Heavy Water Board, Mumbai

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2 ORGANISATION CHART OF DEPARTMENT OF ATOMIC ENERGY ATOMIC ENERGY COMMISSION DAE Science Research Council DEPARTMENT OF ATOMIC ENERGY ATOMIC ENERGY REGULATORY BOARD R&D ORGANISATIONS PUBLIC SECTOR UNDERTAKINGS INDUSTRIAL FACILITIES SERVICE ORGANISATIONS Bhabha Atomic Research Centre, Mumbai Indira Gandhi Centre for Atomic Research, Kalpakkam Centre for Advanced Technology, Indore Variable Energy Cyclotron Centre, Kolkata Nuclear Power Corp. of India Ltd., Mumbai Indian Rare Earths Ltd., Mumbai Uranium Corp. of India Ltd., Jaduguda Electronics Corp. of India Ltd., Hyderabad Heavy Water Board, Mumbai Nuclear Fuel Complex, Hyderabad Directorate of Purchase & Stores, Mumbai Directorate of Construction, Services & Estate Management, Mumbai Atomic Minerals Directorate for Exploration & Research, Hyderabad Bharatiya Nabhikiya Vidyut Nigam Ltd., Kalpakkam Board of Radiation & Isotope Technology, Mumbai General Service Organisation, Kalpakkam Board for Research in Nuclear Sciences Tata Institute of Fundamental Research, Mumbai Institute of Physics, Bhubaneswar Institute of Mathematical Sciences, Chennai National Board of Higher Mathematics Homi Bhabha National Institute Tata Memorial Centre, Mumbai Saha Institute of Nuclear Physics, Kolkata Harish-Chandra Research Institute, Allahabad Institute for Plasma Research, Ahmedabad Atomic Energy Education Society, Mumbai

3 HWP, Kota HWP, Talcher Boron Enrichment Plant VSP Plant HWP, Baroda TBP Plant TBP Plant Boron Enrichment Plant HWP, Hazira HWB at V.S. Bhavan Training School HWP, Manuguru Elemental Boron Plant VSSP Plant HWP, Thal HWP, Tuticorin

4 Production of heavy water for NPP- PHWR & AHWR Production of 10 B enriched Boron - FBRs Production of Solvents - nuclear hydro-metallurgy Societal initiatives Oxygen-18 water for diagnostic & bio-medical use Deuterium Depleted Water Environmental initiatives AFGC Technology initiatives indigenization Closed cell technology for NG Sodium production Efficient equipment CE, ARDC for solvent extraction Cryo-technology

5 Heavy water production - A complex & energy intensive technology Involves separation of deuterium from feed as low as 105 ppm & enrichment up to 99.90% Electrolysis of water & cryogenic distillation of hydrogen HWP, Nangal (plant now decommissioned) H 2 S H 2 O Exchange Process (GS Process) NH 3 -H 2 Exchange Process Ammonia - Water front-end Process Vacuum Distillation for up-gradation

6 Water conservation globally & more particularly to Indian situation is extremely important Major problem areas Alarming depletion in ground water resources Vagaries ofmonsoon Contamination ofwater through industrial activity Multipronged approach required for managing this issue - Ground water depletion & monsoon issue to be dealt by Hydrologists and implemented at root level Water conservation in industry within scope of industrialists, engineers & scientists - must be given priority as mission oriented programme

7 Water is mainly used in Heavy Water Plants for Deuterium Extraction (Process Feed Water) Steam Generation (Boiler Feed Water) Cooling of Hot Process Fluid (Raw) Cooling Water (Raw or partially DM) Chilled Water Valve Sealant Dilution of Process Effluents (Raw or partially DM) Fly Ash Disposal (Raw or partially DM) Fire Hydrant (Raw) Drinking (Potable quality) Sanitation & Gardening (Raw)

8 Huge water intake for heavy water production; major portion generates effluent HWB deeply concerned over water conservation HWB committed for zero discharge of effluents in all its plants Implemented major water conservation measures Drastically reduced water intake ~ 75% reduction in intake through various measures and efforts are on for further reduction

