Water Management System at Chaibasa Cement Works presented by A.K.Srivastava

• 1. Water Management System at CCWVenue:CII- Godrej GBC HyderabadDate :16.12.2008Name of the Presenter:A.K. Srivastava Head Plant Operations Chaibasa Cement WorksThis 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.

2. Company ProfileEstablished in 1947.Part of ACC/ Holcim, anational and global l dti l d l b l leaderExpansion & modernizationin 2005. 1.2MTPAintegrated cement plantSituated i K lhSi d in Kolhan region i A hard core tribal belt ,80 Km. from Jamshedpur.QMS & EMS established asper IS/ISO 9001 & 14001.OHSMS established as per Reliable and respected Holcim OH&S pyramid. 2 ACC LimitedCII Water Excellence Award 200816.12.2008 3. Process DetailsHighly sophisticated and modern plant with state of the arttechnology.Semi d process (up to 23% enriched slurry feed in VRM)Si dry ( t i h d lf diRaw mat. extraction Raw material preparation Pyro processing Raw meal preparationShippingCement Grinding Shipping 3 ACC Limited CII Water Excellence Award 200816.12.2008 4. Roadmap for meeting the Environment goals 200820092010 2011Stack emissions 50 30 30 30 (mg/nm3) Fugitive Emission SPM500040003000 2000 (g/nm3) Kg of CO2/ ton of650634 618602 Cementitious Material CEMS Installation on 1 kiln Kiln StackWater Consumption-30%-20%-15% -10% EnvironmentRoad Map Power Consumption88.7 86.4 84.3 82.2 KWh / ton Tonnage of alternative840014024 1515022201 fuels & raw mat. (tons)Thermal Substitution0.53 1.43 1.62 1.99 Rate (%) AFR Installation0.95 2.8 5.00.5 Capex Rs. Cr Total GAV (Savings) Rs.0.29 3.47 4.30 5.89 Cr4 ACC LimitedCII Water Excellence Award 200816.12.2008 5. Water Conservation InitiativesAnnual Water InvestmenYear ofSavingst madePayback Sl. Water conservationImplemenperiod No. initiativestationRs.R (months) m3Rs. Lakhs Lakhs Strengthening of water monitoring system byg y y 1 installation of water 2005-06- -2.22- metersatsource points Recycling of Effluent by rerouting of reject pit 2 2006-07 165000 4.8525 discharge to abandoned mine pit Zero effluent d hffl discharge byproviding 3 sedimentation tanks 2007-08 3300009.7 12.115 andreutilization of effluentffl5 ACC Limited CII Water Excellence Award 2008 16.12.2008 6. Specific Water Consumption 3.00 3 002.502.40 2.28 2.02 2.005% m3/MT 1.501.211.00 0.700.500.000 000.000 00 0.002004 05 2005 06 2006 072007 08 Benchmark 6 ACC LimitedCII Water Excellence Award 2008 16.12.2008 7. Road map to achieve global benchmark Objective & targets Plan of ActionExpected Technical justification Dateof Completion Strengthening of waterInstallationofDec. 2009Water recycled from reject pit is monitoring system atwater metersat collected in mines abandoned pit user enduser end (A block) for further use inplant, this reutilized water isagain counted as fresh waterdue to lack of monitoringsystem.At present, water meters areinstalled only at sources and weare unable to take initiativesdepartment wise.dtt i To achieve specific installation of Dec. 2011At present water consumption in water consumption 700 modernized floatation process is about 950 ltr./ MT of Clinker fromFiltration Floatationltr. per tonnes of clinker. By present level of 1519 Plant (FFP)(FFP).implementingthis proposed ltr./ MTof Clinker project dry cake will be fed toVRM and 130 ltr. water pertonnesof clinkerwill beconsumed in this process.7ACC Limited CII Water Excellence Award 2008 16.12.2008 8. Sustainability Indices 8 ACC LimitedCII Water Excellence Award 2008 16.12.2008 9. 