water management system at ccw · venue :cii- godrej gbc hyderabad date :16.12.2008 name of the...
Post on 28-Jul-2020
3 Views
Preview:
TRANSCRIPT
Water Management System at CCW
Venue :CII- Godrej GBC Hyderabad
Date :16.12.2008
Name of the Presenter :A.K. Srivastava
Head Plant Operations
This 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.
Chaibasa Cement Works
Company Profile
Established in 1947.
Part of ACC/ Holcim, ati l d l b l l dnational and global leader
Expansion & modernizationin 2005.
1.2 MTPA integratedcement plant
Si d i “K lh iSituated in “Kolhan region– A hard core tribal belt” ,80 Km. from Jamshedpur.
QMS & EMS established asper IS/ISO 9001 & 14001.
OHSMS established as per
2
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
OHSMS established as perHolcim OH&S pyramid.Reliable and respected
Process Details
Highly sophisticated and modern plant with state of the art technology.
S i d ( t 23% i h d l f d i VRM)Raw material preparationRaw mat. extraction
Semi dry process (up to 23% enriched slurry feed in VRM)
Pyro processing
Raw meal preparation
3
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Cement Grinding ShippingShipping
Roadmap for meeting the Environment goals
2008 2009 2010 2011
3030 30Stack emissions (mg/nm3) 50
650 602634 618Kg of CO2/ ton of Cementitious Material
(mg/nm )
20004000 3000Fugitive Emission SPM (µg/nm3) 5000
Environment
1 kilnCEMS Installation on Kiln Stack
-30% -10%-20% -15%Water Consumption
Tonnage of alternative fuels & raw mat. (tons) 222018400 14024 15150
Environment Road Map 88.7 82.286.4 84.3Power Consumption
KWh / ton
AFR InstallationCapex Rs. Cr 0.50.95 2.8 5.0
Thermal Substitution Rate (%) 1.990.53 1.43 1.62
4
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Total GAV (Savings) Rs. Cr 5.890.29 3.47 4.30
Water Conservation Initiatives
Sl.No.
Water conservationinitiatives
Year ofImplementation
Annual Water Savings
Investment made Payback
period(months)R tation (months)
m3 Rs. Lakhs Rs. Lakhs
Strengthening of watermonitoring system by
1g y y
installation of watermeters at sourcepoints
2005-06 - - 2.22 -
Recycling of Effluent by
2
Recycling of Effluent byrerouting of reject pitdischarge toabandoned mine pit
2006-07 165000 4.85 2 5
ffl d h
3
Zero effluent dischargeby providingsedimentation tanksand reutilization offfl
2007-08 330000 9.7 12.1 15
5
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
effluent
Specific Water Consumption3 003 00
2.402.50
3.00
2.402.50
3.00
2.02
2.28
2.00
2.28
2.00 5 %
1.21
1.50
m3/M
T
1.50
m3/M
T
0.70
1.00
0.70
1.00
0.50
0 00 0 00
0.50
6
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
0.00
2004 – 05 2005 – 06 2006 – 07 2007 – 08 Benchmark
0.00 0.000.00
2004 – 05 2005 – 06 2006 – 07 2007 – 08 Benchmark
Road map to achieve global benchmarkObjective & targets Plan of Action Expected
Date ofCompletion
Technical justification
Strengthening of water Installation of Dec. 2009 Water recycled from reject pit ismonitoring system atuser end
water meters atuser end
collected in mines abandoned pit(A block) for further use inplant, this reutilized water isagain counted as fresh waterdue to lack of monitoringdue to lack of monitoringsystem.At present, water meters areinstalled only at sources and weare unable to take initiativesd t t idepartment wise.
To achieve specificwater consumption 700ltr./ MT of Clinker frompresent level of 1519
installation ofmodernizedFiltration FloatationPlant (FFP)
Dec. 2011 At present water consumption infloatation process is about 950ltr. per tonnes of clinker. Byimplementing this proposedpresent level of 1519
ltr./ MTof ClinkerPlant (FFP). implementing this proposed
project dry cake will be fed toVRM and 130 ltr. water pertonnes of clinker will beconsumed in this process.
7
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Sustainability Indices
8
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
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
7 3
8 0
7 5 7 67 5
8 0
8 5 Atmospheric Emission: PMEnval Performance Indicator
6 2
6 6
6 0
6 5
7 0
EP
I (%
)
5 0
5 5
2 0 0 5 2 0 0 6 2 0 0 7 2 0 0 8 2 0 0 7 2 0 0 6
Y e a r
9
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
CCW Performance CCW Target
ACC Avg. Performance HOLCIM Avg. Performance
Commitment towards reduction in GHG Emission
Our objective is to reduce by the year 2010 the averagespecific net CO2 emission by 20 % from the reference year1990 l l d WBCSD CO l
900 075 0
1990, calculated per WBCSD CO2 protocol.
