This is a presentation from ITC Limited, Tribeni, 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. ITC Limited
Pape rboards & Specialty Papers Division
Unit – Tribeni
WATER MANAGEMENT
CII–SO HRABJI GO DREJ GR EEN BUSINESS C ENTRE
16th – 17th Decemb er 2008
Unit Profile
• A Specialty Paper Mill
• Three Paper Machines
• Production 2007-08: 23387 MT
• Annual Turnover = Rs. 1937 Million
• Certified ISO 9001, 14001 and OHSAS 18001
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2. Organisation Structure
Vice Pre side nt
Tribe ni O pe rations
HOD
DG M
Finance
Operations
HOD
HOD HOD Ma terials
Engineering Produ cti on (Was te &
Haz.ch em
HOD
IS (Mech. ) IS (PM 3&4 ) Mg r)
Techni cal
MR ISO HOD CS
IS (Elect .) IS (PM 1)
HOD
Safety HOD IT
IS (Instmn. ) IS (FH) MR OHSAS
HOD HR
IS (E & U) CMO IS (Secu rity)
TEM
Water & Bio Med Fire Co-o rd
Coo rdinator
Energy Mg r Waste Mg r & Afforestn.
Source of Water
f17 Nos. of Borewells located within Mill and
Estate Area
fSink Depth of 600 ft below ground level
fTapping is done at a depth of 350-550 ft
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3. Water Balance
Area Quantity m3/day
Average daily 5959
consumption
Paper Machine 1 1311
Paper Machine 3 2169
Paper Machine 4 1740
DM Plant 345
DIW & ETP 110
Chemical Kitchen 120
Mill Drinking Water 164
Fresh Water Consumption
( April – Q uantity , m3 Produ ction in Specific water
March ) Tonnes consu mption,
m3/ MT
Industrial Do mes ti c
2004-05 25323 51 13216 8 23667 107
2005-06 25161 96 12696 74 24024 105
2006-07 23953 56 11507 34 24250 99
2007-08 21148 30 11315 97 23387 90
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4. Fresh Water Consumption
Specific Fresh Water Consumption
(kL/t)
230 213
178
180
128
130 107 105
99
90
80
2001- 2002- 2003- 2004- 2005- 2006- 2007-
2002 2003 2004 2005 2006 2007 2008
With con tinuous efforts and several fresh water saving initiativ es impl emen ted,
we have reach ed this position.
Fresh Water Consumption
Cumulative % reduction in Fresh Water intake w.r.t 2001-02
60 57
49 50 53
50
39
40
% reduction
30
20
16
10
0
2002-03 2003-04 2004-05 2005-06 2006-07 2007-08
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5. Fresh Water Consumption
Benchmarking
Tribeni Mill National Internation CPCB
Benchmark al Norms
Benchmark
90 m3/T Not 100 m3/T 150 m3/T
Available (w.r.t waste wate r
norms of 120)
Best Availabl e Ref erences of European Countries fro m th e
"BREF Pulp and Pap er", el ectronic ad aptation of the Eu ropean
ref erence docu ment on Best Availabl e Techniques (in the slant of
redu cing th e agg res sions to man and environment) in the Pulp
and Paper manufa ctu ring industry.
Implemented Projects 07-08
Scheme-1: Recirculation of Fresh Water from Overhead
Tank for Compressor cooling
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6. Implemented Projects 07-08
Scheme 1
Old System: New System:
F/water r equir ement 30 m3/hr . F/water r equir ement 30 m3/hr .
