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Water Audit in Industry – CII’s Perspective June 22 2011 Pranab Dasgupta

Water Audit in Industry – CII’s Perspective June 22 2011 Pranab Dasgupta. National Seminar on “Standards for Quality and Empowerment” Directorate of Standardization MOD Dept of Defense Production New Delhi. Agenda for today’s presentation. Water Audit – Introduction & key drivers

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Water Audit in Industry – CII’s Perspective June 22 2011 Pranab Dasgupta

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  1. Water Audit in Industry – CII’s PerspectiveJune 22 2011Pranab Dasgupta National Seminar on “Standards for Quality and Empowerment” Directorate of StandardizationMODDept of Defense ProductionNew Delhi

  2. Agenda for today’s presentation • Water Audit – Introduction & key drivers • Standardization and Benchmarking • Approach and Methodology supported with case study • Water Audit in building • Monitoring & Reporting • Typical Scope of Water Savings • Report Card – CII Water Audit Program • How to scale up Water Audit • Introduction to CII Triveni Water Institute • Business Communication

  3. 8 Keys to Successful Water Management -water audit being a core component WATER AUDIT reqd Steps 3-8 • Integrated Approach • Address both Technical + Human side • Accurate baseline data • Logical sequence –implementation in phases • Not only how much water but how it is used • Quality versus Application matching • Considering True Cost of Water • Understanding Life Cycle Cost

  4. Water Audit – Core Element of Water Management Program • A Water Audit is a “Systematic Approach of Identifying, Measuring, Monitoring and Reducing the Water Consumption by various activities in an Industry” • Why Water Audit ? • One should know exactly how the water is being used in his premises prior to planning any water management program.

  5. Key Drivers of Water Audit Legal Requirement AP, TN, Karnataka, Gujarat, Maharashtra CREP (Corporate Responsibility for Environmental Protection) – 17 industry sec Water stress regions – Availability / Quality Corporate image Business risk involved - Sustainability Payback options in places of high water tariff for industry

  6. Standardization and Benchmarking Industry are continuously minimizing their water footprint thus setting standards for SPECIFIC WATER CONSUMPTION in their units. Objective is to match National and International Benchmarks established in each of the sector

  7. Examples on Specific Water Consumption Pursuing to match or even parallel with national and international benchmarks

  8. Binani Cement

  9. Binani Cement - continue

  10. Vehicles Manufacturing – 2007-08

  11. Paper industry - Sripathi Sivakasi 2007-08

  12. JK Tyre & Industries Ltd 2007-08

  13. Steel industry - Vizak Steel 2007-08

  14. Chemicals – TATA Chemicals

  15. Approach to Water Audit in Industry • Starts with Training and Awareness • Inculcating water saving thoughts within the employees • Establishment of Water Balance within the premises • Application of 3 R’s principle – Reduce, Reuse and Recycle • Monitoring & Reporting to Sustain the Benefits

  16. Training and Awareness – sample sheet Water Loss One drop/second Hourly loss 0.5 litres Annual loss 5 m3 Min. Annual water only cost Rs. 7.5 Union Flange Water Loss 0.1 litres/minute Hourly loss 6 litres Annual loss 53 m3 Min. Annual water only cost Rs. 80 Valve Water Loss 0 - 4 litres/minute Hourly loss 0 - 240 litres Annual loss 0 - 2100 m3 Min. Annual water only cost Rs. 0 - 3150 Pump shaft seal

  17. Water Mass Balance

  18. Borewell Pumps – 3800 kLD Fire Hydrant Drinking/ Process Water 3790 kLD ProcessWater Drinking Water Industrial Cooling/ Process – 2450 kLD Domestic – 1340 kLD Sand Filter 838 1730 DM Plant 270 Softener 450 327 175 Canteen – 180 SMD Toilets – 113 PMD Toilets – 120 colony – 411 AC Cooling Tower – 465 Admin – 14 DG Cooling Tower – 533 Air Washer CTS – 359 Vac Pump, Blower & Air Comp – 33 PMD Process –373 Air Washer SMD – 105 Backwash – 50 PMD Cleaning – 110 Dust & Odor – 202 Unmetered – 327 Boiler - PMD Humiduct

  19. Example: M&M Nashik Plant

  20. Water Management Approach # 4 Reduce at Source(How much water is really required?)

  21. Reduction at Source Better operating controls Installation of water saving devices Change of device/ equipment Process modification Few case studies are discussed herewith

  22. Suggested action plan Immediately avoid use of hydrant water for other applications Safety aspects Mandatory requirement Create awareness amongst Plant personnel Contractors & suppliers Introduce Work permit system for FH water usage Continuous monitoring required Good potential to save process water Atleast 50 m3/h or 1200 m3/day Case Study 1 Avoid use of fire hydrant system for miscellaneous applications

  23. Case Study 2 Water use in rinsing section Before Components Fresh Water Fresh Water To ETP To ETP • 30 m3/day • pH -5.0, TDS-900 • 30 m3/day • pH -6.5, TDS-100 Fresh Water Consumption = 70 m3/day Excellent potential to reuse 2nd stage rinse water in 1st stage rinsing

  24. Reuse 2nd stage rinse as I rinse After Components Fresh Water To ETP Fresh Water Saving = 30 m3/day

  25. Benefits • Water Saving • 9000 m3/yr • Annual savings = Rs.1.50 Lakhs • Investment = Nil • Payback period = Immediate

  26. Case Study 3 Optimize pump gland seal water consumption in the plant Approach for optimization Throttle the individual valves Alternatively, further reduce the line size As a long term option Install a closed loop seal water circulation system Provide dedicated cooling towers Individual plants – Can be combined where feasible Industry best practice For mechanical seals “Smartflow” intelligent control system – Safematic Inc. Allows water only when cooling is required

