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Water Policy and Implementatio3

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Welcome

Recycling of Effluent for Reuse

in Process through the BOOT Model

Tata Motors Ltd. – CVBU Pimpri Pune Mr V V Joshi

Mr B B Patil

Mr A T Gaikwad

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Water Policy and Implementatio3

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Flow of Presentation

1. Tata Motors CUBU Pimpri Pune – Layout .

2 Tata Motors CUBU Pimpri Pune Manufacturing Process.

3. Project Uniqueness - Selection of System - Cost , Quality – Sustainability

4.Project Uniqueness in Nature of Agreement , Technical & Quality Aspects=

5. Major Trigger – Need & Details of the Project

6.Plant Constituents and Key Advantage

7. Project – Financial Perspective

8. RO BOOT Project Tangible Benefits

9. RO BOOT Project Non - Tangible Benefits – Plant Performance

10. Replication Potential – Progress - Status and Steps taken

11. Replication Potential – Within Sector – Propagation of Concept

12. Challenges – Bottlenecks during Projects Implementation

13. Achieving National Benchmark / Standard – Environmental Performance

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� Multi-location manufacturing facilities in India. CVBU – Commercial Vehicle Business Unitcomprises 5 Plants – Jamshedpur, Pune , Lucknow, Pantnagar and Dharwad. PVBU-Passenger vehicle Business Unit comprises of Pune and Sanand Plant

CVBU Pune plant – Manufacturing of Commercial vehicles.

1. Tata Motors CUBU Pimpri Pune – Layout

Resi Area 393 Acr

Lake & Pond 85 Acr.

Plantation 183 Acr

Plot Area 380 Acr.

Green Area 55 Acr

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CII – ‘Excellence in Energy

Management -2015Srishti Good Green Governance Award

CII – CII-GreenCo ‘GOLD’ ratingCII-GBC Green Co Best Practices

Award-2015

CII National Water Award and FICCI National Water Award.

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2. Tata Motors CUBU Pimpri Pune – Manufacturing Process.

Resi Area 393 Acr

Lake & Pond 85 Acr.

Plantation 183 Acr

Plot Area 380 Acr.

Green Area 55 Acr

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Plot Area 380 Acr.

Green Area 55 Acr

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Technology Available in

Market

But at what Cost ?

That Is Important

In normal circumstances with our own investment cost would have been

Running + Capital for 10 years - Rs 1369 Lakh

With innovative approach by selecting the Unique model DBOO ( Design, Built,

Own & Operate) we are now saving Rs 782 Lakh in next 10 Years

Take or pay Agreement

No Investment

No LiabilityPerformance Guarantee

Projects: 1000 KLD BOOT

Basis RO plant

Installed with

Investment from

OEM while TML

reimburses party

on the basis of RO

Water Received

3. Project Uniqueness - Selection of System considering Cost , Quality – Sustainability

Sustainable Model

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4.Project Uniqueness in Nature of Agreement , Technical & Quality Aspects

Technical Aspect

Mobile Plant

Spares by Party

Shared Operation

Supply/Dispose filters by Party

PTRO Membrane

Isolation of membrane

for maintenance

No Ultrafiltration

Low maintenance and break

downs

Reject is less hazardous

Less use of Chemical

Less Hazardous process

Quality Aspect

75 % Recovery

Input Quality acceptable

limit for SDI is 15 as against

3 to 5

Inlet TDS 800

Inlet TSS < 5 ppm

Inlet COD < 56 ppm

Inlet Hardness 300 ppm

Outlet TDS - 75 PPM

Outlet TSS - NIL

Outlet COD - NIL

Hardness < 50 ppm

Agreement

Minimum Intake

Minimum Generation

Penalty for less Intake or

Generation

Defined Quantity

Ten Year Agreement

Free Power Supply – linked

with quality feed

Ten Year Agreement

Metering – Water - Power

Early exist clause

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� Plumber available in both shift.

� On receipt of complaint, complaint number is given to complainer

� Plumber immediately reaches to the location based on no. & location & stops/attend the

leakages.

� In case of major leakages stop the water & call for additional help.

� Daily review of complaint status.

� Proactive actions on the basis of

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5. Major Trigger – Need & Details of the Project

Aspiration – Water Positive

Water Foot Print

Hot Spot Identifica

tion

ZLD – Zero Liquid

Discharge Conditions

by SPCB

Drought Situation –

Supply restrictions-Scarcity of

water

Green and Climate change

initiatives

Recycling of

treated Effluent




leakages.




