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RCMS: Business Advisory Services Sharpening your competitive edge

Joint Director FICCI - Resource Conservation & Management Group


Email: bob.johnthomas69@gmail.com

John Thomas

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

Some Statistics .

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

How much water goes in to produce ..


1) A cup of coffee ? 2) 1 kg of Wheat ?

RCMS: Business Advisory Services Sharpening your competitive edge

2006 UNESCO-IHE and University of Twente.

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

1. VIRTUAL WATER

2. WATER FOOTPRINT

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The virtual water concept


VIRTUAL WATER content of a product: is the volume of water used to produce the product, measured at the place where the product was actually produced (production site specific definition) OR where the product is consumed (consumption site specific definition).
The adjective virtual refers to the fact that most of the water used to produce a product is in the end not contained in the product. The real water content of products is generally negligible if compared to the virtual water content.

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National Virtual Water Balances


(related to the international trade of products)
Period 1997-2001.

Net exporters are shown in GREEN and Net importers in RED.

2006 UNESCO-IHE and University of Twente.

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Regional virtual water balances and net interregional virtual water flows related to the trade in agricultural products.
Period: 1997-2001

2006 UNESCO-IHE and University of Twente.

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Applications of Virtual Water Concept


National Water saving A nation can save its domestic water resources by importing a water-intensive product rather than produce it domestically. Global Water saving International trade can save water globally if a water-intensive commodity is traded from an area where it is produced with high water productivity (resulting in products with low virtual water content) to an area with lower water productivity.

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The water footprint concept was introduced in 2002 by Arjen Hoekstra in analogy to the well known concept of ecological footprint'.

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The WATER FOOTPRINT Concept


The Water Footprint of an individual, business or nation is defined as the total volume of fresh water that is used to produce the foods and services consumed by the individual, business or nation. A water footprint is generally expressed in terms of the volume of water use per year.

Individual Water footprint


The water footprint of an individual is defined as the total water used for the production of the goods and services consumed by the individual. It can be estimated by multiplying all goods and services consumed by their respective virtual water content.

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Nation's Water footprint


The water footprint of a nation is defined as the total amount of water that is used to produce the goods and services consumed by the inhabitants of the nation.

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The national water footprint can be assessed in two ways.


1. Bottom Up Approach

2. Top-down Approach

1. The bottom-up approach is to consider the sum of all goods and services consumed multiplied with their respective virtual water content. It should be noted that the virtual water content of one particular consumption good can vary as a function of the place and conditions of production. 2. In the top-down approach, the water footprint of a nation can be calculated as the total use of domestic water resources plus the net virtual water import.

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

2006 UNESCO-IHE and University of Twente.

RCMS: Business Advisory Services Sharpening your competitive edge

Part - II

Joint Director FICCI - Resource Conservation & Management Group


Email: john.thomas@ficci.com

John Thomas

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

RCMS: Business Advisory Services Sharpening your competitive edge

The World's Water Hotspots

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RCMS: Business Advisory Services Sharpening your competitive edge

Water Consumption by Industries


Characteristics:
Supplied: By Others OR Self supplied Source: Surface Water OR Ground Water Amount of Use Rate of Use Efficiency of Use Applications Type of Water used (Quality) Product / Process Cooling (Process / Env HVAC) Conveyance Rinsing & Cleaning Landscape Irrigation

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RCMS: Business Advisory Services Sharpening your competitive edge

WATER AUDIT & CONSERVATION SERVICES

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Water Audit Services


Objective
Promote efficient Water Utilization, Conservation & Management Reduce Operating Costs Reduce industrial water use per unit of production

Promote Corporate Social Responsibility

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DRIVING FORCES FOR WATER MANAGEMENT


POOR AVAILABILITY OR NON-AVAILABLITY OF WATER HIGH COST OF WATER RESTRICTION ON DISPOSAL TO ANY RECEIPIENT MEDIA COST OF PUMPING < COST OF FILTERED WATER FROM WTP < COST OF SOFTENED WATER < COST OF DEMINIRALISED WATER < COST OF RO WATER

THIS SCENARIO VERSUS COST OF WATER WILL DICTATE ACHIEVABILITY OF NEAR ZERO DISCHARGE

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HOW DO WE GO ABOUT IN CONDUCTING WATER AUDITING?

