1 ITC Limited Paperboards & Specialty Papers Division Unit – Tribeni WATER MANAGEMENT CII–SOHRABJI GODREJ GREEN BUSINESS C ENTRE 16 th – 17 th December 2008 Unit Profile •A Specialty Paper Mill •Three Paper Machines •Production 2007-08: 23387 MT •Annual Turnover = Rs. 1937 Million •Certified ISO 9001, 14001 and OHSAS 18001
ITC Limited, Tribeni
Jan 21, 2015
This is a presentation from ITC Limited, Tribeni, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008
The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.
This presentation was in the "Within the Fence" category.
We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.
The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry.
This presentation was in the "Within the Fence" category.
We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
1
ITC LimitedPaperboards & Specialty Papers Division
Unit – Tribeni
WATER MANAGEMENT
CII–SO HRABJI GO DREJ GREEN BUSINESS C ENTRE
16th – 17th Decemb er 2008
Unit Profile
•A Specialty Paper Mill
•Three Paper Machines
•Production 2007-08: 23387 MT
•Annual Turnover = Rs. 1937 Million
•Certified ISO 9001, 14001 and OHSAS 18001
2
Vice President Tribeni O perations
DGM Operations
HOD Produ ction
HODEngineering
IS (E & U)Water &
Energy Mgr
IS (Elect .)
IS (Mech. )
IS (Instmn. )
IS (PM 3&4)
IS (PM 1)
HOD Materials(Waste &Haz.ch em
Mgr)
HOD Finance
HOD IT
HOD CS
HOD HR
HODTechnicalMR ISO
HOD Safety
MR OHSAS
IS (Secu rity)Fire Co-ord& Afforestn.
CMOBio Med
Waste Mgr
IS (FH)
TEMCoordinator
Organisation Structure
Source of Water
f17 Nos. of Borewells located within Mill and
Estate Area
fSink Depth of 600 ft below ground level
fTapping is done at a depth of 350-550 ft
3
Water Balance
164Mill Drinking Water120Chemical Kitchen110DIW & ETP345DM Plant1740Paper Machine 42169Paper Machine 31311Paper Machine 1
5959Average daily consumption
Quantity m3/dayArea
Fresh Water Consumption
( April –March )
Quantity , m3 Production in Tonnes
Specific water consu mption,
m3/MTIndustrial Domesti c
2004-05 2532351 132168 23667 107
2005-06 2516196 1269674 24024 105
2006-07 2395356 1150734 24250 99
2007-08 2114830 1131597 23387 90
4
Fresh Water Consumption
Specific Fresh Water Consumption (kL/t)
90
213
178
128107 105
99
80
130
180
230
2001-2002
2002-2003
2003-2004
2004-2005
2005-2006
2006-2007
2007-2008
With con tinuous efforts and several fresh water saving initiativ es implemen ted, we have reach ed this position.
Fresh Water Consumption
Cumulative % reduction in Fresh Water intake w.r.t 2001-02
50 575349
39
16
0
10
20
30
40
50
60
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08
% re
duct
ion
5
150 m3/T(w.r.t waste wate r
norms of 120)
100 m3/TNot Available
90 m3/T
CPCB Norms
International
Benchmark
National Benchmark
Tribeni Mill
Benchmarking
Best Available Ref erences of European Countries from th e"BREF Pulp and Pap er", el ectronic ad aptation of the Eu ropean
ref erence docu ment on Best Available Techniques (in the slant ofredu cing th e aggressions to man and environment) in the Pulp and Paper manufactu ring industry.
Fresh Water Consumption
Implemented Projects 07-08Scheme-1: Recirculation of Fresh Water from Overhead
Tank for Compressor cooling
6
Implemented Projects 07-08
Scheme 1
Old System:F/water r equir ement 30 m3/hr .
Water sent back to Over head Tank : Nill
Actual cooling Water consumed : 30m 3/hr
New System:F/water r equir ement 30 m3/hr .