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6. Plant Constituent – Key Advantages

Plant Constituents

• Low Pressure / High

pressure pump

• Anti-Scalant , Acid and CIP

System

• First stage RO 32 No SW

membrane

• Bag filter 20 micron ,

• Cartridge filter 10 micron

• Second stage 80 Nos PTRO

membrane

Advantage of RO plant Advantage of RO plant

over other DM Plant • Physical Separation

• Less Hazardous process

• Less Chemicals

• Low maintenance and

breake downs

• Easy for maintenance

• Reject is less hazardous

• Isolation of poor

performance membranes

• Isolation for membrane

for maintenance

• Better Automation

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leakages.




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7. Project – Financial Perspective

• Plant Capacity 1000 KLD

• Minimum generation 270000 Cum

• Reimbursement Rs 8/Cum

• Escalation Rs 0.25/Cum

• Max -Power 1.4 Kwh/Cum

• For less Lift Rs 4.05/Cum

• Penalty For less Generation Rs 6/Cum

• Excess Power-Penalty-Prevailing power tariff

• Special provision for long term shutdowns

Financial

Perspective




leakages.




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8. RO BOOT Project - Tangible Benefits

Tangible - Benefits

• 550 Lacs 300 Mechanical + 250

Civil investment eliminated

• RO Water Generation cost Rs 16

to 17 /KL less than MIDC

• Daily water saving of 1000 KLD

• 305800 KL Effluent Recycling

during 16-17

• ZLD – Achievements

• No maintenance burden and No

conflict with OEM – key in RO

operation

• Maintenance issues eliminated

• Backwash / reject disposal issue

addressed

222414

100762

305800

50000

150000

250000

350000

14-15 15-16 16-17

48.26

16.11

23

0

20

40

14-15 15-16 16-17

Effluent Recycling for Process Use In KL

Saving In Rs Lacs

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leakages.




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9. RO BOOT Project Non - Tangible Benefits – Sustenance of Plant performance

Non - Tangible - Benefits Non - Tangible - Benefits

• Moving towards Water positive

• Reduction in water foot print

• Environment protection

• Improved Safety Status

• Maximizing the reuse

• Quality of treated effluent

improved – with enhance control

• Reduction in chemical usage

• House keeping improved

• Branding of plant

• Reduction of water extraction

• Automation - Better Quality

control

Plant Performance• Recovery Satisfactory

• Quality Ok

• Feed TDS s 450 ppm

• Acceptance Variable

feed quality

• Power 1.1 Kwh/Cum

• One Breakdown

• ORP Increase

• Strainer Introduced

• Reject Recycled

• Cost Rs 16 -17 /Cum

• MIDC Water cost Rs

32.25- 21.50/ Cum




leakages.




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10. Replication Potential – Progress - Status and Steps taken

• Can be replicated across all Automobile

Manufacturing Industries

• Replicated at Pune – added capacity 500 KLD.

• Replicated – at TML Lucknow – 500 KLD -

commissioned Dev 16

• Proposed 500 KLD Pimpri – expected to start by

Oct 17

• Under consideration for Dharwad - which will

also account for borewell water and higher TDS

Level up to 1200

• Future - Under consideration – Jamshedpur

Plant

• Shared the case study through group level inno-

vista competition

Replicability

TML - Cross

Location /

Within

Group

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leakages.




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11. Replication Potential – Within Sector – Propagation of Concept

•• OEM- is branding the concept under

RO-SERVE Brand

• Presented a case study as a party of CII

– National Water award presentation

• The rental concept is developed by

party

• Leasing concept – where in party is

providing finance is also developed

• Mutually agreed Taylor made solutions

are being provided

• Outright purchase option is also

available

FICCI

2 nd India Industry Water Conclave on

“ Sustainable Water Management”

Session

Water Use Efficiency in Industries -

Best Practices




leakages.




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12 Challenges – Bottlenecks during Projects Implementation

• Analysis of Earlier data

• Finalization Design Range

• Joint operation

responsibility

• Segregation of

streams

• Minimum Power fixed

• Power Consumption Linked

with TDS level

• Penalty for excess power / KL

RO Generation

• Recovery as per

prevailing power tariff

• Combination of RO membranes• Combination of RO membranes

• Sharing of O & M responsibility

• Both way penalty

• Minimum in take and

generation criteria

• Separate work out

for less intake

• Escalation over minimum rate

• Separate work out for less

generate

• Chemicals by party

• Disposal of waste material by

party

• Use of reject water

Project

Cost

Economics

Variable

Feed

Quality

Power

Cost

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leakages.




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DBOO – Basis

RO PLANT

Easy

Replicate

No Capital

Investment

Taylor

Made Design

Acceptance

of High SDI

Address

ZLD

Easy to

install and Maintain

Best –Option For Recycling of

Treated Effluent

New installation coat of

1000 KLD – 550 Lacs No specific National

Benchmark

13 Achieving National Benchmark / Standard – Environmental Performance

Water Generated

6.27 Lac Cum –

Saving Rs 90 Lacs

Use of Existing

Infrastructure

Load on Environment

Reduced –

No reject Disposal –

Power Conswervation

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