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National Seminar on “Standards for Quality and Empowerment” Directorate of Standardization MOD Dept of National Seminar on “Standards for Quality and Empowerment” Directorate of Standardization MOD Dept of Defense Production New Delhi Water Audit in Industry – CII’s Perspective June 22 2011 Pranab Dasgupta © Confederation of Indian Industry

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

8 Keys to Successful Water Management water audit being a core component 1. Integrated 8 Keys to Successful Water Management water audit being a core component 1. Integrated Approach 2. Address both Technical + Human side 3 Accurate baseline data 4 Logical sequence –implementation in phases 5 Not only how much water but how it is used 6 Quality versus Application matching 7 Considering True Cost of Water 8 Understanding Life Cycle Cost © Confederation of Indian Industry WATER AUDIT reqd Steps 3 -8

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

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

Standardization and Benchmarking Industry are continuously minimizing their water footprint thus setting standards for 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 © Confederation of Indian Industry

Examples on Specific Water Consumption Pursuing to match or even parallel with national and Examples on Specific Water Consumption Pursuing to match or even parallel with national and international benchmarks © Confederation of Indian Industry

Binani Cement © Confederation of Indian Industry Binani Cement © Confederation of Indian Industry

Binani Cement - continue © Confederation of Indian Industry Binani Cement - continue © Confederation of Indian Industry

Vehicles Manufacturing – © Confederation of Indian Industry 2007 -08 Vehicles Manufacturing – © Confederation of Indian Industry 2007 -08

Paper industry - Sripathi Sivakasi 2007 -08 © Confederation of Indian Industry Paper industry - Sripathi Sivakasi 2007 -08 © Confederation of Indian Industry

JK Tyre & Industries Ltd © Confederation of Indian Industry 2007 -08 JK Tyre & Industries Ltd © Confederation of Indian Industry 2007 -08

Steel industry - Vizak Steel 2007 -08 © Confederation of Indian Industry Steel industry - Vizak Steel 2007 -08 © Confederation of Indian Industry

Chemicals – TATA Chemicals © Confederation of Indian Industry Chemicals – TATA Chemicals © Confederation of Indian Industry

Approach to Water Audit in Industry 1. Starts with Training and Awareness 2. Inculcating Approach to Water Audit in Industry 1. Starts with Training and Awareness 2. Inculcating water saving thoughts within the employees 3. Establishment of Water Balance within the premises 4. Application of 3 R’s principle – Reduce, Reuse and Recycle 5. Monitoring & Reporting to Sustain the Benefits © Confederation of Indian Industry

Training and Awareness – sample sheet One drop/second 0. 5 litres 5 m 3 Training and Awareness – sample sheet One drop/second 0. 5 litres 5 m 3 Rs. 7. 5 Water Loss Hourly loss Annual loss Min. Annual water only cost 0. 1 litres/minute 6 litres 53 m 3 Rs. 80 Water Loss Hourly loss Annual loss Min. Annual water only cost Union Water Loss Hourly loss Annual loss Min. Annual water only cost 0 - 4 litres/minute 0 - 240 litres 0 - 2100 m 3 Rs. 0 - 3150 Flange Valve Pump shaft seal © Confederation of Indian Industry

Water Mass Balance © Confederation of Indian Industry Water Mass Balance © Confederation of Indian Industry

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

Example: M&M Nashik Plant © Confederation of Indian Industry Example: M&M Nashik Plant © Confederation of Indian Industry

Water Management Approach # 4 Reduce at Source (How much water is really required? Water Management Approach # 4 Reduce at Source (How much water is really required? ) © Confederation of Indian Industry

Reduction at Source v Better operating controls v Installation of water saving devices v Reduction at Source v Better operating controls v Installation of water saving devices v Change of device/ equipment v Process modification Few case studies are discussed herewith © Confederation of Indian Industry

Case Study 1 Avoid use of fire hydrant system for miscellaneous applications v Suggested Case Study 1 Avoid use of fire hydrant system for miscellaneous applications v Suggested action plan Ø Immediately avoid use of hydrant water for other applications q Safety aspects q Mandatory requirement Ø Create awareness amongst q Plant personnel q Contractors & suppliers Ø Introduce Work permit system for FH water usage Ø Continuous monitoring required v Good potential to save process water Ø Atleast 50 m 3/h or 1200 m 3/day © Confederation of Indian Industry

Case Study 2 Water use in rinsing section Before Components Fresh Water To ETP Case Study 2 Water use in rinsing section Before Components Fresh Water To ETP 30 m 3/day p. H -5. 0, TDS-900 To ETP 30 m 3/day p. H -6. 5, TDS-100 Fresh Water Consumption = 70 m 3/day Excellent potential to reuse 2 nd stage rinse water in 1 st stage rinsing © Confederation of Indian Industry

Reuse 2 nd stage rinse as I rinse After Components Fresh Water To ETP Reuse 2 nd stage rinse as I rinse After Components Fresh Water To ETP Fresh Water Saving = 30 m 3/day © Confederation of Indian Industry

