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John Thomas
Some Statistics .
1. VIRTUAL WATER
2. WATER FOOTPRINT
Regional virtual water balances and net interregional virtual water flows related to the trade in agricultural products.
Period: 1997-2001
The water footprint concept was introduced in 2002 by Arjen Hoekstra in analogy to the well known concept of ecological footprint'.
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.
Part - II
John Thomas
THIS SCENARIO VERSUS COST OF WATER WILL DICTATE ACHIEVABILITY OF NEAR ZERO DISCHARGE
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)
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
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.
PROCESS SELECTION
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
WATER AUDITS: POTENTIAL BENEFITS Reduction in specific water consumption. Reduced Pumping/ Distribution & Treatment costs Better Utilization of Water within the plant
- through Reuse, Recycling
Better Public Image Reduced incidence of production losses due to increased water availability.
Authorized Consumption
Revenue Water
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
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
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
Ratio of Current Annual Real Losses (CARL) to Unavoidable Annual Real Losses (UARL); good for operational benchmarking for real loss control.
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.
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
WATER SOURCING
RAW WATER
Groundwater from Borewells Cost: @ Rs. 18 20 per KL Supplied vide Tankers or pumped in through pipelines
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
KL 45666 53454 51235 37890 28000 33450 37500 32005 29500 39085
12500 10000
3927
1 87
1 504
3897
COST OF WATER : Month: XXXX Filtered Water Rs. 2,23,460/@ Rs. 20/- per KL
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
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
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.
Recommendations
Water savings expected: 12720 KL/annum, resulting in reduction of water consumption approx @ 0.2 hl/ hl of beer produced.
Payback period: 1 month
Recommendations
Recommendations
WATER GUZZLERS
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
Treated Effluent
-now used for irrigating sugar cane fields
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.)
High TSS observed in treated effluent - Brim of clarifier not cleaned periodically.
Recommendations
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
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
Use nozzles for increased pressure and reduce water consumption and better washing
Optimize vacuum pump cooling & flushing water and reuse for floor cleaning
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
8121.60 2568.00
BLOWDOWN 200.47
MINE PIT
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
Sl # Recommendations
1
Remarks
NO additional cost
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
Hot Water
Pump
Make Up Water