9 Plant HWP, Baroda HWP, Hazira HWP, Kota HWP, Manuguru HWP, Thal HWP, Tuticorin Source Mahi River Tapi River Rana Pratap Sagar Lake Godavari River Patalganga River Tamrabarani River Total water intake for HWPs Design basis: m 3 /day (66 million GPD) Actual: m 3 /day (16 million GPD) Recycle & reuse has substantially reduced water intake Water drawn from source is treated to get desired quality for different applications

10 Reducing heating & cooling requirement Reducing effluent water temperature from 75ºC to 50ºC reduced dilution load Operating Cooling Towers at higher CoC Reduced CT blow down through improved water chemistry & maintaining higher CoC through CW treatment programme Recycling & Reuse of effluents Rain water harvesting at HWP, Talcher Mass awareness on water conservation

11 Recycle & Reuse of Process Effluents as Feed to DM plant of CPP at HWPM Boiler Water make up at HWP, Kota Cooling water make up at all HWPs Blow down water for ash slurry system, HWPM Dilution for cooling of process effluents at HWP, Manuguru & Kota Back washing filter beds at HWP, Manuguru & Kota Horticulture & house keeping requirements Effluent water reuse through RO process, HWP, Tuticorin Recycling of cooling tower blow down to fire water reservoir

12 Recirculation of sealant water to process feed water Recycling of DU ejector condensate to cooling tower Recycling process feed pump balancing water to WTP Sewage Treatment Plant recycling sewage effluent for gardening purpose Reverse Osmosis Plant at Tuticorin Fly ash transportation from CPP to ash ponds Guard pond water to cool effluent water

13 m 3 /hour HWP,Kota HWP,Manuguru Year

14 m 3 /hour Water Consumption m 3 /hour 200 HWP, Thal HWP, Hazira Year

15 Reduction in Process Effluent Temp. Case Study of HWPK Plant Effluent 1100 m 3 /h Dilution 530 m 3 /h; 70 o C To River 1ºC reduction in effluent temp ~ 1 MT/h of steam saving 1MT/h Steam saving ~ 35 Lakhs per annum Necessitates waste heat recovery

16 Phase-1: Waste Heat Recovery Plant Effluent 1100 m 3 /h Dilution 530 m 3 /h; 68 o C To River Waste Heat Recovery Heating BFW (60 m 3 /h 28 0 C to 68 0 C) Saving Steam 3MT/h ~ 1crore per annum

17 Waste Heat Recovery Unit at HWPK Makeup Water Preheated from 28 o C to 68 o C

18 Installation of Effluent Cooling Tower Case Study of HWPK XU effluent is 530 m 3 /h at 68ºC after waste heat recovery unit This effluent is mixed with raw water (1100 m 3 /h) to bring down its temperature below 40ºC before discharging it to open atmosphere Dilution helps in : Bringing down the temperature of effluent Oxidizing dissolved H 2 S in effluent by raw water. Diluting dissolved sulphide content

19 Installation of Effluent Cooling Tower Case Study of HWPK Plant Effluent 530 m 3 /h; 68 o C No Dilution Waste Heat Recovery BFW, Make-up CT Make-up Gardening Heating BFW 60 m 3 /h 28 0 C to 68 0 C 35 o C Effluent Cooling Tower No Dilution saves power for dilution & raw water and cess

20 Benefits of Effluent Cooling Tower Natural Resource conservation by stopping effluent dilution Reduction in Raw Water consumption from 1300 to 700 m 3 /h Electrical power savings of 80 kw when scheme is fully implemented (excluding additional saving of 150 kw of 1300 m 3 /h raw water pump replacement) Approach towards zero effluent discharge Green belt development around the plant

21 Use of Low Temperature Heat Source for generation of Cold Plant Effluent 530m 3 /h; 68 o C 530m 3 /h; 54 o C No Dilution Waste Heat Recovery Heating BFW 60 m 3 /h 28 0 C to 68 0 C Vapour Absorption Refrigeration BFW, Make-up CT Make-up Gardening 1000 T of Refrigeration Effluent Cooling Tower 1000 T refrigeration equivalent cooling effect for use in maintaining cold tower temperature. 35 o C