Clinker Factor Specific Net CO2 Emission
876.0
840.0
860.0
880.0
900.0
Cem
. M
at.
69.5
73
65 0
70.0
75.0
804.0 800.0
781.0
760.0
780.0
800.0
820.0
. C
O2
/ M
T o
f
60.3
55.955.0 55.0
55.0
60.0
65.0
%
720.0
740.0
2005 2006 2007 2008
Year
Kg
.
50.02005 2006 2007 2008 2007 2006
Year
10
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
CCW Performance CCW TargetCCW Performance CCW Target
ACC Avg. Performance HOLCIM Avg. Performance
Commitment towards reduction in GHG EmissionThis reduction will be achieved through improving the four key eco-efficiency parameters:
clinker factorspecific thermal energy consumption
1050 0
specific thermal energy consumptionspecific electrical energy consumptionthermal substitution rate
Specific Electrical Energy ConsumptionSpecific Thermal Energy Consumption
106
100.0
105.0
110.0
Cem
en
t
995.0
876900.0
950.0
1000.0
1050.0
Cli
nker
91.9
89.0
85 6 85 0
91.42
90.0
95.0
100.0
kW
h/
MT o
f
755.0 750.0 748.8 751
700 0
750.0
800.0
850.0
KC
al/
Kg
. o
f C
85.6 85.0
80.0
85.0
2005 2006 2007 2008 2007 2006
Yea
600.0
650.0
700.0
2005 2006 2007 2008 2007 2006Year
K
11
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Year Year
CCW Performance CCW Target ACC Avg. Performance HOLCIM Avg. Performance
Water Conservation Initiatives
Phase 1st :Strengthening of water monitoring system
Phase 2nd :Recycling of Effluent
Phase 3rd :Zero effluent discharge
12
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Phase 1st :Strengthening of water monitoring system
Objectives
Compliance with environmental legal requirements
To improve Environmental Performance Indicator (EPI) of the plantTo improve Environmental Performance Indicator (EPI) of the plant
Regular monitoring of water consumption
Conservation of natural resources
Project Mission
Installation of water meters at source level
Project Organization
Client: Mr. A. Roy Choudhary, Vice President
Project Manager: Mr. A.K. Srivastava, Manager Engineering
Project Member: Mr S K Mazumdar HOD Water SupplyProject Member: Mr. S.K. Mazumdar, HOD Water Supply
Mr. Pradeep Singh, HOD Environment
Mr. P.K. Bhattacharya, Asst. Officer, WS
13
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Phase 1st :Strengthening of water monitoring system
Identified Risks in planning phase
Sr. No.
Identified Risks Remedial Actions
1. Unavailability of layout drawings (plant established in the year 1947)
Study and develop water line layout
2. Procurement of the water meters in the time frame Adherence with delivery schedule.
Att ib t & A ti l
Sr. No. Activity Accomplished
byPlanned date of commencement
Actual date of commencement
Planned date of
completion
Actual date of
completion
Attributes & Action plan
1.Study of existing lay out and generate requirement for water meters
HOD: Water Supply 05.04.2005 05.04.2005 15.04.2005 10.04.2005
2. Procurement of water meters HOD: Purchase 15.04.2005 10.04.2005 30.06.2005 10.08.2005meters
3. Installation of water meters
HOD: Water Supply 01.07.2005 12.08.2005 31.07.2005 25.09.2005
4Establishment of system for daily water Mgr Engee 01 08 2005 01 10 2005 Cont Cont
14
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
4. for daily water consumption monitoring
Mgr. Engee. 01.08.2005 01.10.2005 Cont. Cont.
Phase 1st :Strengthening of water monitoring system
Out come of Team WorkMonitoring of water consumption started on daily basis.Monitored water consumption was double than derived from formula on monthly production basis.
Abandoned Quarry
Source End user
monthly production basis.
Quarry Pit (G Block)
Active Quarry Pit
Clinkerisation Plant
C i P
M
MQuarry Pit
Check Dam(River)
Captive Power Plant
Floatation Plant
M
M
Abandoned Quarry Pit (A Block)
Plant
Cement Grinding &
Packing Plant
M
15
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Domestic
Phase 2nd :Recycling of Effluent
Objectives
To improve life of reject pit
To improve stability of reject pitTo improve stability of reject pit
To improve Environmental Performance Indicator (EPI) of the plant
Conservation of natural resources
Project Mission
Recycling of Effluent by rerouting of reject pit discharge to abandoned mine pit
Project Organization
Client: Mr. A.K. Srivastava, GM (Tech.)
Project Manager: Mr. KRK Prusty, Manager Mining
Project Member: Mr. P.K. Nanda, Jt. Manager Mining
Mr. Rajesh Kumar, Jt. Manager Mining
Mr Y Kumar Dy Manager CSR
16
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Mr. Y. Kumar, Dy. Manager CSR
Phase 2nd :Recycling of Effluent
Identified Risks in planning phase
Sr. No.
