IPPTA Zonal Seminar Ahmedabad 6 th & 7 th August 2015 IPPTA Zonal Seminar Ahmedabad 6 th & 7 th August 2015 Water Management and Recycling Practices ITC Limited, Paperboards and Specialty Papers Division, Unit : Kovai

Contents of the Presentation 1.Introduction 2.Approach to Water Conservation 3.Case studies 4.Sustenance & Improvements 5.Results 6.Conclusion

TL wire Coater Dryers, MG, Calender Board machine ETP Treated Effluent for Irrigation Petax Filter Cogen 8MW Steam Water from River Condensate Fuel Emission: SPM <30ppm Reel & Rewinder Sheeters Finishing House DispatchDispatch Stock Preparation Pulper Waste Paper Screen Centricleaner Hot disperser FL wire Pulper Waste Paper Screen Centricleaner Hot disperser BL wire Pulper Waste Paper Screen Centricleaner Hot disperser Water Treatment DM Plant Press & Temsec Rewinder Treated Effluent Reuse TSS <30ppm Windmill 7.5MW Process Flow

Irrigation ETP 1650 Outsiders Cooling tower 70 Board Machine Water meters Stock Preparation KROFTAPetax From River Water Treatment Clarifier Boiler DM plant Gardening Drinking & cooking Domestic STP 1 & 2 Fire system water 650 EL -230 EL -325 EL -290 EL –Evaporation Loss EL -30 Plant Water Balance 100% Water Consumption is metered

WORLD CLASS ZERO LOSSES Organization Journey to World Class Eliminate Waste Enhance Speed Efficient Value Streams Lower Inventories Reliable and effective Supply Chain Total Employee Involvement Continuous Improvement Process, Asset & People Care Sustain Gains

Lean Organization Planned Maintenance Pillar Team Process & Asset Care Teams - 16 Unit Level Area Level Shift Level EHS Pillar Team PSPD Level Divisional Management Committee Pillar Teams 16 PACTs USB Plant Facilitator HR Pillar Team (Skill Development) Quality Pillar Team Unit Steering Board Pact Pillar Team Utilities Board machine Stock Finishing House Finance Quality Engineering Area Effectiveness Team Materials Out side Sheeting Personnel & Welfare Information system Admin Customer Service Cell Office Pillar Team Service Effectiveness Team

7 Approach for Water Conservation Idea Generation Internal/TEI PACT/AET - Kaizens Water Audits Campaigns/ Posters Training EMS/EMC Review ExternalTrainingSeminarsCompetitions

Water Conservation Technique Recycle Reuse Reduce Recharge 4 R – Technique

Water Conservation “Reduce” Reduce

10 Water Conservation “Reduce” The activities involved under this category are; To identify the required sizes of nozzles, showers and pipelines with respect to sizes and required numbers To identify the auto control loop required locations with respect to operational parameter requirements Optimization of chemical usage To identify areas of Water Wastage i.e., Leakages To identify the areas where the requirement of water is less and the actual usage is high, especially utility purposes e.g, Toilets, Canteen, Gardening etc.

Key initiatives 11 Water Conservation projects “Reduce” S.NoTitle of Water Saving project implemented Year of Implementation Annual Water Savings Investment Made m3m3 Rs. Lakhs 1Level Control for Top liner back water chestJan-0815, Optimization of back liner wire edge cleaning shower Jan-0815, Optimization of 4 number of Press part LP shower Jan-0879,200Nil 4 Temperature control loop for vacuum seal pit make up fresh water Feb-0895, Reducing sealing water in condensate vacuum pump Jul-0823,760Nil 6 Replacing all LP showers in wire part with new one Jan-0933,0004 7Optimizing Top liner backwater in systemJan-1121, Optimizing RCC tower cleaning waterDec Nil 9Ordinary water tap replaced with Foam tapMay

12 Past Scenario: Vacuum pump sealing water used to get make up with fresh water on continuous basis to avoid higher temperature so as to control scaling related issues. Present Scenario: A Temperature Indication and control system along with control valve has been introduced in the loop which reduced the fresh water make up directly. Project Summary: Fresh Water Savings95040M 3 /Annum Investment1.75Lakhs Fresh water Temperature Control Loop for Vacuum Seal pit make up Flume Pit Fresh water TIC Case Study:1 Vacuum Pump

13 Past Scenario: Top liner Back water goes to Silo I and Silo II then to Save all supply chest where all three layer water stored and recycled for further usage. Present Scenario: Top liner Silo II water is now diverted to one additional storage tank and taken to stock preparation for pulper dilution purposes which avoid fresh water make up in stock preparation Project Summary: Fresh Water Savings21250M 3 /Annum Investment0.22Lakhs Optimizing Top liner Backwater System RCC TL Silo II TL Silo II Save all supply Save all supply TL Silo I TL Silo I RCC TL Silo II TL Silo II Save all supply Save all supply TL Silo I TL Silo I T/L Storage tank T/L Storage tank TL Make up in Stock Case Study:2 To Stock