  27. Case Study 3 -continue Water Savings = 4,95,000 m3/yr Annual savings = Rs.9.90 lakhs Investment reqd = Nil • Benefits • Atleast 15% fresh water savings in gland seals • Fresh water savings ~ 1500 m3/day • Continuous awareness and monitoring required • Sustain the benefits achieved

  28. Water Management Approach # 5 Recycle and Reuse

  29. USES OF RECYCLED WATER LOW END APPLICATIONS Toilet flushing Gardening Floor washing HIGH END APPLICATIONS Boiler feed Cooling water make-up Process water

  30. Recommendations WTP Filtration Cycle Collect filter back wash only In Chamber (in Man hole) Install tube settler Treat & recycle In Raw Water Tank STP Filtration Cycle Collect all Back wash water in a collection sump MGF ACF Sand Filters (2 Nos) Input as feed to R.O Use for Beneficial applications - CT Make up / Gardening Case Study 1 Reuse of Filter Backwash Water in Beneficial Application

  31. Benefits WTP Filtration Cycle • Water Saving • 50 m3/day • Annual Water Savings - 18250 m3 /annum • Annual Cost Savings - Rs. 6.0 lakhs • Investment - Rs. 3 Lakhs • Payback - 6 months STP Filtration Cycle • Water Saving • 40 m3/day • Annual Water Savings - 14600 m3 /annum

  32. Seal water consumption 11 vacuum pumps ~ 50 m3/h Seal water drained to ETP Fresh water being used for refiner seal 8 refiners ~ 40 m3/h Both water drained to ETP Equivalent fresh water consumed Case Study 2 Install a cooling tower for vacuum pump seal water and refiner seal water in paper machine

  33. Case study 2 - continue Fresh water header Refiner seal water – 8 nos. M/c backwater Fresh water makeup Vacuum Pump seal water 11 nos. Clarified water tank Cooling tower

  34. Drained seal water quality tested in lab Vacuum pump - Same as inlet fresh water Refiner - Same as inlet fresh water Lab tests conducted by plant team Oil & grease ~ BDL Good potential to install a cooling tower system for seal water Recirculate after cooling Fresh water only for cooling tower make-up Good potential to reduce fresh water consumption ~ 80 m3/h or 1920 m3/day Case study 2 - continue

  35. Water savings = 6,33,600 m3/yr Annual Savings = Rs.12.67 lakhs Investment reqd. = Rs.8.00 lakhs Simple payback = 8 months Case study 2 - Install a cooling tower for vacuum pump seal water and refiner seal water in paper machine

  36. Case Study 3 Treated Domestic Water Reuse Colony domestic wastewater Generation - 1000 m3/day Discharged outside after treatment Treated domestic water characteristic Treated domestic water • pH – 7.2 • Conductivity - 500 ppm • Turbidity – 10 NTU • BOD < 10 ppm • COD < 50 ppm Process water • pH – 7.4 • Conductivity - 400 ppm • Turbidity < 15 NTU • COD < 50 ppm Good Potential for reuse as DM Plant feed

  37. Treated Sewage Reuse Scheme Raw Sewage Existing treatment scheme Additional treatment scheme Bar Screen Chamber Sewage Collection Tank Aeration tank Tube settler Air Blower Sludge drying Beds Garden / DM Plant Clarifier Chlorine Dosing

  38. Case study 4 -Treated Wastewater Reuse Scheme pH-7.2 TSS < 700 ppm COD < 1000 ppm TDS < 800 ppm Paper stream Inlet Collection sump Aeration tank Secondary Clarifier SC1 Primary Clarifier PC2 pH-7.5 TSS < 60 ppm COD < 80 ppm TDS < 800 ppm Sludge re-circulation pumps Micron Filter Pressure Sand filter Clarified Water Tank Activated Carbon Filter Treated wastewater to process RO Filter Feed Pumps pH-6.8-7.2 TSS < Nil COD < 30 ppm TDS < 50 ppm High Pressure pump Chlorine Dosing

  39. Benefits • Water Saving • 1000 m3/day • 3,30,000 m3/annum • Annual Savings - Rs 6.60 Lakhs • Investment - Rs 15.00 Lakhs • Payback - 27 months

  40. Case Study 4 Blow Down Optimization in Boiler • Soda Recovery Boiler • Operating at ~ 90 TPH, 63.5 ata & 450oC • Online Conductivity meter installed • 30 mS maintained in boiler drum • Present blow down ~ 4.5% • Low conductivity maintained • Recommend to increase conductivity in steps • Maintain 80 mS in line with CFB • DM Water Saving ~ 1.8 m3/h

  41. Water Audit in building On-site survey and assessment of Water using hardware, fixtures, equipment, landscaping To develop recommendations for improving water use efficiency Typical Water Consumption Pattern in Building Cooling tower 30% Leakages 25% Domestic 40% Others 5% -(Irrigation & landscaping /Vehicle cleaning)

  42. Electronic wash system Electronic hand wash Saves up to 70% water in hand wash Handles high TDS up to 1800 ppm Foam spray taps Saves up to 40% water in handwash

  43. Electronic flush system Electronic urinal flush Saves up to 40% water in flush Handles high TDS up to 1800 ppm Flush System

  44. Water less Urinals 100% Water Savings

  45. Rain Water Harvesting

  46. Grey Water Recycling • 140 lit/day of fresh water For Washing and Cleaning

  47. Water Management Approach # 5 Monitoring and Reporting

  48. MONITORING Monitor daily, monthly, yearly Institute specific format Introduce as a part of log sheet

  49. Ashok Leyland – Monitoring and Reporting System

  50. Typical Scope of Water Savings – Ex: Hindustan National Glass & Industries Limited, Nashik

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