15 th & 16 th Oct 2018 at Hyderabad National Awards for Cement Industry and Conclave on Sustainability Excellence of Indian Cement Industry Water Excellence at Shree Raipur Cement Plant
15th & 16th Oct 2018 at Hyderabad
National Awards for Cement Industry and Conclave on Sustainability Excellence
of Indian Cement Industry
Water Excellence
at
Shree Raipur Cement Plant
Contents
• Overview
• Water Management Strategies
➢ Target setting
➢ Awareness creation
➢ Technology adaption
➢ Water harvesting
➢ Others
• Water Consumption
• Recognitions
• Largest cement player of North India and has diversified into power business including Green Power.
• Operations at eleven locations at Beawar, Ras, Raipur, Kodla, Khushkhera, Roorkee, Jaipur, Suratgarh, Aurangabad, Panipat & Bulandshahr.
• Cement Production capacity of 41.9 MTPA and Power Generation Capacity of 646 MW.
• Awarded as Asia’s most trusted company 2018 by IBC InfoMediaPvt. Ltd.
Overview
Thermal & WHR Power capacity increasing rapidly
Cement capacity has Increased more than five folds in last ten years
6.39.1
12 13.517.5
23.6 25.629.3
34.9
41.9
07-08 08-09 09-10 10-11 13-14 14-15 15-16 16-17 17-18 Till Date
Cement Capacity (MTPA)
210
260
560 570 597 597 646 612 646
46 46 46 5681 96 111 111 126
09-10 10-11 11-12 12-13 13-14 14-15 15-16 16-17 17-18
Power Capacity (MW)
Rapidly growing company
Overview
• To harness sustainability through low-carbon philosophy
• To maintain its reputation as one of the most efficient
manufacturer globally
• To continually have most engaged team through R&D
• To drive down cost through innovative practices
• To continually add value to its products and operations
meeting expectations of all its stakeholders
• To continuously build and upgrade the skills and competencies
of its employees
Mission at Shree Cement
Overview
“Lead in Creating Prosperity & Happiness for all Stakeholders
through Innovation & Sustainable Practices”
• Enforce good corporate governance practices
• Encourage integrity of conduct
• Ensure clarity and unambiguity in communication
• Remain accountable to all stakeholders
• Ensure socially responsible behavior
Guiding Principles
Vision of Shree Cement
Overview
➢ SA- 8000 Social Accountability
➢ ISO-9001 Quality Management System
➢ ISO-14001 Environmental Management System
➢ OHSAS - 18001 Occupational Health & Safety Assessment Series
➢ ISO- 50001 Energy Management System
Management systems
Overview
Energy : Continuous reduction in GHG emission
Environment : Better climate & conservation of resources
Water : Conservation of water and water harvesting
CSR : Uplift-ment of social strata
Quality : Leading to consistent improvement
Health & Safety : Safe & healthy workplace
Human Resource : Empowering people
IT : System & transparency driven process
HIV/AIDS : Health management for stakeholders
Social Accountability : Welfare of stakeholders
A focused policy driven company for proper and systematic working through following policies.
Corporate policies
Overview
Cement Prod. Capacity: 3.0 MTPA
Clinker Prod. Capacity : 5.2 MTPA
Power Plant Capacity : 25 MW
WHRS Capacity : 30 MW
Mines Capacity : 8.6 MTPA
CGWA permission to : 3000 KLD
withdraw ground water
Overview
Shree Raipur Cement Plant
WE CONSERVE WATER
• Targets
• Awareness creation among stakeholders
• Optimization & adoption of latest technologies
• Implementation of water harvesting measures
➢ Inside the plant boundary
➢ Outside the plant boundary
• Other ways of water conservation
Water Management Strategies
➢ Zero Liquid Discharge
➢ To reduce 5% specific water consumption in 2017-18
➢To become water positive Unit
Targets
Water Management Strategies
Contd…
Awareness creation among stakeholders
Water Policy
To provide sufficient and safe water to people & plant as well as to
conserve water, we are committed to efficient water management
practices viz.
• Develop means & methods for water harvesting
• Treatment of waste discharge water for reuse
• Educate people for effective utilization & conservation of water
• Water audit & regular monitoring of water consumption
“Water adds value to people & organization, conserve it intelligently.”