Water Conservation “Reuse” Reuse

15 Water Conservation “Reuse” The activities involved under this category are; Identifying potential area of replacing Fresh Water with back Water Identifying locations where fresh water is used for floor cleaning Identifying excess water availability for storage and reuse Identifying major ‘sealing water’ source to reuse Exploring usage of all ‘blow down water’ for some processes

Key Initiatives 16 Water Conservation projects “Re-use” S.NoTitle of Water Saving project implemented Year of Implementation Annual Water Savings Investment Made m3m3 Rs. Lakhs 1Top liner tray water diverted to top liner siloMar-0811, Reusing main condensate vacuum pump outlet water in processMar-0923, Reducing & reusing water consumption by providing logic control in dilution systems Oct-0912,000Nil 4Reusing sump pit water & pulp in processDec Reusing main condensate vacuum pump sealing water in process Jan Reusing of Effluent water to ETP Dilution & internal cleaningMar Reusing Save all and Recovered chests excess waterDec-1039, Reusing of hydrant system run check - drain waterOct-10600Nil 9Re using sealing water from coater sectionFeb Nil 10Re using m/c base wire pit section water into Filler silo tankOct Effluent drain water collected in new SS tank and reusedMay Top liner Silo - II overflow collected and reusedSep Chest no -5 overflow to excess water tankDec Top liner Krima Disperser sealing water reusedDec Back water in place of Fresh Water used for Floor cleaning in board machine Sep Drum Pulper Liquid cyclone drain water reusedDec

Past Scenario : Filtrate waters from save-all supply and recovered fiber chest overflow sent to ETP whenever pump is having issue and imbalance in system till steady state is reached. Present Scenario: – Overflow line provided to a collecting chest and being pumped to back water supply tank. – This has decreased fiber loss, and increased reuse of water in the plant. Project Summary: Reusing Save-all and Recovered fiber chest excess water Case Study:3 Fresh Water Savings39,450M 3 /Annum Investment0.35Lakhs

Excess water chest Save all Supply chest Reusing Save-all and Recovered fiber chest excess water

Past Scenario: Filtrate waters from middle liner systems, back liner systems and top liner poire systems washings, spillages, hydra screens etc from six meter, zero meters of stock preparation containing water, pulp and plastics are being collected in a sump and pumped to ETP Present Scenario:  Collected water is being diverted to two pulpers.  First it is pumped to the plastic separating screens and then to the pulper.  This has decreased fiber loss, plastic load to ETP and increased reuse of water in the plant. Project Summary: Reusing Sump pit water and pulp in process Case Study:4 Fresh Water Savings39,600M 3 /Annum Investment1.0Lakhs

Reusing Sump pit water and pulp in process

21 Drum pulper Liquid cyclone water Re-use Past Scenario : Drum pulper Elutriation water used to go to sand separator and then after separating dense particle, water drained. Present Scenario: After sand separator a collection tank provided with raised bottom and then the water is now taken to middle layer cloudy water tank for further use. Project Summary: Fresh Water Savings1750M 3 /Annum Investment1.75Lakhs Collec tion tank Liquid cyclone Sand Separator To drain Sand Separator Liquid cyclone Before After Case Study:5 Mid Liner Cloudy water tank

22 Krima Disperser Sealing water Re-use Past Scenario : Fresh water is used to cool the lubrication system in Krima hot disperser of both Top liner and Bottom liner. The fresh water then was drained. Present Scenario: Small funnel was provided at both outlets of cooling system and water is collected and stored along with screen dilution water for further usage. Project Summary: Fresh Water Savings15750M 3 /Annum Investment0.50Lakhs Disperser Lubrication Drain Disperser Lubrication Screen Dilution tank Funnel Fresh water Cooling Before After Case Study:6

Water Conservation “Recycle” Recycle

24 Water Conservation “Recycle” The activities involved under this category are; Identifying the areas of excess back water availability which can be treated/processed for further usage in the process Upgrading water treatment facilities to enable recycling of waste water Exploring the usage of ETP treated water in process operation Exploring Best Available Technology (BAT) for maximum recycling of waste water

Key initiatives 25 Water Conservation projects “Recycle” S.NoTitle of Water Saving project implemented Year of Implementation Annual Water Savings Investment Made m3m3 Rs. Lakhs 1 New shell and tube heat exchanger installed in place of plate type heat exchanger to improve the condensate recovery May-0833, New ETP to treat the Top liner and coating separately Nov-081,75, Fiber Recovery systemAug Reusing fiber recovery tank water by providing logic control Feb Nil 5Mini press installationJun Chest 5 & 7 fresh water make up reduction by using clarifier water Jun Filler Line KROFTA Clarifier Capacity UpgradeMay ETP Treated water used in PETAX filter Accept in place of Fresh water Jun Top Wire Shower Fresh water replaced with PETAX water Mar Fill Less Cooling tower for Vacuum Flume water Mar