Water sent back to Over head Tank : Nill Water sent back to Over head Tank : 30 m3/hr
Actual cooling Water consumed : 30m 3/hr Actual cooling Water consume d : Nil
Savings : 237600 m3 / year
Investment Rs.0.2 Lakhs
Implemented Projects 07-08
Scheme-2: Reduction of sealing water in Couch of PM4 by use of
Anti friction bearing
Savings : 31680 m3 / year
Investment Rs. 9 Lakhs
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7. Implemented Projects 07-08
Scheme3: Refurbishing of PM4 steam & condenser circuit
Implemented Projects 07-08
Scheme3: Refurbishing of PM4 steam & condenser circuit
Old System: New System:
Steam r equir ement : 110 TPD Steam r equir ement : 80 TP D
Condensate r ecover y : 39 TP D Condensate r ecover y : 56 TP D
Water r equir ement : 21 TPD
Water r equir ement : 7 1 TPDr Water saving : 50 TP D
( This saving would come in DM wa ter )
Savings : 49500 m3 / year ( DM water)
Investment Rs. 120 Lakhs
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8. Implemented Projects 07-08
Scheme5: Se quencing of Coloure d Laminating Grade making on PM4
Grade change in Colour laminating grades is associated with lot of
water for cleaning & flushing the system. T PM team has come
together to reorganize making schedule with in-depth R& D inputs to
avoid water usage during many grade changes
Savings : 12000 m3 / year
Investment : Nil
Implemented Projects 07-08
Scheme 6: Use of New Generation CentriCleaner system on PM1
Picture before modification Picture after modification
Water requirement : 6m3/hr Water requirement : 4m3/hr
Savings 15840 m3 / year
Investment Rs.28 Lakhs
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9. Implemented Projects 07-08
Scheme 7:
Reduction of leakage of Gland sealing water through use of
Mechanical seals
Savings : 15840 m3 / year
Investment Rs. 24 Lakhs
Implemented Projects 07-08
Scheme 8:
Use of highly efficient imported Vacuum Pumps requiring less
sealing water
Before Modernisation After Modernisation
Savings : 23760 m3 / year
Investment Rs.57 Lakhs
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10. Implemented Projects 07-08
Scheme 9:
Reduction in consumption of Make up water in Cooling Tower by
improving COC
Implemented Projects 07-08
Scheme 9:
Reduction in consumption of Make up water in Cooling Tower by
improving COC
Old System: New System:
For TG2 For TG2
Evaporation loss: 1 1 m3/hr Evaporation loss: 1 1 m3/hr
Blow down : 27. 5 m3/hrl Blow down : 5.5 m3/ hrl
Total mak e up water : 38.5 m3/hr Total mak e up water : 16.5 m3/hr
For TG3 For TG3
Evaporation loss: 14.7 m3/ hr Evaporation loss: 14.7 m3/ hr
Blow down : 36. 7 m3/hrl Blow down : 7.4 m3/hrl
Total mak e up water : 51.4 m3/hr Total mak e up wate r : 22 m3/h r
Total mak e up water reqd.: 89.9 m3/ hr Total mak e up water reqd.: 38.5 m3/ hr
Savings : 50 m3 / hour
Investment Rs. 40 Lakhs
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11. Implemented Projects 07-08
Scheme 10:
Introduction of Reverse Osmosis system in PM1
Savings : 39600 m3 / year
Investment Rs.40 Lakhs
Waste Water Discharge
Specific Waste Water Discharge (kL/t)
11 0
80.7
69.3
63 61.5
60
2004-2005 2005-200 6 2006-2007 2007-2008
With con tinuous efforts in max imising pro cess wa ter recy cling
we hav e redu ced belo w 50 % of CPCB norms.
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12. Waste Water Discharge
Waste Water Discharge - Benchmarking
Tribeni Mill National International CPCB Norms
Benchmark Benchmark
61.5 m3/T Not Available 60 m3/T 120 m3/T
Best Availabl e References of Europ ean Countries fro m th e "BRE F Pulp and
Paper", el ectronic ad apta tion of the Eu rop ean reference do cument on B es t
Availabl e Techniques (in the sl ant of reducing the aggressions to man and
environment) in the Pulp and Paper manufactu ring industry.
The Road Map towards Zero Discharge
3-step process:
• Implementation of Future Fresh Water Conservation Projects
• Closing the Water Loop with reuse of Mill
Treated Water
• Continuous Monitoring and Control to sustain
the System
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13. Monitoring
f All fresh water consuming areas are provided with water flow
meters connected to DCS system.
f Daily, weekly and monthly MIS reports contain the fresh water
consumption figures.
f Monitoring is done online, by the respective utilities and paper
machine shift incharges.
f Specific Key Focus Areas are predefined for respective managers
as a part of their annual appraisal system for Water Conservation
Measures and Monitoring
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