Water Management Strategies
Engage stakeholders to celebrate-
• Water Day
• Earth Day
• Environment Day
• Ozone Day etc.
Spread community awareness through-
• Rallies
• Meetings
• Hoardings, etc.
Conduct various competitions-
• Poster, Essay, Speech etc.
Contd…
Awareness creation among stakeholders
Water Management Strategies
Earth provides enough to satisfy every man’s need, but not every man’s greed– Mohandas K. Gandhi
Water Management StrategiesAwareness creation among stakeholders
MonitoringDaily:• Section wise & Unit wise
specific water consumption
• Installed water meters at various location
Monthly:• Performance review
comparison with target/Benchmark.
• Trend analysis
• Awareness programs• Training• Brain Storming
• Suggestion Scheme
Idea / informationsharing with otherindustries/manufacturers
Action Plan &Target Setting
Constitution of water management cell
Audits
Water Management StrategiesAwareness creation among stakeholders
Installed Waste Heat Recovery Boilers –
Case Study I
In normal case the Pre-heater exit gases are
being passed through a Gas Conditioning
Tower to cool down by spraying water.
To save these losses, Shree has installed Pre-
heater and AQC Boiler to produce 30 MW power
Benefits:
➢ Water Saving- 1329 KLD
➢ Reduction of CO2 emission of approx 837
Lakhs kg in FY 2017-18
Water Management StrategiesOptimization & adaptation of latest technologies
Installed Air Cooled Condenser for
Power Plant & WHR – Case study II
Specific Water Consumption for Water Cooled
Condensers is approx. 2.8 Lt./ KWh.
Specific Water Consumption for Air Cooled
Condensers is approx. 0.13 Lt./ KWh.
Reduced more than 95 % of water
consumption per KWh
Benefits:
➢ Saved 6.12 Lakhs KL water in FY 2017-18
Water Management StrategiesOptimization & adaptation of latest technologies
S. No. Initiatives Adapted Saving KLD
1 Reject water use in Bed ash & fly ash quenching instead of fresh water 18
2 Used RO reject water as cooling tower make-up water instead of fresh
water
50
3 Using air cooled condensor instead of water cooled in compressors 0.2
4 Installed dry seal for water supply pumps 3
Contd…
Optimization & adaptation of latest technologies
Water Management Strategies
S. No. Initiatives Adapted Saving KLD
5 Laying separate water line for reject water use after neutralisation in Mill
spray
35
6 Laying separate water line from STP-1 to cement mill for mill spray 4
7 Installed sensor based urinals, electronic hand wash, foam spray taps, push
types taps
5
8 Concreted truck parking area to avoid water spray 10
Optimization & adaptation of latest technologies
Water Management Strategies
➢ Reject water from RO-I is re-treated in RO-II
➢ Rejected water from RO-II is used in
Cement Mill Spray & Ash Quenching
➢ Overall water recovery of this plant is 100%.
SRCP - Captive Power is a combination of zero water disposal on land.
RO Plant
Use of RO rejected water
Water Management StrategiesImplementation of water harvesting measures –
Inside plant boundary
STP (2 X 40 KLD Capacity)
Use STP treated water for plantation
resulted in saving of approx. 8,048 KL
fresh water in 2017-18
Installed Movable Bed Bio - Reactors in
STP with following benefits-
• Effective sludge retention time
• Lower sludge production
• Less area required
• Resilient to toxic shock
#Treated sludge is also being used as manure for plantation.
