This is a presentation from Sterlite Industries Ltd, 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. National Awar d for Excellence in Wa ter Manageme nt 2008:CII
Sterlite Industries India Ltd- Silvassa
Excellence i n Water
Ma nage me nt 2008
OVERVIEW STRUCTURE
p A leading producer of ke y
Aluminium
commodities
Co p p er
n Group turno ver FY 07 -08 $ 8.2 bn Zinc
Iron
p Listed on the London Stock
Exchange
Copper Zinc Aluminum Iron
p 30,000+ Employees
p US$ 2.2bn pipeline of bro wn –
and greenfield projects
Sterlite Vedanta
KCM HZL Balco Sesa Goa
Alum ina
(Copper) (Copper) (Zinc ) (Aluminium) (Iron)
(Alumina)
Malco
(Aluminium)
Excellence i n Water
Ma nage me nt 2008

2. REFINERY CC ROD
ANODE ELET RO REFI NIN G CAST ING ROLLI NG
CAT HODE CC R OD COIL
Excellence i n Water
Ma nage me nt 2008
PROJECTS WITH ZERO INVESTMENTS:
q Modification in Thermoshypon cooling water arrangement.
Savings : 4380 m3 : Rs. 1.4 Lacs.
q Condensate Re covery of RVD fo r Filter Pre ss Backwa shing.
Savings : 1284 m3 : Rs. 0.41Lacs
q Reu se of collected condensate water generated by anode casting
cooling water.
Savings : 655 m3 : Rs. 0.21 Lacs
Excellence i n Water
Ma nage me nt 2008

3. PROJECTS WITH INVESTMENTS:
q Rain water harve sting.
Savings : Year - Water Sav ings
2005 - 4178 m3 (Rs. 1.25 Lacs)
2006 - 6225 m3 (Rs. 1.86 Lacs)
2007 - 9475 m3 (Rs. 2.84 Lacs)
2008 - 3560 m3 (Rs. 1.13 Lacs)
Total - 23438 m3 (Rs. 7.08 Lac s)
Investment : Rs. 10 Lacs
Payback Pe riod : 67 months
Excellence i n Water
Ma nage me nt 2008
PROJECTS WITH INVESTMENTS:
q Conv ersion of Gland Packing Pumps into Mechanical Seal
Savings : 1728 m3 Water (Rs. 0.55 Lacs)
Investment : Rs. 3.0 Lacs
Payback Period : 65 months
q Prov ision of Electrolytic Cell cov ers in Refinery
Savings : 3703 m3 Water (Rs. 1.18 Lacs)
Investment : Rs. 1.0 Lacs
Payback Period : 14 months
q Control v alve prov ision in FO storage tank steam line
Savings : 1501 m3 Water (Rs. 0.5 Lacs)
Investment : Rs. 0.98 Lacs
Payback Period : 24 months
q Installation of v acuum pump in Rotory Vaccum Drier
Savings : 444 m3 Water (Rs. 0.41 Lacs)
Investment : Rs. 0.48 Lac
Payback Period : 39 months
Excellence i n Water
Ma nage me nt 2008

4. PROJECTS WITH INVESTMENTS:
q Modification i n CSM for cathode washin g
Savings : 1027 m3 Water (Rs. 0.34 Lacs)
Investment : Rs. 0.49 Lacs
Payback Period : 17 months
q Special Nozzles for ASWM washing
Savings : 148 m3 Water (Rs. 0.05 Lacs)
Investment : Rs. 0.05 Lacs
Payback Period : 12 months
q Bosch tank renovation
Savings : 375 m3 Water (Rs. 0.12 Lacs)
Investment : Rs. 2.45 Lacs
Payback Period : 233 months
q Leaching process alteration for steam reduction
Savings : 555 m3 Water (Rs. 0.186 Lacs)
Investment : Rs. 0.9 Lacs
Payback Period : 58 months
Excellence i n Water
Ma nage me nt 2008
WATER CONSERVATION PROJECTS - SUMMARY:
Total no of projects implemented = 13
ü Projects implemented without investments = 3
ü Projects implemented with investments = 10
Savings : 42015 m3 Water
Total Inv estments made : Rs 20.85 Lacs
Total Sav ings Ac hiev ed : Rs 13.05 Lacs
Excellence i n Water
Ma nage me nt 2008