A SOURCE TO SINK examination of water management is essential


i.e. Assessment of 1. Water Resource Availability 2. Storage systems & practices 3. Current Water Treatment practices 4. Distribution System & its associated loss 5. Process usage patterns 6. Internal reuse & recycle avenues 7. Wastewater treatment and final disposal 8. Value added usage, if any. IN SHORT WATER AUDIT MUST BE BOTH FOR: - Water Quantity, and Water Quality

WATER QUANTITY & QUALITY AUDIT

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FACETS OF WATER RESOURCE MANAGEMENT


RESOURCE CREATION RESOURCE CONSERVATION RESOURCE QUALITY MANAGEMENT RESOURCE REUSE, RECYCLE & RECLAIM RESOURCE PRICING

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WATER AUDIT METHODOLOGY


Plan & Organise Walk Through Survey Primary Data Collection Process Flow Diagram, Water Utility Diagram

Conduct Survey & Monitoring- Internal team formation and external facilitation for monitoring & measurement of key sources, water balance assessment etc.
Water Sampling & Analysis at various stages for relevant parameters

Analysis of Water Use - Evolution of innovative strategies for Water Conservation, reuse & recycle, alternate sourcing, crosssectoral recycle practice etc
Identification opportunities of Water Conservation (WATCON)

Cost-Benefit Analysis of WATCON opportunities


Preparation of Action Plan Reporting & Presentation Assist in implementation of WATCON recommendations

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Pre-audit Activity
Collect base line data relevant to the study P&I diagram Operation manual Water Balance Quality and quantity for each end use. Established industrial norms for consumption of water . Historical data - failure analysis

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Essential ingredients of Water audit


Water consumption Install water meters for measurement of water consumption at each location. Establish industry norms for consumption of water for each application. Identify areas (equipments, processes & practices) of excess consumption.

Eliminate the root cause and implement


systems to reduce water consumption.

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Address following questions:


1) How much water is being used? 2) Where is the water being used? 3) When and for how long is water being used? 4) How is water being used? 5) Who is using water? 6) Why is water being used? 7) Do we need to be using water at all? 8) Can the water quality of a process discharge be matched with the water quality of another process or equipment need?

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Essential ingredients of Water audit


Water quality Assess the correct quality of water required for each application. Provide adequate instrumentation to monitor the desired water quality parameters;Calibrate them at regular intervals. Review input parameters at periodic intervals and correct operational parameters to produce the right quality of water at all times.

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Essential ingredients of Water audit


Operating costs Assess the present cost of treating water. Power,chemicals for treatment of water & waste water, replacement of media. Modify process parameters based on changed input parameters. Retrofit/refurbish in case of drastic changes in input conditions.

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Analysis & Implementation Plan


Cost Effectiveness Analysis
process or practice change

- for each type of equipment,

Identify Water Efficiency Opportunities (WEO) that are cost-effective. If NOT Cost-Effective, WEO may still be implemented
due to high visibility, ease of implementation, or general employee, customer and community goodwill. Develop an Action Plan.

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PROCESS SELECTION

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The National Water Conservation Rating and Labelling Scheme


Products can be rated as indicated in the labels below

1A

2A

3A

4A

5A

The more 'As' the more water efficient the product is.
Ref. Australian/New Zealand Standard AS/NZS6400 Water efficient products Rating and labelling

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WATER AUDITS: POTENTIAL BENEFITS Reduction in specific water consumption. Reduced Pumping/ Distribution & Treatment costs Better Utilization of Water within the plant
- through Reuse, Recycling

Reduced consumption/wastage of other raw materials


- process cost / production cost

Reduction in effluent generation Reduced Waste Water / Effluent Treatment Cost


- land, capital, chemicals, energy and labor costs

Better Public Image Reduced incidence of production losses due to increased water availability.

