This is a presentation from ITC Limited, PSPD, Unit - Kovai, one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. PSPD, KOVAI
CII National Award 2008
“Excellence In Water Management”
16 & 17 Dec 2008
ITC Limited, PSPD, Unit - Kovai
Company Profile:
PSPD, KOVAI
ITC Limi ted , PSPD Unit:Kov ai
• ITC Ltd is a multi business Co rpo rat e with En viron mental Philoso phy o f
Trusteeship rel ated to soci al & envi ronment al resources, aligned to the purs uit o f
economic obj ectives.
• PSPD is the Paperboard & Specialty P apers Di vision, 1500 crore busin ess having
4 manufacturing Units
• Unit: Kov ai is On e o f th e units, locat ed 42 k m north o f Coimb ato re, Tamil Nadu.
- Acquired from B IPCO in M arch 20 04
- Production capacity o f 9 0000 t/ y ear ( from 55,000 t / year)
- Manu facture Du plex Board from 10 0 % recycl ed fi ber
- ISO 9001, ISO 14 001 & OS HAS 1 8001 certi fi ed
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2. Process Flow - Block diagram
Fuels Emission:
SPM
<50ppm PSPD, KOVAI
Water Water
Treatment
from River Powe r: 8 m w
DM
Sp. Water: 13.4 m3/t Boiler
Plant
White Con dens ate
Cutti ngs recovery
Steam
Screen
+3 Hot
Pulper
centricl Dis TL wire
eaner per
ser.
D
Screen Coaters Sheeter
Press: e
+ Hot Suction Top : : 2&
Pulper centricl Dis FL wire Dryers, Blade+ godown
s
+ bi nip Rewin&
Reel der
eaner per Temsec MG, Rod Rewinder : 3 p
ONP + ser. Calender Back : a
Mag Blade t
Screen
+3 c
Pulper BL wire
centricl Finishing h
eaner
House
Board machi ne
Waste
Paper Stock
Storage Preparation Petax
Sp. Effluent
filter ETP Treated Effluent Discharge – 9.33
for Irrigation m3/ton
Certifications & Awards: Unit - Kovai
PSPD, KOVAI
Certifications:
• ISO 9001 : 2000
• ISO 14001 : 2004
• OSHAS 18001 : 1999
• British Safety Counc il Award 2007 : Rating
• British Safety Counc il Award 2008 : Rating
Awards:
• “ Excellent Water Efficient Unit” – CII National awar d
for Excellence in Water Management 2007
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3. Preservation of Environment:
PSPD, KOVAI
• Priority for Conse rvation of Re sources
• Wate r & Ene rgy Conse rvation
- Recyclin g & redu cing us ag e : Inv ested Rs 3.0 cr in new tech nologi es.
- Invested Rs 55 cr in Energy cons erv ation.
- Evaluatio n & improv em ents th roug h regul ar audits
• Re cycling of solid waste :
- 100 % fly ash from boiler, ETP sludge, Dein king slud ge & Pl astics fro m
wast e p ap er are recy cl ed
• Facilitie s & Proce sses are e nvironment frie ndly:
- Onlin e stack monit orin g – SPM, SOx, NOx and continu ous AAQS to
improv e environm ent al stand ards
• CDM Proje ct:
- Predo min antly using wast e biomass in boil er as fu el, 96,000 tons o f CO2
red ucti on per annum
Preservation of Environment by Using
PSPD, KOVAI
Treated Effluent:
Tre e Population Gree n Belt De velopment:
14 000 0 • 245 acre und er cultiv ation usin g
1 200 00 treated effl uent.
12 000 0
10 000 0 • 1,20,000 trees o f variou s species
No of trees
805 00
8 000 0
5 500 0 • Long t erm tie u p with Tamilnadu
6 000 0 Agri cultural Universit y to monitor
and stud y the imp act o f treat ed
4 000 0 efflu ent on soil & gro und wat er.
20 000
2 000 0
0
2 004 - 05 200 5 - 0 6 2006 - 0 7 200 7 - 08
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4. Mill water Balance:
Intake from river : 3000 to 3800 m3/day
PSPD, KOVAI Effluent Discharge : 2200 to 2600 m3/day
From Ri ver
Water Treatment Water meters
3800
500
700 Stock
Preparation
1650
4600
3000
2575 Board 1900 3500 500
KRO FTA Petax
Machine 2600
1350 ETP
1415
Steam
690 Boiler & 175
Utility
15 10 Irrigation
Domestic
Specific Water Consumption:
PSPD, KOVAI
25
22
20
cu.m / ton of paper board
15.26 58%
15 13.31 reductio n
13.2
9.31
10
5
0
2004 - Q1 2004 - 05 2005 - 06 2006 - 07 2007 - 08
after ITC
4