26 Past Scenario: Vacuum pump sealing water used to get re-circulated with temperature controlled fresh water make up. Present Scenario: A new Fill less cooling tower has been introduced to recycle the flume pit water after reducing temperature which avoid fresh water make up. The freshwater make up at cooling tower is relatively negligible. Project Summary: Fresh Water Savings58800M 3 /Annum Investment7.1Lakhs Fill Less Cooling tower (-10 0 C ) Flume Pit Fresh water Fill Less Cooling Tower for Vacuum Flume water Case Study:7 Vacuum Pump Fresh water New Old

27 Past Scenario: ETP treated water was taken to irrigation to our own land. The water quality was further improved after installing Equalization tank. Present Scenario: Disc Filter introduced to further improve the water quality. SS pipeline from ETP to Secondary Fiber Treatment plant was laid and an additional filter was installed before SFT. The water is taken to SFT for screen dilution purpose which replaced freshwater make up. Project Summary: ETP treated water Recycling in Stock Preparation Fresh Water Savings52500M 3 /Annum Investment25Lakhs Case Study:8

ETP treated water Recycling in Stock Preparation ETP Secondary Clarifier Outlet Tank Irrigation 2200 M3 / Day Before After ETP Secondary Clarifier Disc Filter Outlet Tank Irrigation 1600 M3 / Day 600 M3 / Day To Process

29 Recycling fiber recovery tank water by providing logic control Past Scenario : Pulping water for Drum pulper was taken from RCC tower, hence fresh water used to get make up Present Scenario: Fiber recovery tank over flow recycled to drum pulper pulping with logic control Project Summary: Fresh Water Savings182500M 3 /Annum InvestmentNilLakhs Case Study:9

30 Recycling of process waste water with Mini press installation Past Scenario : In Secondary Fiber treatment (SFT) plant, fiber with low consistency gets rejected at various stages of screening and centri-cleaning. These rejects has high water content and drained to ETP stream. Present Scenario: Three Mini press installed at rejection stage to handle and recover fiber and waste water Project Summary: Fresh Water Savings87500M 3 /Annum Investment1.0Lakhs Case Study:10

Pulping Screen rejects & Centri cleaner rejects Hydra Screen Fiber & Plastic Rejects ETP Drain Pulping Screen rejects & Centri cleaner rejects Waste water to reuse ETP Drain Reject to Boiler Recycling of process waste water with Mini press installation Before After Collection tank

Water Conservation “Recharge” Recharge

33 Water Conservation “ Recharge “ The activities involved under this category are; To recharge the rainwater to the ground to increase the water table. Though the recharge is not directly reducing water usage, it is the key factor to save water for near future and for the benefit of the society in large. The implementation is done under two category; a) Internal / Inside mill b) External /Surrounding mill

Area of Roof-top with Rain water Recharging 83.2% Roof Area % of roof tops are are re-charged and maintained The potential of this saving is about 10,040 M 3 /Annum. In addition pave and unpaved area also covered. Water Conservation projects “Recharge” Inside mill

35 Water Conservation projects “Recharge” Outside mill The surrounding areas are selected based on survey by experts and various type of water conservation infrastructures have been developed. The unit involves itself in Ground Water augmentation beyond the fence through; Farm ponds Percolation ponds Check Dams Contour bunding Drip irrigation

Green Belt Development

37 Water Saving Kaizens

KAIZEN – By Water & Waste water Team KAIZEN – By Water & Waste water Team

39 Bench marking

Benchmarking – Specific Water Consumption Benchmarking – Specific Water Consumption Source: NPC

41 Sustenance & Improvements

Review : Sustenance & Improvements Consumption at all consuming points are captured in DCS Daily area wise fresh water consumptions are monitored Water consumptions reviewed, variance analysis carried out & corrective actions planned - Daily AET’s meetings - Weekly Energy Management Cell review - Monthly review by Unit Steering Board - Designated Water Manager Regular Training on water conservation

AET Activity Board Daily trend of Raw Water Consumption being tracked 43

Training Calendar and records Topic : Water Clarification & Krofta 44

45 Awareness on Water Needs to Stakeholders

World Environmental Day - Awareness Environment protection Oath - employees Awareness Rally Environment protection Oath - Community

World Water Day - Awareness Water Day celebration Water conservation Oath Motivation for Best suggestions

Celebration of Water Day 48

Involving Local Community in Tree plantation

Water - Posters

Knowledge Sharing All innovative ideas and suggestion are shared across our units through lotus notes. Quarterly review meeting across the units for sharing ideas and suggestion for improvement Innovative ideas are shared with neighboring industries Shared online in In-house Bhadra net across units Best Energy Saving Kaizens are shared with unit level and rewarded for motivation. Lean Express – Internal knowledge sharing Magazine

Results The unit achieved 33% reduction in last three years and about 65% since inception. Innovation, timely up-gradation of new technology, employees involvement under TPM and top management commitment are the key factor to achieve the excellence in water Management.

Conclusion Mill approach towards continual improvement through Total Employee Involvement (TEI) resulted in achieving Excellence in water management and also helped the unit to become the first paper mill in India to receive the CII – Green Co-Platinum rating – the highest rating in the country for meeting the world class standards in sustainability

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