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, Hyderabad
A. Padmanabhan, General Manager (Projects) M/s ITC Limited Paperboards & Specialty Papers Division, Unit Bhadrachalam
PSPD
BHADR AC H AL AM
Company profile
PSP D, a Division of ITC Ltd, formed in Apr 2002, by merging group businesses i n Paperboards & Spe cia lty Papers. PSP D co nsist of Unit Bha dra chalam , Unit Kovai, Unit Tribeni, Unit Bollaram , w ith turnover of Rs.2364 Crores duri ng 2007-08. Bhadra chalam tur nover more than is Rs.1200 Cr Unit Bhadra chalam is Indias la rgest single lo cation integrated paperboard compa ny of capa city 4.0 lac TPA. 98% self sufficie ncy in pow er requirement through co-ge neration. ISO 9001:2000, ISO 14001-2004 and OSH AS18001 certification fo r Unit Bhadra chalam are a p roof of Qua lity, Environme nt, Health and Sa fety Systems.
n n
I nvest
Reduct ion by ins t allat ion of pus h t ype but t ons at t oilets t o re du ce 300m 3/d of 2007-08109500 dom es t ic w at er cons um pt ion. Reus e of C aus t icizing CD filt er, com pres s or and pump s ealing w at er 2007-08264000 for log w as hing t o s ave 900m3/d Reus ing of PM -5 lean t ank ex ces s back w at er f or t ow er dilut ion at 2007-08 82500 ble ach e d t ow er s uct ion t o s ave 250m 3/d I nst alled Dis c filt er for PM -5 t op l ayer t o re cycle t he back w at er t o s ave 2007-08 36300 1100m3/d. Reus e of SRB-3 HBL t ank pum ps s ealing w at er as Evaporat or - 3 c oolin g t ow er 2007-08 33000 make u p t o s ave100m3/d.
2.74
0.50
2.2
6.60
11.30
20.5
2.06
11.30
65.7
9.08
105.00
138.80
0.83
1.60
23.3
49500
1.24
1.85
17.9
Reuse of sand f ilter blow down wa ter from TG 5, as make up for TG5 Cooling tower to save 100m3/d
2007-08
33000
0.83
0.65
9.5
Rectif ication of 20 numbers of leakages thro ugh on -line wa ter leaks arresting method in the mill to save 250m3 /d
2007-08
82500
2.06
0.87
5.1
10
Reuse of Evapara tor-4 Pumps sealing wa ter as make up for cooling tower to save 2007-08 450m3/d.
148500
3.71
3.50
11.3
12
2007-08 148500
3.71
4.50
14.5
13
2007-08
82500
2.06
2.50
14.5
14
2007-08 165000
4.13
5.00
14.5
15
Reuse of excess pulp s heeting machine backwater for D1 d ilution screw a t N FL-1 to 2007-08 save 700m3/d for 7 days in a mon th TOTA L
58800
1.47
4.50
36.7
1752300
43.81
159.3
43.60
PSPD
BHADR AC H AL AM
Water savings Savings Investment Payback (m3) (Rs. Lakhs) (Rs. Lakhs) (Months) 579150 2175690 1136800 1752300 5 49 49 44 5 237 52.2 159.3 12 58 13 43.6
PSPD
BHADR AC H AL AM
Even w hen production has more than doubled since last 10 years, fresh w ater intake has increased by only 9% . Achieved majorly by reduction, reuse and recy cli ng appro ach throug h in-ho use efforts and technology route.
PSPD
BHADR AC H AL AM
Consist ent effort s for water conservat ion over a decade t hrough 3R has r esult ed in 51.2% r educt ion in specifi c wat er consumpt ion for decade a nd 21.33% reduct ion in last four years.
