industry
Water less Urinals
100% Water Savings
© Confederation of Indian Industry
Rain Water Harvesting
© Confederation of Indian Industry
Grey Water Recycling
140 lit/day of fresh water For Washing and Cleaning
© Confederation of Indian Industry
Water Management Approach # 5
Monitoring and Reporting
© Confederation of Indian Industry
MONITORING
Monitor daily, monthly, yearly
Institute specific format
Introduce as a part of log sheet
© Confederation of Indian Industry
Ashok Leyland – Monitoring and Reporting System
© Confederation of Indian Industry
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
© Confederation of Indian Industry
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
© Confederation of Indian Industry
What Next ? Scaling up of Water Audit !!
1.Water Foot Printing in
Industry
2.Blue Rating of
products / organizations
© Confederation of Indian Industry
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
© Confederation of Indian Industry
National & International Partners
National State and Central
Government
International Partners Water Industry Alliance,
South Australia
Cleantech, Switzerland
IFC, USAID,
Netherlands, Israel –
Expressed interest
© Confederation of Indian Industry
CII Water Activities
Events & Award Programs
Information Dissemination Centre including Publications Education & Training
CII TriveniWater Institute
AdvisoryServices
© Confederation of Indian Industry
Business Communication
S Raghupathy - Executive Director
Email: [email protected]
K S Venkatagiri – Principal Counsellor
Email: [email protected]
Pranab Dasgupta – Senior Counsellor
Email: [email protected]
THANK YOU