Water Management Strategies
Sewage Treatment Plant
Implementation of water harvesting measures – Inside
plant boundary
Analysis of STP Treated Water
Parameters Standards STP-2
Treated Water Quantity
pH 5.5 – 9.0 7.48
BOD mg/lt. 30 5.8
COD mg/lt. 250 17.3
TSS mg/lt. 100 <10
O&G mg/lt. 10 <4
Parameters Standards STP-1
Treated Water Quantity
pH 5.5 – 9.0 7.67
BOD mg/lt. 30 6.2
COD mg/lt. 250 18.3
TSS mg/lt. 100 <10
O&G mg/lt. 10 <4
Water Management Strategies
Close to truck parking In front of Unit- II
De-silting Pit
Filter Pit
Open Well
De-silting Pit
Filter Pit
Open Well
Contd…
Rain water recharge structures
Water Management StrategiesImplementation of water harvesting measures – Inside
plant boundary
RWH Pond - I RWH Pond - II
RWH Pond - in Mines
Contd…
Rainwater harvesting – Inside plant boundary
Water Management Strategies
Description of initiative Capacity (Lakh KL)
1. Rainwater harvesting in pond - I
2. Rainwater harvesting in pond - II
3. Rainwater harvesting in mining area
1.0
1.0
2.5
Total 4.5
Contd…
Implementation of water harvesting measures –
Inside plant boundary
Water Management Strategies
Formed the Village Development Committee
(VDC) for the development of overall natural
resource management.
Provide trainings to villagers regarding Roof-
top Rain Water Harvesting, Constructed rain
water harvesting structures, Best practices of
cultivation etc.
Contd…
Water Management Strategies
Implementation of water harvesting measures –
Outside plant boundary
Pond Deepening at near by villages
Contd…
Pond Wall at Chandi Village Pond Wall at Khapradih Village
Pond Wall at Karhi Village Pond Wall at Jhipan Village
Water Management StrategiesImplementation of water harvesting measures – Outside plant
boundary
Earlier : Drinking water was supplied through tankers.
Later on : Constructed permanent drinking water tanks in villages.
Water Management Strategies
Implementation of water harvesting measures – Outside
plant boundary
➢ Reduced water leakages in plant and colony
➢ Sensor operated flush system in urinals
➢ Replaced underground pipes by overhead pipes
➢ Shading of water storage tank
➢ Use of compactors on road in mines.
➢ Constructed concrete roads and parking area
➢ Roof Top Water Harvesting Systems
➢ Adoption of sprinkler and drip water irrigation
➢ Camera to ensure zero discharge outside plant
➢ Installed water meters at all the withdrawal points
Water Management Strategies
Other ways of water conservation
S. No. Parameters %
1. Recycled water use in Process 3.73
2. Recycled water used in other utilities 1.9
3. Fresh water used in cement manufacturing 30
4. Fresh water used in CPP & WHRB 18.63
5. Projects, domestic, plantation, miscellaneous 45.74
Recycled & Fresh Water Consumption
Water Consumption
Specific Water Consumption
0.024
0.018
16-17 17-18
KL/ton cement
0.011 0.011
16-17 17-18
KL/ton limestone
2.5
0.420.28
Norm 2016-17 2017-18
KL/MW power
Water Consumption
➢ Compliance as per MOEF&CC, SPCB and CGWA
➢ Water disclosures through Corporate
Sustainability Reporting and to Cement
Sustainability Initiative.
➢ Installation of Piezometers : 6 nos.
➢ Installation of Telemetry Systems : 6 nos.
➢ Installation of water meters at all withdrawal
points
Water Management
Compliance and public reporting
• Use of Global Water Tool by CSI-WBCSD
• Construction of Green Building in all up-coming offices to better human health and
natural environment
• Implementation of WHR in all upcoming
Units
• To sustain we are committed to returnevery thing from mother earth, which we
take from it
Water Management
Futuristic approach
Recognitions
Entrepreneur for the Year Award 2017 to Shri H.M.
Bangur, Managing Director of the Company
Best Energy
Performance AwardNational Awards for Energy Efficiency and Quality Excellence by NCCBM
Awards
▪ Asia’s Most Trusted Company 2018 by
International Brand Consulting Corporation, USA.
▪ Sustainability Performance Award by Indian
Chamber of Commerce.
▪ Best Performer in terms of energy saving under
Perform, Achieve and Trade Scheme by Bureau of
Energy Efficiency for Beawar and Ras units.
▪ First prize in Cement Sector in “Rajasthan Energy
Conservation Award 2017” instituted by Rajasthan
Renewable Energy Corporation Limited.
▪ NCCBM Award for Best Quality Excellence for the
year 2016-17.
▪ National awards for Excellence in Water
Management 2011 as “Water Efficient Unit” by CII.
Awards
Website : www.shreecementltd.com
Yesterday’s Fight was for-Land
Today’s Fight is for- Energy
Tomorrow’s Fight will be for-Water