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 85 Enval Performance Indicator Atmospheric Emission: PM 8080 75 7675 73 70 66 EPI (% )65 6260 55 5020052006200720082007 2006 Year CCW PerformanceCCW TargetACC Avg. Performance HOLCIM Avg. Performance9ACC Limited CII Water Excellence Award 2008 16.12.2008 10. Commitment towards reduction in GHG EmissionOur objective is to reduce by the year 2010 the average specific net CO2 emission by 20 % from the reference year 1990, l l 1990 calculated per WBCSD CO2 protocol.dl Clinker Factor Specific Net CO2 Emission75.0 75 0 73 900.0 900 0876.0 880.0Kg. CO2/ MT of Cem. Mat. 69.5 70.0860.0 840.0 65.0 65 0 820.0804.0 % 800.060.3 800.0 60.0781.0 780.055.955.055.0 55.0760.0.740.0 50.0720.02005 2006 200720082007 2006 20052006 20072008 Year YearCCW Performance CCW Target CCW Performance CCW TargetACC Avg. PerformanceHOLCIM Avg. Performance10 ACC Limited CII Water Excellence Award 200816.12.2008 11. Commitment towards reduction in GHG EmissionThis reduction will be achieved through improving the four key eco-efficiencyparameters: clinker factor specific thermal energy consumption specific electrical energy consumption thermal substitution rate Specific Thermal Energy ConsumptionSpecific Electrical Energy Consumption 1050.0 1050 0 110.0 995.01061000.0 kWh/ MT of Cement 105.0950.0KCal/ Kg. of Clinker900.0 876 100.0 C850.095.0800.0 91.991.42 755.0 750.0 748.8 75190.089.0750.085.6 85 6 85.085 0K 700.0700 085.0650.0 80.0600.0 2005 2006 2007 2008 20072006200520062007 2008 20072006YearYea YearCCW Performance CCW TargetACC Avg. PerformanceHOLCIM Avg. Performance 11ACC LimitedCII Water Excellence Award 200816.12.2008 12. Water Conservation InitiativesPhase 1st :Strengthening of water monitoring systemPhase 2nd :Recycling of EffluentPhase 3rd :Zero effluent discharge 12 ACC LimitedCII Water Excellence Award 2008 16.12.2008 13. Phase 1st :Strengthening of water monitoring systemObjectives Compliance with environmental legal requirements To improve Environmental Performance Indicator (EPI) of the plant Regular monitoring of water consumption Conservation of natural resourcesProject Mission Installation of water meters at source levelProject Organization Client:Mr. A. Roy Choudhary, Vice President Project Manager: Mr. A.K. Srivastava, Manager Engineering Project Member:Mr. S.K. MazumdarMr S K Mazumdar, HOD Water SupplyMr. Pradeep Singh, HOD EnvironmentMr. P.K. Bhattacharya, Asst. Officer, WS13 ACC Limited CII Water Excellence Award 2008 16.12.2008 14. Phase 1st :Strengthening of water monitoring system Identified Risks in planning phase Sr. Identified Risks Remedial Actions No. 1.Unavailability of layout drawings (plant established Study and develop water line layout in the year 1947) 2.Procurement of the water meters in the time frameAdherence with delivery schedule. Attributes Action plan Att ib t & A til PlannedActual date Sr.Accomplished Planned date ofActual date ofActivitydate of of No. bycommencementcommencementcompletioncompletionStudy of existing lay outHOD: Water1. and generate requirement 05.04.200505.04.2005 15.04.2005 10.04.2005Supply for water metersProcurement of water2.HOD: Purchase 15.04.200510.04.2005 30.06.2005 10.08.2005 metersInstallation of waterHOD: Water3.01.07.200512.08.2005 31.07.2005 25.09.2005 meters SupplyEstablishment of system4.4for daily waterMgr. Engee.Mgr Engee 01.08.200501 08 200501.10.200501 10 2005Cont.Cont Cont. Cont consumption monitoring 14ACC Limited CII Water Excellence Award 2008 16.12.2008 15. Phase 1st :Strengthening of water monitoring systemOut come of Team WorkMonitoring of water consumption started on daily basis.Monitored water consumption was double than derived from formula onmonthly production basis.SourceEnd userQuarryAbandonedQuarry PitM (G Block)ClinkerisationPlant Active Quarry Pit M Captive PC i PowerPlant Check DamM(River) Floatation PlantAbandonedQuarry Pit Cement (A Block)MGrinding & Packing PlantDomestic 15 ACC Limited CII Water Excellence Award 200816.12.2008 16. Phase 2nd :Recycling of EffluentObjectives To improve life of reject pit To improve stability of reject pit To improve Environmental Performance Indicator (EPI) of the plant Conservation of natural resourcesProject Mission Recycling of Effluent by rerouting of reject pit discharge to abandoned mine pitProject Organization Client:Mr. A.K. Srivastava, GM (Tech.) Project Manager: Mr. KRK Prusty, Manager Mining Project Member:Mr. P.K. Nanda, Jt. Manager MiningMr. Rajesh Kumar, Jt. Manager MiningMr. Y Kumar, Dy.Mr Y. Kumar Dy Manager CSR 16 ACC Limited CII Water Excellence Award 2008 16.12.2008 17. Phase 2nd :Recycling of Effluent Identified Risks