Benefits v Water Saving Ø 9000 m 3/yr v Annual savings = Rs. 1. Benefits v Water Saving Ø 9000 m 3/yr v Annual savings = Rs. 1. 50 Lakhs v Investment = Nil v Payback period = Immediate © Confederation of Indian Industry

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

Case Study 3 -continue v Benefits Ø Atleast 15% fresh water savings in gland Case Study 3 -continue v Benefits Ø Atleast 15% fresh water savings in gland seals q Fresh water savings ~ 1500 m 3/day v Continuous awareness and monitoring required Ø Sustain the benefits achieved Water Savings = 4, 95, 000 m 3/yr Annual savings = Rs. 9. 90 lakhs Investment reqd = Nil © Confederation of Indian Industry

Water Management Approach # 5 Recycle and Reuse © Confederation of Indian Industry Water Management Approach # 5 Recycle and Reuse © Confederation of Indian Industry

USES OF RECYCLED WATER v LOW END APPLICATIONS 8 Toilet flushing 8 Gardening 8 USES OF RECYCLED WATER v LOW END APPLICATIONS 8 Toilet flushing 8 Gardening 8 Floor washing v HIGH END APPLICATIONS 8 Boiler feed 8 Cooling water make-up 8 Process water © Confederation of Indian Industry

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

Benefits WTP Filtration Cycle v Water Saving Ø 50 m 3/day v Annual Water Benefits WTP Filtration Cycle v Water Saving Ø 50 m 3/day v Annual Water Savings - 18250 m 3 /annum v Annual Cost Savings - Rs. 6. 0 lakhs v Investment - Rs. 3 Lakhs v Payback - 6 months STP Filtration Cycle v Water Saving Ø 40 m 3/day v Annual Water Savings - 14600 m 3 /annum © Confederation of Indian Industry

Case Study 2 Install a cooling tower for vacuum pump seal water and refiner Case Study 2 Install a cooling tower for vacuum pump seal water and refiner seal water in paper machine v Seal water consumption Ø 11 vacuum pumps ~ 50 m 3/h Ø Seal water drained to ETP v Fresh water being used for refiner seal Ø 8 refiners ~ 40 m 3/h v Both water drained to ETP Ø Equivalent fresh water consumed © Confederation of Indian Industry

Case study 2 - continue Fresh water header Refiner seal water – 8 nos. 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 © Confederation of Indian Industry

Case study 2 - continue v Drained seal water quality tested in lab Ø Case study 2 - continue v Drained seal water quality tested in lab Ø Vacuum pump - Same as inlet fresh water Ø Refiner - Same as inlet fresh water v Lab tests conducted by plant team Ø Oil & grease ~ BDL v Good potential to install a cooling tower system for seal water Ø Recirculate after cooling Ø Fresh water only for cooling tower make-up v Good potential to reduce fresh water consumption Ø ~ 80 m 3/h or 1920 m 3/day © Confederation of Indian Industry

Case study 2 - Install a cooling tower for vacuum pump seal water and Case study 2 - Install a cooling tower for vacuum pump seal water and refiner seal water in paper machine Water savings = 6, 33, 600 m 3/yr Annual Savings = Rs. 12. 67 lakhs Investment reqd. = Rs. 8. 00 lakhs Simple payback = 8 months © Confederation of Indian Industry

Case Study 3 Treated Domestic Water Reuse v Colony domestic wastewater Ø Generation - Case Study 3 Treated Domestic Water Reuse v Colony domestic wastewater Ø Generation - 1000 m 3/day Ø Discharged outside after treatment v Treated domestic water characteristic Treated domestic water Ø p. H – 7. 2 Ø Conductivity - 500 ppm Ø Turbidity – 10 NTU Ø BOD < 10 ppm Ø Process water COD < 50 ppm Ø p. H – 7. 4 Ø Conductivity - 400 ppm Ø Turbidity < 15 NTU Ø COD < 50 ppm Good Potential for reuse as DM Plant feed © Confederation of Indian Industry

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

Case study 4 -Treated Wastewater Reuse Scheme Paper stream p. H-7. 2 TSS < Case study 4 -Treated Wastewater Reuse Scheme Paper stream p. H-7. 2 TSS < 700 ppm Inlet COD < 1000 ppm TDS < 800 ppm Collection sump Primary Clarifier PC 2 Secondary Clarifier SC 1 Aeration tank p. H-7. 5 TSS < 60 ppm COD < 80 ppm TDS < 800 ppm Sludge re-circulation pumps Treated wastewater to process p. H-6. 8 -7. 2 TSS < Nil COD < 30 ppm TDS < 50 ppm RO Micron Filter High Pressure pump Activated Carbon Filter Pressure Sand filter © Confederation of Indian Industry Clarified Water Tank Filter Feed Pumps Chlorine Dosing