5. Water Conservation Projects:
PSPD, KOVAI
Under Waste Water Reuse:
S Projects Inv estm ent Impl emented Water
No in Lak hs year savings
(m3/year)
1 Krim a sealing wat er o utlet 0.8 Sep 200 6 13,200
reused in proces s
2 Using boil er blo w down for 0.7 Jan 20 07 11,550
cooling tower m ake up
3 Petax Filter accept us ed for 0.5 Jan 20 07 33,000
filt er b ack was h instead o f
fresh wat er
4 Top liner silo 2 ex cess back 1.4 Feb 200 7 29,700
wat er us ed for pul ping
Water Conservation Projects:
PSPD, KOVAI
Under Waste Water Reuse:
S Projects Inv estm ent Impl emented Water
No in Lak hs year savings
(m3/year)
5 Sealin g water reci rculation for 6.2 Mar 2007 1,15,500
vacuum p umps
6 Reus e of foam t ank overflow 1.0 May 2 007 33,000
to fill er pul per
7 Top liner tray water divert ed to 0.15 Mar 2008 11,880
top liner silo
5

6. Water Conservation Projects
PSPD, KOVAI
Unde r Waste Wate r Re cycle :
S Project Inv estm ent Impl emented Water
No in lakhs Year Savings
m3/year
1 Petax filt er inst alled fo r 200 April 20 05 9,90,000
recy cling o f pro cess water
2 Recycling dei nking wast e 1.0 Dec 200 6 90,750
wat er in th e top liner
3 Kro ft a Clari fied water used 0.5 Oct 20 07 47,520
in Broke Thickener
4. Stock Preparation rej ect 12 Dec 200 7 79,200
thick ening for recy cling o f
back water
Water Conservation Projects
PSPD, KOVAI
Under Water Reduction:
S Project Inv estm ent Implem ent ed Water savi ngs
No in lakhs Year m3/year
1 Top LP Shower worn 2.0 March 2006 24,750
out nozzl e change
2 Felt lubri cation nozzl e 2.0 Sep 200 6 33,000
changed to wid e angl e
3 Using Pet ax wat er in 0.5 Feb 200 7 66,000
fill er lin er d andy shower
4 Reduction o f P ump and 1.0 April 20 07 1,58,400
agitat or s ealing water
5 Optimi zation o f booster Nil June 2 007 63,360
pump
6 Redu ction o f R aw water 4.0 Aug 20 07 33,000
head er p ress ure
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7. Water Conservation Projects
PSPD, KOVAI Under Water Reduction: contd
S Project Inv estm ent Implem ent ed Water savi ngs
No in lakhs Year m3/year
7 Lev el control for white 0.28 Jan 20 08 33,000
back, back wat er chest
8 Lev el Cont rol fo r Top 0.38 Jan 20 08 15,840
liner back water chest
9 Optimi zatio n o f b ack 0.15 Jan 20 08 15,840
liner wire ed ge cleanin g
shower
10 Optimi zatio n o f 4 Nil Jan 20 08 79,200
numb er o f P ress part LP
shower
11 Temperat ure control loop 1.75 Feb 200 8 95,040
for v acuum s eal pit m ake
up fresh wat er
Innovative Project 1 – Thickening of Stock
PSPD, KOVAI
preparation tertiary screen rejects
• Past S cenario :
Vibrating s creen and Side Hill s creen were us ed to thick en th e tertiary
screen rejects, the out put co nsistency of sludg e was 2 to 4 % and th e filtrate
collect ed was us ed in the syst em
• Pres ent Scena rio:
– Vibrating s creen and Side hill screen were replaced by two
hydras creen.
– Hyd ras creen consist o f s crew co nv eyo r en clos ed by a screen, which
helped to avoid jam ming prevailing in old syst em
– The consist en cy o f th e rej ects in creased from 2% to 20 % which
increas ed the filt rat e qu antity by 10 cu.m/h r
• Project Summary:
– Fresh wat er s avings per annum – 79,200 m3
– Inv estm ent cost – 12 lacs
– Payback Peri od – 26 months
7