in planning phase Sr. Identified Risks Remedial Actions No. 1.During project bund may be collapsed and lead to Strengthening of bund. flood in near by areas.Dewatering of reject pit.Attributes & Action plan PlannedldActual date ld Sr. AccomplishedPlanned date ofActual date ofActivity date ofof No.by commencementcommencement completion completionStrengthening of bund by1.Mgr. Mining gg10.10.2006 07.10.2006 15.11.2006 23.11.2006 dumping overburden soilDewatering of reject pit2.Mgr. Mining15.11.2006 23.11.2006 30.11.2006 07.12.2006 through diesel pump Laying of pipe with valvesy gpp & strainer in bund for3. regular dewatering ofMgr. Mining20.11.2006 27.11.2006 30.11.2006 05.12.2006 clean water through gravity. Development of natural4. drain for the recirculationMgr. Mining20.11.2006 29.11.2006 31.01.2007 20.02.2007 of mine discharge water 17ACC Limited CII Water Excellence Award 2008 16.12.2008 18. Phase 2nd :Recycling of Effluent Source End user Q Quarryy Abandoned Quarry Pit M(G Block) ClinkerisationPlant Active Quarry Pit MCaptive Power PlantCheck DamM (River) Floatation oatat o Reject j Abandoned Evaporation/p /Plant Mine Pit Natural seepage Abandoned Quarry Pit Cement(A Block) M Grinding &Packing Pl tP kiPlantDomestic18ACC Limited CII Water Excellence Award 2008 16.12.2008 19. Phase 2nd :Recycling of Effluent Out come of Team WorkPit life increased by 1 year.Dewatering pump operation not required ( Rs 10 Lakhs/ annum) Rs.annum).Stability of bund increased.Clean water is being recycled (approximately 2000 KL per day) in A block pitfor reutilization in cement plantplant.Water Silica 19ACC Limited CII Water Excellence Award 2008 16.12.2008 20. Phase 3rd :Zero effluent dischargeObjectives Conservation of natural resources (water & energy) Control of water pollution To improve Environmental Performance Indicator (EPI) of the plantProject Mission To achieve Zero effluent dischargeProject Organization Client:Mr. I.M. Sharma, Plant Head Project Manager: Mr. A.K. Srivastava, GM (Tech) Project Member:Mr. P Singh, Asst. Manager EnvironmentMr.Mr J N Prasad Jt Manager Civil Prasad, Jt.Mr. Y Singh, Dy. Manager CR-RMMr. M Singh, Asst. Engineer CR-RMMr. P K Bhattacharya, Asst. Officer WS20 ACC Limited CII Water Excellence Award 2008 16.12.2008 21. Phase 3rd :Zero effluent dischargeAttributes & Action planPlanned Actual date Sr.AccomplishedPlanned date ofActual date ofActivitydate ofof No. byy commencementcommencementcompletion completionDy. Manager & Initial Cleaning & Asst. Engr. CR- 1. 12.09.200712.09.200730.09.2007 25.09.2007 Arresting leakages RM, Asst. MgrEnv. Construction of effluent collectionsump Jt. Mgr. Civil 2.(1mX1mX1m) to collect Asst.Officer 12.09.200712.09.200730.09.2007 25.09.2007 compressor cooling water WS & pump installation Revamping of old settling Dy. Manager & tank and procurement & 3.CR-RM, Jt. Mgr.01.10.200726.09.200731.01.2008 31.01.2008 installation ofrecycle Civil pump. Minimising water AsstAsst. Officer 4.consumptioninWet WS, Asst. Engr. 12.09.200712.09.200730.09.2007 30.09.2008 grinding & thickening. CR-RM Recycling effluent in wet Asst. Mgr Env., grinding & stopping river 5.Asst.Officer 01.02.200801.02.200815.02.2008 15.02.2008 water consumption in the WS same.21 ACC Limited CII Water Excellence Award 2008 16.12.2008 22. Phase 3rd :Zero effluent discharge SourceEnd user Quarry Abandoned Quarry Pit M(G Block) ClinkerisationPlant ActiveE Quarry Pit M Captive PowerPlantSTFF Check DamM L (River) (Ri )Floatation PlantSTU AbandonedE Quarry Pit Cement((A Block)) M ST N Grinding &Packing Plant TDomestic 22ACC Limited CII Water Excellence Award 200816.12.2008 23. Phase 3rd :Zero effluent dischargeOut come of Team Work Conservation of water (approx. 1000 KL per day) Conservation of energy energy. Control of pollutionPump installed to recycle effluent.Pumping facility installed to recycle effluent. 23 ACC Limited CII Water Excellence Award 200816.12.2008 24. HAND IN HAND - TOGETHER EACH ACHIEVE MORE Thank you for your benign presence & support y yg p pp 24 ACC LimitedCII Water Excellence Award 2008 16.12.2008