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Water Balance - Drinking Water Utilities


Billed Authorized Consumption Unbilled Billed Metered Consumption (including water exported)

Authorized Consumption

Billed Unmetered Consumption


Unbilled Metered Consumption Unbilled Unmetered Consumption Unauthorized Consumption

Revenue Water

System Input Volume


(corrected for known errors)

Authorized Consumption Apparent Losses

Customer Metering Inaccuracies Data Handling Errors

NonRevenue Water
(NRW)

Water Losses

Leakage on Transmission and Distribution Mains Real Losses Leakage and Overflows at Utility's Storage Tanks Leakage on Service Connections up to point of Customer metering
Copyright 2006 American Water Works Association

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Performance Indicators for Non-revenue Water and Water Losses


Performance Indicator
Volume of Non-revenue water as a percentage of system input volume Volume of Non-revenue water as a percentage of the annual cost of running the water system Volume of Apparent Losses per service connection per day

Function
Financial - Non-revenue water by volume Financial - Non-revenue water by cost Operational - Apparent Losses Inefficiency of use of water resources Operational: Real Losses
UARL (gallons/day) = (5.41Lm + 0.15Nc + 7.5Lp) x P

Comments
Can be calculated from a simple water balance; good only as a general financial indicator Allows different unit costs for Nonrevenue water components Basic but meaningful indicator once the volume of apparent losses has been calculated or estimated Unsuitable for assessing efficiency of management of distribution systems Good operational performance indicator for target-setting for real loss reduction A theoretical reference value representing the technical low limit of leakage that could be achieved if all of today's best technology could be successfully applied. A key variable in the calculation of the Infrastructure Leakage Index (ILI) It is not necessary that systems set this level as a target unless water is unusually expensive, scarce or both

Real Losses as a percentage of system input volume Normalized Real Losses Gallons/service connection/day when the system is pressurized

Unavoidable Annual Real Losses (UARL)

where Lm = length of water mains, miles Nc = number of service connections Lp = total length of private pipe, miles = Nc x average distance from curbstop to customer meter

Infrastructure Leakage Index (ILI)

P = average pressure in the system, psi Operational: Real Losses

Ratio of Current Annual Real Losses (CARL) to Unavoidable Annual Real Losses (UARL); good for operational benchmarking for real loss control.

Copyright 2006 American Water Works Association

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LEAK DETECTION DEVICES FOR UNDERGROUND PIPES

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RCMS: Business Advisory Services Sharpening your competitive edge

Scope of Work
Assessment of Raw Water Sources and the existing Storage systems Assessment of the Water Treatment vis--vis Water Application / Use. Assessment of existing Water Distribution system & associated losses. Assessment of Water use and Waste Water discharged (Water Quality & Quantity) across the process. Assessment of water usage for Utilities. Process Mapping and Development of Water balance across the entire system. Identification of consumption of each existing sub meter and the distribution of water under each of the sections. Suggestions for reduction, reuse and recycling options for water conservation with cost benefit analysis and the required investment.

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METHODOLOGY
Plan & Organise Walk Through Survey Primary Data Collection Process Flow Diagram, Water Utility Diagram Conduct Survey & Monitoring- Internal team formation and external facilitation for monitoring & measurement of key sources, water balance assessment etc. Water Sampling & Analysis at various stages for relevant parameters Analysis of Water Use - Evolution of innovative strategies for Water Conservation, reuse & recycle, alternate sourcing, cross-sectoral recycle practice etc Identification of Water Conservation (WATCON) opportunities

Cost-Benefit Analysis of WATCON opportunities


Preparation of Action Plan Reporting & Presentation

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RCMS: Business Advisory Services Sharpening your competitive edge

WATER SOURCING

RAW WATER
Groundwater from Borewells Cost: @ Rs. 18 20 per KL Supplied vide Tankers or pumped in through pipelines

Water Source Quality Variations


Location A1 A2 A3 A4 A5 A6 A7 A8 A9 A10 A11 A12 Total Chloride Hardness TDS
(ppm) (ppm) (ppm)

Water Supplied % Supply


(KL)