Water sent back to Over head Tank : 30 m3/hr
Actual cooling Water consumed : Nil
Savings : 237600 m3 / yearInvestment Rs.0.2 Lakhs
Implemented Projects 07-08
Scheme-2: Reduction of sealing water in Couch of PM4 by use of Anti friction bearing
Savings : 31680 m3 / yearInvestment Rs. 9 Lakhs
7
Implemented Projects 07-08
Scheme3: Refurbishing of PM4 steam & condenser circuit
Implemented Projects 07-08
Scheme3: Refurbishing of PM4 steam & condenser circuit
Savings : 49500 m3 / year ( DM water)Investment Rs. 120 Lakhs
Old System:Steam r equir ement : 110 TPD
Condensate r ecover y : 39 TP D
Water r equir ement : 71 TPDr
New System:Steam r equir ement : 80 TP D
Condensate r ecover y : 56 TP D
Water r equir ement : 21 TPD
Water saving : 50 TP D
( This saving would come in DM water )
8
Scheme5: Sequencing of Coloured Laminating Grade making on PM4
Savings : 12000 m3 / yearInvestment : Nil
Grade change in Colour laminating grades is associated with lot of water for cleaning & flushing the system. TPM team has come together to reorganize making schedule with in-depth R& D inputs to avoid water usage during many grade changes
Implemented Projects 07-08
Implemented Projects 07-08
Scheme 6: Use of New Generation CentriCleaner system on PM1
Picture before modificationWater requirement : 6m3/hr
Picture after modificationWater requirement : 4m3/hr
Investment Rs.28 LakhsSavings 15840 m3 / year
9
Implemented Projects 07-08
Scheme 7:Reduction of leakage of Gland sealing water through use of
Mechanical seals
Savings : 15840 m3 / yearInvestment Rs. 24 Lakhs
Implemented Projects 07-08Scheme 8:
Use of highly efficient imported Vacuum Pumps requiring less sealing water
Savings : 23760 m3 / yearInvestment Rs.57 Lakhs
Before Modernisation After Modernisation
10
Implemented Projects 07-08Scheme 9:
Reduction in consumption of Make up water in Cooling Tower by improving COC
Old System:
For TG2
Evaporation loss: 11 m3/hr
Blow down : 27.5 m3/hrl
Total mak e up water : 38.5 m3/hr
For TG3
Evaporation loss: 14 .7 m3/hr
Blow down : 36.7 m3/hrl
Total mak e up water : 51.4 m3/hr
Total mak e up water reqd.: 89.9 m3/hr
New System:
For TG2
Evaporation loss: 11 m3/hr
Blow down : 5.5 m3/hrl
Total mak e up water : 16.5 m3/hr
For TG3
Evaporation loss: 14 .7 m3/hr
Blow down : 7.4 m3/hrl
Total mak e up water : 22 m3/hr
Total mak e up water reqd.: 38.5 m3/hr
Implemented Projects 07-08Scheme 9:
Reduction in consumption of Make up water in Cooling Tower by improving COC
Savings : 50 m3 / hour Investment Rs. 40 Lakhs
11
Implemented Projects 07-08Scheme 10:
Introduction of Reverse Osmosis system in PM1
Savings : 39600 m3 / year
Investment Rs.40 Lakhs
Waste Water Discharge
Specific Waste Water Discharge (kL/t)
80.7
69.363 61.5
60
110
2004-2005 2005-2006 2006-2007 2007-2008
With con tinuous efforts in maximising process water recycling we have redu ced below 50% of CPCB norms.
12
120 m3/T60 m3/TNot Available61.5 m3/T
CPCB NormsInternational Benchmark
National Benchmark
Tribeni Mill
Waste Water Discharge - Benchmarking
Best Available References of Europ ean Countries from th e "BRE F Pulp and Paper", el ectronic ad aptation of the Eu rop ean reference document on B est Available Techniques (in the slant of reducing the aggressions to man and
environment) in the Pulp and Paper manufactu ring industry.
Waste Water Discharge
The Road Map towards Zero Discharge
3-step process:
• Implementation of Future Fresh Water Conservation Projects
• Closing the Water Loop with reuse of Mill
Treated Water
• Continuous Monitoring and Control to sustain
the System
13
Monitoring
f All fresh water consuming areas are provided with water flow meters connected to DCS system.
f Daily, weekly and monthly MIS reports contain the fresh water consumption figures.
f Monitoring is done online, by the respective utilities and papermachine shift incharges.
f Specific Key Focus Areas are predefined for respective managers as a part of their annual appraisal system for Water Conservation Measures and Monitoring
Related Documents