PSPD
BHADR AC H AL AM
Global Benchmark
So urce: N at ional Product iv ity Council, New Delhi Final re port o n w at er conserv at ion i n pulp and paper sect or. Table 14: Re gio n/ Co unt ry specific av erage w at er cons umpt ion i n l arge scale w ood base d pulp and paper mills, (Page 48/ 115)
PSPD
BHADR AC H AL AM
(A) Capacity utilization - to reduce specific water consumption - to reduce water usage for non productive purpose (B) Technology up gradation - to reduce fresh water consumption, waste water generation & improve quality of waste water - to built-in water reuse and recycling facilities (C) Employee participation and water audits - water & process mapping to identify opportunities - to reduce wastage and losses - to create awareness & update with latest water conservation techniques and products
PSPD
BHADR AC H AL AM
PSPD
BHADR AC H AL AM
As per CRE P (Corporat e Res po nsibility for Env ironme nt al Prot ect ion) propose d by MoEF and CPCB max imum li mit is 10 0 kiloliter per tonne
PSPD
BHADR AC H AL AM
CREP: Corporat e Res pons ibilit y for Environment Prot ect ion ( CREP) by M oEF, * Nat ional Product ivit y Council, New Delhi
PSPD
BHADR AC H AL AM
Adsorbable Organic Halides (AOX) in the treated waste water hav e been reduced to 0.011 Kg/ton of production during 2007-08
AOX (Kg/ Tonn e) Bhadrachalam Mill Indian Paper/Paperboards Mills* European Paper Industrie s# World Bank Standard** 0.011 0.46-0.8
0.03 0.2
*Average as per C ompreh ensi ve I ndust ry Document for Large S cal e P aper M ills, st udy con du ct ed by Cent ral Pulp & P aper R ese arch I nst it ut e, 2007 I # CEPI ( Confeder at ion of European P aper I ndust ries,) Sust ainabilit y Report 2007 I **W orld Bank Gui deline f or New Paper M ills.
PSPD
BHADR AC H AL AM
PSPD
BHADR AC H AL AM
Trigger:
- Water consum ption per ton of blea ched pulp is 25m3/t ( cooking & fiberline only) is high compared to international stand ards. - Color in pulp mill efflue nt - M ax imize utilization of effl uent w ater for irrigation Ana lysis: - Ozone b leaching is effe ctive at high(35% - 40%) consistency presses Action: First installation in India w ith O2 generation plant, Ben efits: - Guara nteed w ater consumption is 15m3/t - Reduction in color of p ulp mill effluent by 50%. - Reduction in AOX to 0.1 to 0.01kg/ton. - ClO2 co nsumption reduced by 50%
PSPD
BHADR AC H AL AM
Trigg er: - Once thro ugh seal ing w ater for evaporator vacuum pumps d ue to fouling of seali ng w ater - Evaporator cooling tow er blow dow n is drained to control COC Ana lysis: Blow dow n w ater is not fit for reuse in vacuum p umps seali ng purpose due to high TDS. Need for chemi ca l treatment for blow dow n w ater to pass through va cuum pumps for se aling p urpose Ben efit: -Chemical treatment of blow dow n w ater at inlet of vacuum pumps and dra ining after usage - Reduction of 500m3/d of fresh w ater consumption fo r sealing.
PSPD
BHADR AC H AL AM
Trigg er: - Sp w ater consumption is hig h for paper machine due to variation in product mix - Backw ater not fit for reuse due to high fiber a nd filler co ntent Ana lysis: -ClariDis c filter fo und s uitable for recycling of b a ck w ater for reuse in machine . - Filter produces super clear, cle ar and cloudy filtrate to be used for specific a pplication. Ben efit: - Recy cling o f 1000m3/d of ba ck w ater (capa city is 3000m3/d) - Recovery of fiber by using cloudy filtrate at tow er dilution purpose
PSPD
BHADR AC H AL AM
PSPD
BHADR AC H AL AM
M onitoring & Reporting: 4 M onitoring on shift basis , pro cess pla nt drains le ading to ETP to monitor discharge of efflue nt w ater and chara cteristics. 4 Water audits are carried out annually through ex perts. 4 Water balance carried out on mo nthly basis , department w ise. 4 Capital and revenue b udget to for audits and im plementation of proposals. 4 Water flow meters at w ater intake and dis cha rge are regul arly calibrated as per ISO s che dule 4 IMIS reports for daily and monthly cons umption and dis cha rge. 4 M onthly review against the norms for improvement
PSPD
BHADR AC H AL AM
Thank You