46 60 237 227 32 35 114 89 103

137 200 385 235 161 157 223 248 245

340 440 920 850 380 380 650 520 640

8660 8000 6000 8250 3100 3250 1500 1033 3600 1117 800 2007 47317

18.3 16.9 12.7 17.4 6.6 6.9 3.2 2.2 7.6 2.4 1.7 4.2 100.0

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Water Consumption Pattern (Month-wise)


60000 50000 40000
KL

30000 20000 10000 0


APRIL (05) MAY (05) JUNE JULY (05) (05) AUG (05) SEP (05) OCT (05) NOV (05) DEC (05) JAN (06)

KL 45666 53454 51235 37890 28000 33450 37500 32005 29500 39085

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Water Consumption across sections: Quality & Quantity


Water Consumption in various sections
16000

cum per month (Jan 06)

14000 12000 10000 8000 6000 4000 2000 0


Brew House Series1 9336 Yeast Room 257 CELLE FILTER RS ATION 987 51 6 BBT 1 377 Bottling 1 4857

Water Consumption Pattern for various sections


15000
cum per month (Jan 06)
Garden/ KEG Cooling Boiler Admin/ FILLING Tower House Temple

12500 10000
3927

CO2 Plant 1 260

1 87

1 504

3897

7500 5000 2500 0


B rew Ho use Filtered Water So ft Water DM Water 955 1 42 8239 Yeast Ro o m 1 24 63 70 CELLE FILTER RS A TION 951 36 0 64 452 0 BBT 1 70 1 207 0 KEG Garden/ Co o ling B o iler B o ttling FILLIN A dmin/ To wer Ho use G Temple 1 906 1 2951 0 21 1 1 0 56 0 1 504 0 0 3927 0 3897 0 0 CO2 P lant 1 260 0 0

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Water Accounting & Auditing

COST OF WATER : Month: XXXX Filtered Water Rs. 2,23,460/@ Rs. 20/- per KL

Soft Water Rs. 4,68,204/@ Rs. 22/- per KL

DM Water Rs. 3,54,858/@ Rs. 42/- per KL

Current Yield per regeneration of DM plant is 2.5 Lakh Litres


The above cost does not account for electricity and manpower cost

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Process Water Balance


Detailed Process Water Balance Across Sections
1. Brew House 2. Yeast Room 3. Cellars

4. Filteration
7. Keg Filling 10. Garden / Admin/ Temple

5. BBT
8. Cooling Tower 11. CO2 plant

6. Bottling
9. Boiler House 12. WTP

Ref: Section 3.3 and 3.4 of the Report Line Diagram: Water Balance & Flow across sections

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Specific water Consumption


(hl/hl of beer bottled)
SECTION Brew House Yeast Room CELLARS FILTERATION BBT Bottling KEG FILLING Cooling Tower Boiler House Garden/Admin/Temple CO2 Plant TOTAL (Accounted) UNACCOUNTED (HL/HL) Total WTP - Regeneration Total (hl/hl) DM 1.6 0.01 0 0 0 0 0.01 0 0 0 0 1.63 0.02 1.64 SOFT Filtered 0.03 0.19 0.01 0.02 0.01 0.19 0.09 0.01 0.23 0.03 2.52 0.37 0.02 0 0.29 0 0.76 0 0 0.76 0 0.25 3.97 1.82 0.17 0.35 4.14 2.17 Total 1.82 0.05 0.19 0.1 0.27 2.89 0.04 0.29 0.76 0.76 0.25 7.42 0.54 7.96 0.93 8.89 % 23 1 2 1 3 36 0 4 10 10 3 93 7 100

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RCMS: Business Advisory Services Sharpening your competitive edge

Observations
1. Quality of raw water purchased have large variations in terms of hardness, chloride, TDS levels , ..etc. 2. The raw water from all sources are collected in a common tank and the whole lot is passed through Sand and Activated Carbon filter. The filtered water is then softened or demineralized. 3. High TDS in raw water has led to decreased yield in DM plant (4.5 lakh litre to 2.5 lakh liter per regeneration cycle) 4. All grades of water (Soft, DM, Filtered) are metered. 5. Meter for filtered water to Garden & Admin section was not working 6. Flow meter to Line-1 Bottle washer is erratic

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Observations
7. Flow meter gives macro level water consumption. Meters lacking at critical processes water addition by approximation/
experience, guesstimates

8. Specific Water consumption in Line 1 bottle washer is about 3 times that of Line 2 bottle washer . 9. Drains in Cellars are not properly designed for drainage by gravity, leading to high water usage for flushing of solids. 10. Process floor is tiled and have lots of potholes makes cleaning high water consuming activity. 11. Cycle of Concentration in Cooling Towers was found to be 1.5 to 2 due to presence of high chloride in raw water.

