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

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

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

3000
1900
375
250
475
Water Treatment
From River Plant Water Balance
500
1400
395
Stock
Preparation
440
4905
Clarifier
EL -290
Board
Machine
1320
2490
KROFTA
1960
3735
45
Petax
585
650
1840
ETP
1630
EL -325 EL -30
DM plant
335
Boiler
10
40
70
20
230
15
160
Cooling tower
Outsiders
Gardening
EL -230
20
100% Water Consumption is metered
Drinking & cooking
40
STP 1 & 2
Domestic
Fire system water
EL –Evaporation Loss Water meters
1650
Irrigation

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
Organization WORLD CLASS
ZERO LOSSES

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

PACT/AET -
Kaizens
Idea
Generation
Internal/TEI
Water Audits
Campaigns/
Posters
Training
EMS/EMC
Review
Training
External Seminars
Competitions
7

Water Conservation Technique
4 R – Technique
Reduce
Recycle
Reuse
Recharge

Water Conservation
“Reduce”
Reduce

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.
10

Water Conservation projects
“Reduce”
Key initiatives
5
6
7
8
9
3
4
1
2
S.No
Title of Water Saving project implemented
Level Control for Top liner back water chest
Optimization of back liner wire edge cleaning shower
Optimization of 4 number of Press part LP shower
Temperature control loop for vacuum seal pit make up fresh water
Reducing sealing water in condensate vacuum pump
Replacing all LP showers in wire part with new one
Optimizing Top liner backwater in system
Year of
Implementation
Annual Water
Savings
Investment
Made m 3 Rs. Lakhs
Jan-08 15,840 0.38
Jan-08
Jan-08
Feb-08
Jul-08
Jan-09
Jan-11
15,840
79,200
95,040
23,760
33,000
21,250
0.15
Nil
1.75
Nil
4
0.22
Optimizing RCC tower cleaning water Dec-11 12000 Nil
Ordinary water tap replaced with Foam tap May-13 4200 0.28
11

Temperature Control Loop for
Vacuum Seal pit make up
Case Study:1
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.
Vacuum Pump
Fresh water
Flume Pit
Fresh water
Project Summary:
Vacuum Pump
TIC
Fresh Water Savings 95040 M 3 /Annum
Flume Pit
Investment 1.75
Lakhs
12

Optimizing Top liner Backwater
System
Case Study:2
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:
TL Silo
I
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
TL Silo
Project Summary:
I
TL Silo
II
TL Silo
II
Fresh Water Savings
Investment
21250
0.22
M 3 /Annum
Lakhs
Save all supply
RCC
To Stock
T/L
Storage tank
Save all supply
RCC
To Stock
TL Make up in
Stock
13

Water Conservation
“Reuse”
Reuse

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
15

Water Conservation projects
“Re-use”
Key Initiatives
15
16
4
5
10
11
12
13
14
8
9
6
7
1
2
3
S.No
Title of Water Saving project implemented
Top liner tray water diverted to top liner silo
Reusing main condensate vacuum pump outlet water in process
Reducing & reusing water consumption by providing logic control in dilution systems
Reusing sump pit water & pulp in process
Reusing main condensate vacuum pump sealing water in process
Reusing of Effluent water to ETP Dilution & internal cleaning
Reusing Save all and Recovered chests excess water
Year of
Implementation
Mar-08
Annual Water
Savings m 3
11,880
Mar-09 23,760
Oct-09
Dec-09
Jan-10
Mar-10
Dec-10
12,000
39600
12960
9600
39,450
Reusing of hydrant system run check - drain water
Re using sealing water from coater section
Oct-10
Feb-11
600
8400
Re using m/c base wire pit section water into Filler silo tank
Effluent drain water collected in new SS tank and reused
Top liner Silo - II overflow collected and reused
Chest no -5 overflow to excess water tank
Top liner Krima Disperser sealing water reused
Back water in place of Fresh Water used for Floor cleaning in board machine
Drum Pulper Liquid cyclone drain water reused
Oct-11
May-12
Sep-12
Dec-12
Dec-13
Sep-13
Dec-13
330000
87500
262500
105000
15750
7000
17500
Investment
Made
Rs. Lakhs
0.15
0.1
Nil
1
0.2
2.5
1
-
4
0.5
0.18
0.35
Nil
Nil
-
1.75
16

Reusing Save-all and Recovered fiber chest excess water
Case Study:3
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:
Fresh Water Savings
Investment
39,450
0.35
M 3 /Annum
Lakhs

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

Reusing Sump pit water and pulp in process
Case Study:4
•
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:
Fresh Water Savings
Investment
39,600
1.0
M 3 /Annum
Lakhs

Reusing Sump pit water and pulp in process

Drum pulper Liquid cyclone water Re-use
Case Study:5
Past Scenario :
• Drum pulper Elutriation water used to go to sand separator and then after separating dense particle, water drained.
Before
Liquid cyclone
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:
Mid Liner
Cloudy water tank
To drain
After
Sand Separator
Liquid cyclone
Fresh Water Savings
Investment
1750
1.75
M 3 /Annum
Lakhs Collec tion tank
Sand Separator
21