5. WATER SHARE - SILVASSA
2%
2%
20%
18% 58%
RFNY CCRC CCRP PMP ACP
Excellence i n Water
Ma nage me nt 2008
WATER CONSUMPTION (M3/MT)
0.67
0.70 0. 54 0.4 9
0. 46
0.60
0.50
Sp. Water Consumption
0.40
0.30
0.20
0.10
0.00
2004-05 2005-06 2006-07 200 7-08
Fi sca l Ye a r
Reduc tion in Specific Wa ter Consumption = 31.34 %
Excellence i n Water
Ma nage me nt 2008

6. Waste Water Details : Industrial
10308
12000
8260
Waste Generated ( M3 )
10000
8000 5544 5300
6000
4000
2000
0
2004-05 2005-06 2006-07 2007-08
Fisca l Year
Excellence i n Water
Ma nage me nt 2008
Waste Water Details : Domestic
7093 7054
8000 5838 5808
7000
Quantity Generated (M3)
6000
5000
4000
3000
2000
1000
0
2004-05 2005-06 2006-07 2007-08
Fiscal Year
Excellence i n Water
Ma nage me nt 2008

7. BENCHMARKING
q Our ultimate objectiv e of our plant is to be 0.4 m3/MT of copper cathode.
q We are continuously committed towards natur al resources conserv ation
and water conserv ation is our prime f ocus. This we are achiev ing by TQM
methodolo gy , PEP and internal proj ects .
q To sustain as a ZERO discharge plant in copp er industry .
ROAD MAP FOR THE FUTURE
q Regular Water Aud its & Identif ication of new projects.
q SPC techniques in Water Monitorin g.
q Utilization of waste condensate water.
q Conv ersion of all gland seal pumps into mechanical seals.
q Exploring the possibility of Air Cooled heat exchangers in place of
normal coolin g towe rs.
Excellence i n Water
Ma nage me nt 2008
TQM PROJECT 1: WATER FUL I MPLE MENTATION
KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION
Problem Statement :
Reduction of water & steam in Cathode Stripping Machine
from 10000 M3 to 7000 M3 per annum of cathode
production.
Mission Statement :
Increase in washing effectiveness in CSM & thereby
conservation of water & a saving of approx Rs 1.0 Lac per
year.
Excellence i n Water
Ma nage me nt 2008

8. TQM PROJECT 1: WATER CONSUMPTION REDUCTION
Cause And E ffect Diagra m based on Brai n Storming :
PUMP TANK
Leakages Ev aporation
Tank Los s es
High / low No calibration of ov erf low
Seepage to
pres sure pres sure gauge
Leakages ground
HIGH STEAM
CONSUMPTION
c hoke-up leakages
Les s
Mai tenanc e
n Improper
improper laggin g & Ins uf f icient
angle Insuf fic ient cladding w idt h
Number
PIPELINES
NOZZLES
Excellence i n Water
Ma nage me nt 2008
TQM PROJECT 1: WATER FUL I MPLE MENTATION
KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION
Formulation of Theories
q Overflow and leakages of tan k
q Evaporation losse s in CSM
q Cho ke-up of Nozzle s.
q High or low pressu re in wa shing line.
q Pump & Pipeline leakages
Excellence i n Water
Ma nage me nt 2008

9. TQM PROJECT 1: WATER FUL I MPLE MENTATION
KE Y FACTOR FOR SUCES S CONSUMPTION REDUCTION
Results & Benefits
900
Water Consumption
850 850 845
819.8 3 809.08 804.6 7 804
839.0 8 802
(M3)
835
800
808.83 800.1 7 801.9 2
750
751.7 5 Af ter TQM
Bef ore TQ M
700
20 06-7 May-07 Jul-07 Sep- 07 Nov-07 Jan-08 Mar-08
Month
Reduc tion in Water Consum pti on : 4.7 % ( Rs. 0.34 Lacs )
Excellence i n Water
Ma nage me nt 2008
TQM PROJEFACTOR FOR SUCES S FUL I MPLE MENTATIONN IN
KE Y CT 2 : WATER CO NSUMP TION RE DUCTIO ACP
Contr ol v alv e prov ision in
Steam Readings in MT
FO stora ge tank s team line
Proble m Sta teme nt : 10
Reduction of steam for F O hea ting from 8 8 8.1
T onnes/day to 4 T onnes/day. 7.9
6 Be fore TQM Afte r TQM
5.6
Missi on S tate me nt : 4.1 4 4.2
4 4.1
Effective utilisation of Steam for F O 3.6 3.6
heating and there by a saving of 2
Rs.50,000 per an num. 0
Me th od olo g y o f Im ple mentati on : Dec-07 Jan-08 Feb-08 Mar-08 Apr-08 May-08 Jun-08 Jul -08 Aug-08
§ Analytical study of Steam re quirement. Month 07-08
§ Installation of Steam Control Valve.
§ Continuous monitoring o f the s ystem
and data analysis.
Excellence i n Water
Ma nage me nt 2008