8. Innovative Project 2 – Temperature control
PSPD, KOVAI
loop for vacuum seal pit make up water
• Past S cenario :
Temperat ure o f s ealin g water is criti cal for v acuum pu mp effi ciency,
the tem perat ure was co ntroll ed m anu ally using v alv e
• Pres ent Scena rio:
– A new tem perat ure co ntrol loo p pro vided fo r co ntrol
– Temperat ure set poi nt given and th e flo w o f wat er v ari ed autom atically
to maintai n the temp erature
– This has increas ed reliability in temperature control and reducti on in
fresh wat er m ake up
• Project Summary:
– Fresh wat er s avings per annum – 95,040 m3
– Inv estm ent cost – 1.75 lacs
– Payback Peri od – 4 months
Innovative Project 3 – Krofta clarified water for
PSPD, KOVAI
broke thickener shower
• Past S cenario :
Fresh wat er was used in brok e thickener sho wer with th e no zzl e size
o f 2 mm fo r cl eani ng the thi ck en er m esh
• Pres ent Scena rio:
– Kro ft a clari fi ed wat er with 150 ppm o f TSS is chosen as replacement o f
fresh wat er
– Since the nozzl e size is 2 mm and the m aximum p arti cl e size in the
Kroft a clari fi ed wat er is less th an 75 mi cron, the jammi ng tendency is
too less
– This helped us to stop fresh wat er compl etel y an d res ulted in s avings of
6 cu.m/hr
• Project Summary:
– Fresh wat er s avings per annum – 47,520 m3
– Inv estm ent cost – 0.5 lacs
– Payback Peri od – 2 months
8

9. Bench Mark – Specific water consumption
PSPD, KOVAI
Without Dei nking & CPP Road Map towards International B ench Mark:
10
9.31 • Reus e o f Pro cess Efflu ent by lo calized
9 treatm ent
cu.m / ton of paper
board
9
- Treat efflu ent from Stock p rep aration
sep arat ely witho ut sendi ng to ETP, necess ary
8
facilities are plan ned an d to be install ed in
2007 - 08 Bench Mark - NPC 2008 - 09
With Deinki ng & CPP
• Reus e o f treated efflu ent in the p ro cess
22 19 - Inv estm ent in secon dary treatment plant is
18 plann ed in 20 09 -10
cu.m/ ton of paper
13.4
board
14
10 • Impl ementatio n o f rain wat er h arv estin g inside
6 the plant 2009 - 10
20 07 - 0 8 Bench Mark - NPC
Specific Waste Water Discharge:
PSPD, KOVAI
With Deinking & CPP
50
50
cu.m / ton of Paper Board
40
30
50
20 15
m3 /t
9.3
10
15 m3/t
9.3 m3/t
0
CPCB Norm Bench Mark - NPC Un it - Kovai
9

10. Pe r capita Domestic wate r consumption:
PSPD, KOVAI
18
17
17
Ltrs/person/day
16 15.57
15
14.19
14
13
2005 -2006 200 6 - 2007 2007 - 08
Review : Sustenance & Improvements
PSPD, KOVAI
• Consumpti on at all consuming points are captured in DCS
- Hourly rep ort is generat ed for mo re th an 30 p oints
- Automati c al arms d urin g variatio ns
• Daily area wis e fresh wat er cons umptions are monito red
• Water consumpti ons revi ewed, vari ances analyzed & corrective actions
planned in
- Dail y AET’s meetings
- Weekly Producti on Pillar m eetin g
- Monthly P erformance revi ew by Unit Steerin g Board.
- Designated Wat er M anager facilitat es the revi ews.
• Impl ementatio n status o f s ugg estions fro m PACT memb ers ( wo rkm en )
are revi ewed in mont hly perform an ce reviews.
10

11. Real time MIS report from DCS:
PSPD, KOVAI
ITC PSPD KOVAI
R eport Duration : SHIFT WAT ER REPORT
Operator : SHIFT 1
6am 7am 8am
Engg M ax Min Avg
Sr. No. Description Time Time - - -
Units Value Value V alue
7am 8am 9am
20 Fresh water flow m3/hr 283.50 11:23 65.47 6:51 97.19 82.66 135.69 109.37
21 Raw water pressure bar 4.40 12:15 1.71 7:47 3.80 3.33 2.71 3.66
22 Krofta feed flow rate m3/hr 5999.15 7:27 5605.15 11:37 5768.15 5868.73 5910.60 5805.96
23 Krofta feed line valve opening % 100.00 6:01 100.00 6:01 100.00 100 100 100
24 Main cooling tower level % 87.02 6:10 74.35 8:09 78.32 85.16 79.43 75.42
25 P etax running time in A shift mins 436.00 14:00 0.00 6:01 217.07 29.50 86.65 130.50
26 P etax running time in B shift mins 357.00 6:01 357.00 6:01 357.00 357 357 357
27 P etax running time in C shift mins 443.00 6:01 443.00 6:01 443.00 443 443 443
28 fresh water totalizer for A shift m3 779.70 14:00 1.22 6:01 408.70 43.06 144.60 276.77
Water Conservation in Local community
PSPD, KOVAI
• Awareness program in loca l society
- Involving local community in World
Environment & farmer’s Day celebrations.
- Distribution of saplings.
• Drinking water supply to local village s (2500 people)
• Rain water harvesting facilities
- Check dam s : 7 nos
- De-silting of ponds : 19 nos
- Beneficiaries
Recharged Open wells : 160 nos
Recharged Bore wells : 99 nos
11

12. PSPD, KOVAI
THANK YOU
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