Damodhar Cement Works

Transcription

1 Excellence Through Teamwork Water conservation through recycle and reuse Presented By ACC Limited Damodhar at a glance. DCSL commenced commercial production in October 199 as a joint venture project of WBIDC and Cement Corporation of India Ltd In September 1996 ACC Ltd. took over the management of the Company and it became a Subsidiary of the ACC Ltd. With WBIDC as a partner Capacity enhancement from 2.7 to 5.25 LTPA of Portland Slag Cement in the year 1998 was taken up by ACC An ISO 91 : 2 and ISO 141:24 certified unit

2 Our Strategic Vision Our Environmental Policy

3 Cement Manufacturing Process Wet Slag sto rage at Ropeway Loading Station Ball Mill-2 16 T/H Ropeway 2.6 KM, Capacity 135 TPH Open Wet Slag Storag e Capacity 35 KT Clinker And Gypsum Covered storag e Hall Clinker 18T Dry Sl ag 5T Gypsum 8T Ball Mill-3 15 TPH Cement Sto rage Silo 2 x 38 T Slag Dryer 6TPH Coal Mill 3 TPH Coal Storag e 8 MT Wagon Tippler 6 TPH Ball Mill-1 49 TPH Bagging 1 T Cap. 2 nos Roto Packer Drinking Water Consumption Water consumption in Factory Water Consumption in Colony Lit /Person /Day '4-'5 '5-'6 '6-'7 '7-'8 Lit /Person /Day '4-'5 '5-'6 '6-'7 '7-'8 Year Year 25-6 water consumption high due to fly ash silo and cement silo project 27-8 water consumption high due to new construction of quarters

4 Bench Marking Consumption (K m3) '4-'5 '5-'6 '6-'7 '7-'8 Year Industrial Drinking/Domestic Use Total Specific Water Consumption (m3/t) '4-'5 '5-'6 '6-'7 '7-'8 Year DCW National Benchmark International Benthmark Damodhar River FM Water Flow Diagram FM Process Water FM Drinking Water Plant Colony Village Process water Tank Drinking Water Plant Process Water Over Head Tank Drinking Water Reservoir

5 Sewage Treatment Plant SWEAGE COLLECTION SUMP OXIDIZATION PLANT CIRCULAR TANK BACK WASH WATER TANK FILTER TREATED WATER RESERVOIR SUPPLY FOR IRRIGATION Monitoring & Reporting System Applying Analog Flow Meter for accuracy Maintain daily log sheet to feed the readings Weekly report to Chief Manager Engg., Plant operation head & Director Plant

6 Project -1 : Reuse of Domestic Waste Water The previous system of domestic waste water treatment having following demerits : The Domestic Waste water including the kitchen and washroom discharge is treated at sewage treatment plant After the plant expansion, filtration capacity of STP was not sufficient to take the increase of waste water day to day due to increase of population and quarters in colony Idea Generation Disconnection of Kitchen and bathroom line of A-Block & Hutment buildings from main STP line Waste water from kitchen and bathroom collect in a pond after gravitation filtration process and this water use for gardening and breeding fish Project - 1 : Reuse of domestic waste water Kitchen and Washroom Water Collected into Pond Plantation at Colony

7 Project - 1 : Reuse of domestic waste water 6 RESULTS : Recycling of waste water and optimum usage of resource Smooth and efficient operation of STP Ensure ZERO discharge Volume (Lit.) '7-'8 '6-'7 '5-'6 '4-'5 '3-'4 Year Discharge water (KL) Project 2 : Reduction of river water usage The previous water supply system (surface water from Damodar river) had the following demerits: Unhygienic water quality specially during monsoon. During summer and winter, 1 nos. labor used daily for channeling the water to the pumping point 18 KW pumps used for lifting the water and 7.5 KW pump used for pressure filtration High treatment cost of Rs. 4. per month The Cost of production was Rs. 5.5 per KL.

8 Project 2 : Reduction of river water usage IDEA GENERATION : Elimination of the surface water supply and associated filtration system by installation of a deep bore well pumping unit at middle of river bed Drawing the subsoil water which is much more hygienic and available throughout the year Project 2 : Reduction of river water usage Actions Implemented 4 feet deep bore well pump has been installed Water treatment plant operation has been stopped

9 Project 2 : Reduction of river water usage RESULTS: Continuous supply of good quality drinking water even in rainy season Operation and maintenance cost have been reduced to Rs. 1.2 per KL Hence annual saving is Rs. 2.4 Lakhs Project 3 : Close circuiting of process water Previous water supply system : Cooling water supplied to the machines was not recirculated and reused High water loss High amount of water cess paid by the company Idea Generation All the return water lines have been connected to the main return water pipe.

10 Project 3 : Close circuiting of process water Result : Reduction if water consumption as well as discharge by 8% Reduction in pump house power consumption by 6% Awareness DCW sent representative to Delhi for training on Water Management system Mass awareness of taking hygienic water through distribution of leaflets & electronic media among the nearby community & colony inhabitants Providing hygienic water to the nearby villagers Periodic checking of quality of water by internal as well as exter nal authority Distribution of leaflets for awareness towards water borne diseases Arrange drawing competition on Conservation Of Natural resour ces among the colony & nearby inhabitants children Suggestion Scheme for new idea generation Environmental Quiz Competition conducted by DCW club

11 Sustainable Development Rain Water Harvesting: Constructed earthen pond at Colony & concrete reservoir inside plant Use of Treated water from Sewage Treatment plant for plant & colony plantation & gardening Reserve shower & kitchen water into pond for plantation Complete Looping of process water for recirculation Optimizing the water distribution cycle frequency towards colony & nearby inhabitants Installation of float valves to all the water reservoirs (tanks) at all the colony buildings Our Future Plan.. Integration with OSHAS 181 Annual external audits through authorized auditing agencies Involvement of people through small group activities Developing In-house expertise for audits Installation of flow meter at consumption points for better monitoring Zero water leakage Arrangements for collecting storm water from roof shed and collecting in the earthen ponds

12 We can do no great things ; only small things with great love. - Mother Teresa