10. Employee & Comm uni ty I nv olv ement
APPROACH
T OP D OW N APPR OACH B OTT OM U P APPROACH CSR Activ ities
Policy D ep lo ym ent PEP M echanism
Continuou s Imp rovement W ater Month EDUCATION
S A A P A EE H M A H TS A :
H L LA R V S M O V w have sup por t d " Sh al
e e a
Daily Man ag em ent CSR Activities Pr avesh M oho st v - 0 07" under C R i ni i at ves at Vaso na Sch ool
a 2
s
S
i o
t i
w e 250 new st ude nt hav et aken ad m ssi ni n cl ss 1 ( one) .
er a
Excellence i n Water
Ma nage me nt 2008
SUGGESTION CATEGORY
COP Reduction System Improvement
18% 17%
Process Improvement
Qua lity
14 %
10 %
Wat er Conser vation
16% Safety Env ironment
2 5%
Excellence i n Water
Ma nage me nt 2008

11. Water Month Celebration
q Celebrated Water Month on March 2008.
q Celebrated World Water Da y on March 22 nd 2008.
q Each year carrie s a particular theme on WWD like …
2008 : Theme 2008: Sanita tion
2007 :
2006 : Water and Culture
2005 : Water for Life
2004 : Water and Di sa sters
2003 : Water for the future etc….
q Organized various events related to water awarene ss.
Excellence i n Water
Ma nage me nt 2008
WATER MONITORING & REPORTING SYSTEMS:
q Whole Plant is divided into 5 areas and Water Con sumption for
each plant is monitored and action plans taking according to it.
q Water norm s are fixed for all the equipments & any variation is
alerted by DCS.
q Water audits being done internally by water champions and remedial
actions immediately taken.
q Water report i s getting prepared by the Water Manager and is
getting reviewed by the Head Operations in presence of Sectional
Heads.
q The Water report con sist s of Water Share, Specific Con sumption,
Trend analysis, Internal & External Benchmarking, Concern s and
Action plan for the next month.
Excellence i n Water
Ma nage me nt 2008

12. LIST OF MAJOR ENVIRONMENT IMPROVEMENTS
KE Y FACTOR FOR SUCES S FUL I MPLE MENTATION
q Rain water harvesting in the plant. (10 Lacs)
q Zero Discharge Plant.
q Reduction in air pollution by introducing scrubbers. (3.5 Lacs)
q Installed Sewage Water Treatment facility. Treated water is being
used for gardening purpose. (2.5 Lacs)
q Installed air pre heater in the boiler to reduce fuel consumption.
(5.5 Lacs)
q Installed Acetylene Soot Collection System installed in CCR to
improve working Environment. (5.6 Lacs)
q Soil Correction Carried out in Refinery. (2.62 Lacs)
q Installation of Air Ventilators in Refinery & CCR. (3.23 Lacs)
q Conversion of FO fired boiler into Biomass fuel fired furnace.
(11.4 Lacs )
Excellence i n Water
Ma nage me nt 2008
AWARDS & CERTIFICATION
KE Y FACTOR FOR SUCES S FUL I MPLE MENTATION
q ISO 9001,ISO 14001 and OHSAS 18001 Certified by DNV
qIEI Safety award by Gujarat State – 2007
qCII – Excellent Water Efficient Unit Award – 2007
qCII – Excellent Energy Efficient Unit Award – 2007
qIMEA-Platinum award for Metal Category by M/s Frost and Sullivan
qRBNQA- Commendation Certificate
qQualtech Innovation award – “Recovery of Nickel from Electrolyte Stream”
qCorporate award “ Creative Workplace ”- Sept 2008
qFirst prize for best Suggestor Award@INSSAN- July 2007
qSecond prize for best Suggestor Award@INSSAN- July 2007
qUnique employee involvement practices – INSSAN May 2007
qGolden Peacock National Training award for 2007
Excellence i n Water
Ma nage me nt 2008