Benefits v Water Saving Ø 1000 m 3/day Ø 3, 30, 000 m 3/annum Benefits v Water Saving Ø 1000 m 3/day Ø 3, 30, 000 m 3/annum v Annual Savings - Rs 6. 60 Lakhs v Investment - Rs 15. 00 Lakhs v Payback - 27 months © Confederation of Indian Industry

Case Study 4 Blow Down Optimization in Boiler v Soda Recovery Boiler Ø Operating Case Study 4 Blow Down Optimization in Boiler v Soda Recovery Boiler Ø Operating at ~ 90 TPH, 63. 5 ata & 450 o. C Ø Online Conductivity meter installed Ø 30 m. S maintained in boiler drum v Present blow down ~ 4. 5% Ø Low conductivity maintained v Recommend to increase conductivity in steps Ø Maintain 80 m. S in line with CFB Ø DM Water Saving ~ 1. 8 m 3/h © Confederation of Indian Industry

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

Electronic wash system v Electronic hand wash Ø Ø v Saves up to 70% Electronic wash system v Electronic hand wash Ø Ø v Saves up to 70% water in hand wash Handles high TDS up to 1800 ppm Foam spray taps Ø Saves up to 40% water in handwash © Confederation of Indian Industry

Electronic flush system v Electronic urinal flush Ø Saves up to 40% water in Electronic flush system v Electronic urinal flush Ø Saves up to 40% water in flush Ø Handles high TDS up to 1800 ppm © Confederation of Indian Industry Flush System

Water less Urinals 100% Water Savings © Confederation of Indian Industry Water less Urinals 100% Water Savings © Confederation of Indian Industry

Rain Water Harvesting © Confederation of Indian Industry Rain Water Harvesting © Confederation of Indian Industry

Grey Water Recycling 140 lit/day of fresh water For Washing and Cleaning © Confederation Grey Water Recycling 140 lit/day of fresh water For Washing and Cleaning © Confederation of Indian Industry

Water Management Approach # 5 Monitoring and Reporting © Confederation of Indian Industry Water Management Approach # 5 Monitoring and Reporting © Confederation of Indian Industry

MONITORING Monitor daily, monthly, yearly Institute specific format Introduce as a part of log MONITORING Monitor daily, monthly, yearly Institute specific format Introduce as a part of log sheet © Confederation of Indian Industry

Ashok Leyland – Monitoring and Reporting System © Confederation of Indian Industry Ashok Leyland – Monitoring and Reporting System © Confederation of Indian Industry

Typical Scope of Water Savings – Ex: Hindustan National Glass & Industries Limited, Nashik Typical Scope of Water Savings – Ex: Hindustan National Glass & Industries Limited, Nashik Water Saving Activity Annual Water Saving m 3 Blow down water from cooling tower is treated in STP and used in gardening -2009 Reusing treated water from STP in Cullet washing All underground lines were replaced with overhead lines to minimize unidentified 31025 7200 91250 losses Recirculation of glass gob cooling water 21900 New pit for collection and recirculation to and 29200 from cullet washers Installation of cooling tower to eliminate fresh water usage for the hot cullet scraper during heavy draining of gobs © Confederation of Indian Industry 11880

Report Card – CII Water Audit v Water audits & Training Ø 45 audits Report Card – CII Water Audit v Water audits & Training Ø 45 audits and training till date Ø 2 companies facilitated for ‘Zero Water Discharge’ q. Godrej Industries Ltd, Valia q. ITC Ltd, Munger Annual Water Savings Equivalent Annual Cost Savings (Rs (m 3/year) Lakhs/year) Identified 18 million 1255. 00 Achieved* 4. 0 million 150. 00 (till date) * Balance under implementation © Confederation of Indian Industry

What Next ? Scaling up of Water Audit !! 1. Water Foot Printing in What Next ? Scaling up of Water Audit !! 1. Water Foot Printing in Industry 2. Blue Rating of products / organizations © Confederation of Indian Industry

CII – Triveni Water Institute The first of its kind in the world (Government, CII – Triveni Water Institute The first of its kind in the world (Government, Industry, Civil Society coming together) Jaipur, Rajasthan Bangalore © Confederation of Indian Industry New Delhi Pune

National & International Partners v National Ø State and Central Government v International Partners National & International Partners v National Ø State and Central Government v International Partners Ø Water Industry Alliance, South Australia Ø Cleantech, Switzerland Ø IFC, USAID, Netherlands, Israel – Expressed interest © Confederation of Indian Industry

CII Water Activities Education & Training Information Dissemination Centre including Publications CII Triveni Water CII Water Activities Education & Training Information Dissemination Centre including Publications CII Triveni Water Institute Advisory Services Events & Award Programs © Confederation of Indian Industry

Business Communication v S Raghupathy - Executive Director Email: s. raghupathy@cii. in v K Business Communication v S Raghupathy - Executive Director Email: s. raghupathy@cii. in v K S Venkatagiri – Principal Counsellor Email: k. s. venkatagiri@cii. in v Pranab Dasgupta – Senior Counsellor Email: pranab. dasgupta@cii. in THANK YOU © Confederation of Indian Industry