Identified Risks Remedial Actions
l d l d
1. During project bund may be collapsed and lead to flood in near by areas.
Strengthening of bund.
Dewatering of reject pit.
Attributes & Action plan
Sr. No. Activity Accomplished
byPlanned date of commencement
Actual date of commencement
Planned date of
completion
Actual date of
completion
1. Strengthening of bund by dumping overburden soil Mgr. Mining 10.10.2006 07.10.2006 15.11.2006 23.11.2006dumping overburden soil g g
2. Dewatering of reject pit through diesel pump Mgr. Mining 15.11.2006 23.11.2006 30.11.2006 07.12.2006
Laying of pipe with valves
3.
y g p p& strainer in bund for regular dewatering of clean water through gravity.
Mgr. Mining 20.11.2006 27.11.2006 30.11.2006 05.12.2006
Development of natural
17
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
4.Development of natural drain for the recirculation of mine discharge water
Mgr. Mining 20.11.2006 29.11.2006 31.01.2007 20.02.2007
Phase 2nd :Recycling of Effluent
Quarry
Source End user
Abandoned Quarry Pit (G Block)
Active
Clinkerisation Plant
Q y
M
Active Quarry Pit
Check Dam(River)
Captive Power Plant
Floatation
M
MAbandoned Reject Evaporation/
Abandoned Quarry Pit (A Block)
oatat oPlant
Cement Grinding &
P ki Pl t
M
Mine Pitj p /
Natural seepage
Domestic
Packing Plant
18
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Phase 2nd :Recycling of Effluent
Out come of Team Work
Pit life increased by 1 year.
Dewatering pump operation not required ( Rs 10 Lakhs/ annum)Dewatering pump operation not required ( Rs. 10 Lakhs/ annum).
Stability of bund increased.
Clean water is being recycled (approximately 2000 KL per day) in ‘A’ block pitfor reutilization in cement plantfor reutilization in cement plant.
Water
19
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Silica
Phase 3rd :Zero effluent discharge
Objectives
Conservation of natural resources (water & energy)
Control of water pollutionControl of water pollution
To improve Environmental Performance Indicator (EPI) of the plant
Project Mission
To achieve ‘Zero effluent discharge’
Project Organization
Client: Mr. I.M. Sharma, Plant Head
Project Manager: Mr. A.K. Srivastava, GM (Tech)
Project Member: Mr. P Singh, Asst. Manager Environment
Mr J N Prasad Jt Manager CivilMr. J N Prasad, Jt. Manager Civil
Mr. Y Singh, Dy. Manager CR-RM
Mr. M Singh, Asst. Engineer CR-RM
20
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Mr. P K Bhattacharya, Asst. Officer WS
Phase 3rd :Zero effluent discharge
Sr. No. Activity Accomplished
byPlanned date of commencement
Actual date of commencement
Planned date of
completion
Actual date of
completion
Attributes & Action plan
y completion completion
1. Initial Cleaning &Arresting leakages
Dy. Manager & Asst. Engr. CR-RM, Asst. Mgr Env.
12.09.2007 12.09.2007 30.09.2007 25.09.2007
2.
Construction of effluentcollection sump(1mX1mX1m) to collectcompressor cooling water& pump installation
Jt. Mgr. CivilAsst. OfficerWS
12.09.2007 12.09.2007 30.09.2007 25.09.2007
3.
Revamping of old settlingtank and procurement &installation of recyclepump.
Dy. Manager & CR-RM, Jt. Mgr. Civil
01.10.2007 26.09.2007 31.01.2008 31.01.2008
Minimising water Asst Officer4.
Minimising waterconsumption in Wetgrinding & thickening.
Asst. OfficerWS, Asst. Engr.CR-RM
12.09.2007 12.09.2007 30.09.2007 30.09.2008
5.
Recycling effluent in wetgrinding & stopping riverwater consumption in the
Asst. Mgr Env.,Asst. Officer 01.02.2008 01.02.2008 15.02.2008 15.02.2008
21
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
water consumption in thesame. WS
Phase 3rd :Zero effluent discharge
Source End user
Abandoned Quarry Pit (G Block) Clinkerisation
Plant
Quarry
M
Active Quarry Pit
Check Dam(Ri )
Captive Power Plant
M
M L
F
F
E
ST
(River)
Abandoned Quarry Pit (A Block)
Floatation Plant
Cement Grinding &
M
M N
E
U
LST
ST( )
Domestic
Grinding & Packing Plant T
ST
22
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Phase 3rd :Zero effluent discharge
Out come of Team Work
Conservation of water (approx. 1000 KL per day)
Conservation of energyConservation of energy.
Control of pollution
23
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
Pumping facility installed to recycle effluent.Pump installed to recycle effluent.
HAND IN HAND - TOGETHER EACH ACHIEVE MORE
Thank you for your benign presence & support
24
ACC Limited 16.12.2008CII ‘Water Excellence Award 2008’
y y g p pp
top related