Krima Disperser Sealing water Re-use
Case Study:6
Fresh water
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.
Cooling
Disperser
Lubrication
Before
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 .
Disperser
Lubrication
Drain
Fresh water
Cooling
Disperser
Lubrication
Disperser
Lubrication
Funnel
After
Project Summary:
Fresh Water Savings
Investment
15750
0.50
M 3 /Annum
Lakhs
Screen
Dilution tank
22

Water Conservation
“Recycle”
Recycle

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
24

Water Conservation projects
“Recycle”
Key initiatives
8
9
10
4
5
2
3
6
7
S.No
1
Title of Water Saving project implemented
Year of
Implementation
Annual Water
Savings m 3
Investment
Made
Rs. Lakhs
New shell and tube heat exchanger installed in place of plate type heat exchanger to improve the condensate recovery
New ETP to treat the Top liner and coating separately
Fiber Recovery system
Reusing fiber recovery tank water by providing logic control
Mini press installation
Chest 5 & 7 fresh water make up reduction by using clarifier water
Filler Line KROFTA Clarifier Capacity Upgrade
ETP Treated water used in PETAX filter
Accept in place of Fresh water
Top Wire Shower Fresh water replaced with
PETAX water
Fill Less Cooling tower for Vacuum Flume water
May-08
Nov-08
Aug 2009
Feb-12
Jun-12
Jun-13
May-14
Jun-14
Mar-15
Mar-15
33,000
1,75,000
43000
182500
87500
52500
132000
52500
35000
58800
3.2
25
-
7.1
20
5
Nil
1
0.53
48
25

Fill Less Cooling Tower for Vacuum
Flume water
Case Study:7
Past Scenario:
Vacuum pump sealing water used to get re-circulated with temperature controlled fresh water make up.
Fresh water
Present Scenario:
Fill Less
Cooling tower
(-10 0 C )
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 Savings
Investment
58800
7.1
M 3 /Annum
Lakhs
Fresh water
Vacuum Pump
Flume Pit
New
Old
26

Case Study:8
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:
Fresh Water Savings
Investment
52500
25
M 3 /Annum
Lakhs
27

Before
After
ETP
Secondary
Clarifier
ETP
Secondary
Clarifier
600
M3 / Day
To Process
Disc Filter
Outlet Tank
Irrigation
2200
M3 / Day
Outlet Tank
Irrigation
1600
M3 / Day

Recycling fiber recovery tank water by providing logic control
Case Study:9
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 Savings
Investment
182500
Nil
M 3 /Annum
Lakhs
29

Recycling of process waste water with
Mini press installation
Case Study:10
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 Savings
Investment
87500
1.0
M 3 /Annum
Lakhs
30

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

Water Conservation
“Recharge”
Recharge

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
33

Water Conservation projects
“Recharge”
Inside mill
• 83.2% 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.
Roof Area
SL.No
Location Type of Roof Area-Sq Mtr
1 Finishing House & Godown GI Sheet
2 Board M/c & Stock area GI Sheet
3 Pulp Godown
4 Inside Paper yard
GI Sheet
GI Sheet
5 Coal Godown
6 New Waste paper yard
7 A/c Drives Building
8 Boiler Turbine Hall
GI Sheet
GI Sheet
8550
7560
1500
9828
2992
5757.5
RCC 372
Precast Slab 1048.08
9 Reel Godown
10 Super Calander Area
11 General Stores
12 Capplant
13 Workshop
14 Time office Building
15 Training Hall
16 Bachelor Hostel
17
Drum Pulper & Disc Filter
Build
18 ETP Building
19 New Fuel Shed
GI Sheet
Asbestos
Asbestos
Asbestos
Asbestos
RCC
RCC
RCC
GI Sheet
RCC
GI Sheet
1168.8
421.26
1010.5
705
1008
260
145.2
360
384
168
1704
44942.34
Rain Water
Recharge
Provision
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
%
2.2
0.6
0.3
0.8
2.6
0.9
2.2
1.6
19.0
16.8
3.3
21.9
6.7
12.8
0.8
2.3
0.9
0.4
3.8
Area of Roof-top with
Rain water Recharging
83.2%
34

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
S.No
Recharge
Infrastructure
1 Farm Ponds
2 Percolation Ponds
3 Check Dams
Numbers
Benefit villages
45
9
7
18
9
5
Benefit area
(Acres)
12
161
194
35

160000
140000
120000
100000
80000
60000
40000
20000
10150
0
29076
47128
Cumulative Tree Population
84399
91787 91787
104723
117533
142471
147021 147271

37

KAIZEN – By Water & Waste water Team

39

Benchmarking – Specific Water
Consumption
30
25
20
15
10
5
0
Source: NPC
25
19
9,8
CPCB National
CPCB National ITC Kovai
ITC Kovai

41

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

Awareness on Water Needs to
Stakeholders
45

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

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

Celebration of Water Day
48

Involving Local Community in Tree plantation

•
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
Water Consumption (M3/MT)
9
8
7
12
11
10
16
15
14
13
14,66
2011-12
13,72
2012-13
12,44
2013-14
9,84
7,74
2014-15 2015-16 Plan
• 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

Thank you