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Recommendations

1. Segregate & Treat Raw water based on Water Quality


Expected yield increase for DM plant: 50% (I.e. from 2.5 lakh liter to 4.25 lakh litre per regeneration) Investment involved: Rs. 50,000/Direct savings: Rs. 5,54,400/- per annum Chemical Cost savings expected : Rs. 3,00,000/- per annum Water Cost saved : Rs. 2,54,400/- per annum Indirect savings: Reduced hydraulic loading at ETP

Water savings expected: 12720 KL/annum, resulting in reduction of water consumption approx @ 0.2 hl/ hl of beer produced.
Payback period: 1 month

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Recommendations

1(b) Segregation and use of low chloride streams


Additional Advantages: 1. Would help reach higher cycles of concentration of atleast 5 in cooling towers 2. Annual Savings of Rs. 1,12,500/- and reduction in soft water consumption to the tune of about 4500 KL/annum resulting in further reduction in specific water consumption by 0.07 hl/hl.

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Recommendations

Recycling of CO2 plant scrubber wastewater


Investment involved: Rs. 50,000/(towards activated carbon column, chlorine doser and pipeline)
Direct savings: Rs. 3,02,400/- per annum Water Cost savings expected : Rs. 3,02,400/- per annum Indirect savings: Reduced hydraulic loading at ETP Water savings expected: 15120 KL/annum (i.e. reduction in 3% of total water consumption or 11% of total filtered water consumption and, resulting in reduction of water consumption approx @ 0.24 hl/ hl of beer produced.) Payback period: < 2 months

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WATER GUZZLERS

BOTTLE WASHERS: A Comparative Study (Line 1) vs (Line 2)

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Recommendations
Line-1 Washer Line-2 Washer

S.N.

Particulars

Water 1 Consumption Replacement of Line 1 Washer .. Steam Direct Savings for Water: 2 Consumption 1200 kg/hour 675 kg/hour Operating Water 30480 KL/annum 3 Capacity Approx11500 bottles/hour 21000 bottles/hour reduction in hl/hl of beer = 0.9 Savings seems considerable. 2.08 liters/bottle Financial (0.96 savings: Rs. 7,62,000/- per annum liters/ bottle Need to have a detailed study done discharged &1.12 Specific Water liters/bottle Consumption recycled) 0.36 liters/bottle Specific Steam Consumption 104 kg/1000 bottles 32 kg/1000 bottles

24 KL/hour (13 KL/hour recycled & 11 KL/hour discharged) 7.5 KL/hour

Energy savings (Electrical & Steam)

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Reuse of Treated Effluent

Treated Effluent
-now used for irrigating sugar cane fields

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Recommendations

Reuse Treated effluent following separation of Sewage Treatment Water savings expected:
1. From Gardening application: 36000 KL/annum
(i.e. reduction in 7.5% of to total water or 26% Need have a consumption detailed study of of total filtered water consumption the and,present resultinglevel in reduction of water consumption of about 1 of efficacy and hl/ hl of beer produced.)

effectiveness of the ETP and 2. Floor cleaning application: 18000 KL/annum match upgrade the treated effluent (i.e. reduction in 3.75% / of total water consumption or 13% of total filtered water consumption and, resulting in reduction of water consumption by as per the end use application.
about 0.5 hl/ hl of beer produced.)

Financial savings expected:


1. 2. From Gardening : approx. Rs. 7,20,000/- per annum Floor Washings: approx. Rs. 3,60,000/- per annum

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Better Utilization of Environment Management Infrastructure


Need to have a detailed study for improvement of existing environmental infrastructure

High TSS observed in treated effluent - Brim of clarifier not cleaned periodically.

Effluents are bypassed in Aeration tank

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Recommendations

Segregate high BOD waste streams


Segregate & Treat Brew House discharge: 20 KL/ day of 40 50,000 mg/l

- Reduction in aeration load by about 20% expected


Capital Investment: Rs. 75,000/(towards civil work of a tank of capacity 10 KL, piping, mechanical mixer and pump if required)

Benefits accrued:
Energy savings because of reduced air requirement in the aeration tank about 20% expected Reduced BOD load in the aeration Proposed scheme
High BOD Wastewater streams from brew house Biogas

tank
Treated Water

Anaerobic Treatment (60% BOD removal)

Existing Aeration Tank

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RCMS: Business Advisory Services Sharpening your competitive edge

General Recommendations
Awareness Training Program Installation of water flow meters at critical process control points Calibration of installed water flow meters Increase Floor Washing/ Rinsing Efficiency (specially in bottling section) Better Housekeeping measures Recovery / Reuse/ Recycle options

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HOUSE KEEPING PRACTICES


Lack of proper gradient (slope) and damaged drains causes increased water usage for forcible flushings and also leads to unhygienic conditions in the Cellars, Yeast House sections

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HOUSE KEEPING PRACTICES Floor Cleaning: - Bottling Section

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HOUSE KEEPING PRACTICES


Equipment Cleaning: - Bottling Section

Use nozzles for increased pressure and reduce water consumption and better washing

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RECOVERY/ REUSE/ RECYCLE Options


Recovery of Steam Condensate from Keg filling section Wastewater generated from wort line sterilization before each brew Control of overflow and leakages in Pasteurization unit (line-1)

Optimize vacuum pump cooling & flushing water and reuse for floor cleaning

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RCMS: Business Advisory Services Sharpening your competitive edge

Case Study: Cement Plant Water Network

(Sourcing & Storage)


INCOMING WATER SOURCE DIAGRAM
SP27C SP27D 8.82 (Flow in m3 / day) 275.04 CRUSHER

75.36
12.43 SP32A SP28B 46.33 SP33A SP29 51.07 86.82 SP28A 78.92 SP30 PUMP HOUSE RAW WATER TANK

25.05

MINING AREA

93.96

TANKER FILLING 20.00

SP07 2361.60 DIRECT INJECTION

LEAKAGE NEAR OLD EXPLOSIVE STORE 360.00

COOLING TREATED WATER TANK SP06 40.53 45.64

8121.60 2568.00

79.67 SP22 SP22A

SP27B 81.96 SP20 70.04 SP05 49.37

SP18 1704.00 SP51 50.29

BLOWDOWN 200.47

MINE PIT

20.00 TANKER FILLING

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Water use in Cement Plant

1% 0% 4% 14% 3% 3% 6% 12%
Coal Mill GCT Kiln supply Cement Mill 1 DG Washer & Unaccounted Raw Mill 1 GCT Calciner supply Cement Mill 2 Cooling Tow er

13%

11% 12%

21%

Coal Crusher Raw Mill 2 Clinker Cooling DG & Plant Make up w ater

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Case Study: Cement Plant

Sl # Recommendations
1

Water savings expected


360 cum/day (14% of
Total water consumption)

Remarks
NO additional cost

Stop leakages in mining area

Replace malfunctioning non return Total Water 2 valves for borewells Consumption) Rs. 2000 per NRV or Valve Reuse of Treated water from STP in 150 m3/day ( 6% of Cooling Tower or for spraying in Total Water Consumption) around Rs. 5-6 Lacs 3 GCT

205 m3/day ( 8% of

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Reducing the water loss in DG Cooling Towers


Option1 : Replace existing cooler with Dry / Non Contact type Cooler Option 2 : Using the waste heat of DG sets
FO 5000 KW D.G. set D.G. set HT and LT Heat Exchanger FO Duct Firing W.H.R. Boiler Steam Water

Hot Water

Flash vessel 90C

Pump

Make Up Water

Water saving : 300 m3/day Detailed Energy studies required

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