22 VAPOUR ABSORPTION REFRIGERATION SYSTEM

23 Effluent Cooling Tower at HWP, Kota Effluent From Waste Stripper To Delay Tank 530m 3 /h; 54 o C CHARCOAL BED MIXED BEDS Chlorine Dosing 60 m 3 /h BFW to RAPS Lime Dosing (300 m 3 /h) MAKE-UP COOLING TOWER 30 m 3 /h 60 m 3 /h AUTO FLUSHING GREEN BELT

24 Mist Cooling System at HWP, Kota Cooled Effluent recycled for Boiler feed water make up, Cooling water make up & Gardening and Sand Filter backwash Benefits Fanless Filless : No maintenance requirement, additional power saving 30 kw Water Saving m 3 /day Power Saving 180 kw; Annual Saving ~ 36 Lakhs (@ 180 x 2.8 x 7200)

25 Water Balance HWP, Kota Fresh Water 700 m 3 /hour (All figures in m 3 /hour) As & when required Water Treatment Plant Cooling Tower Fire Water & Miscellaneous 495 Process Feed Water C.T. Make-up 240 Fire Water Make-up Drinking Water 80 Boiler Feed Water Service Water Miscellaneous Sanitation Water Irrigation Water

26 Guard Pond Water Recirculation at HWPM

27 Cooling Tower was bypassed and a power saving of200 kw isrealized. No Fans and Fills are required and one GP recirculation pump isstopped. No maintenance required on Structural Members and Louvers. Achieved sustained GP outlet water temperature well below the State PCB stipulated value of 40 deg.c

28 Water Balance HWP, Manuguru Fresh Water 1700 m 3 /hour 1050 M/P DM Plant (All figures in m 3 /hour) For Irrigation of field to nearby villages Ash Handling Drinking Water M/P Service & Fire Water Miscellaneous 1050 Exchange Unit Guard Pond CPP Cooling Tower CPP Service Water 150 M/P Cooling Tower CPP DM Plant

29 Reverse Osmosis Plant at HWP, Tut. Capacity : 12 m 3 /hour feed processing Product 8 m 3 /hour Benefits : - Reduction in raw water consumption by 180 M 3 /day - Reduction in water effluent discharge - Reduction in chemical consumption for cooling water treatment

30 Reverse Osmosis Plant at HWP, Tut. Pre-treatment Section Membrane Section

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32 Benefits of water Conservation Natural resource conservation Energy conservation Approach towards zero effluent discharge Green belt development around the plant Reduced financial burden rebate in cess

33 Rain Water Harvesting at HWP, Talcher Rain water harvesting at HWP, Talcher (in water starved district of Angul in Odisha state)

34 Mass Awareness Programme on Water Conservation *

35 Mass Awareness Programme on Water Conservation *

36 Mass Awareness Programme on Water Conservation *

37 Mass Awareness Programme on Water Conservation *

38 Heavy Water Board All industrial facilities of HWB have achieved Zero liquid effluent discharge Effluents are fully treated & recycled / reused IETP at Talcher received DAE Excellence Award in Science and Technology for the year 2013.

39 Water conservation & preservation - HWB s motto Substantial reduction in water consumption, ~70% Rain water harvesting Aspiring to be water positive organization Significant improvement in ground water level

40 Indigenously developed solar energy based steam generator installed at HWP, Kota First of its kind application in India for process industry 12 MWp Solar PV Power Plant installed at HWP, manuguru

41 National Water Conservation Award National Award for Excellence in Water Management Being Presented to HWP, Kota

42 We at HWB are putting continuous effort for continual improvement towards Water Resources Management, Energy Conservation, Environment Conservation.WAY FORWARD for Sustainable Development in India

43 Fresh Water Quality compilation required Parameter HWP, Baroda HWP, Kota HWP, Manuguru HWP, Tuticorin HWP, Thal HWP, Hazira ph Conductivity, µs/cm T.D.S., ppm Turbidity, NTU < <2 <2 <1 Total Hardness, ppm as CaCO Alkalinity, ppm as CaCO Chloride, ppm as CaCO

44 Water Quality vis-à-vis Process Problems Potential impurities present in fresh water Suspended solids Dissolved solids Micro-organism Dissolved gases Water quality related process problems Corrosion Scaling Process upsets

45 Water Treatment Philosophy Water is treated to obtain Filter Water Process Feed Water Boiler Feed Water Cooling Water Chilled Water Treatment Scheme Coagulation & Clariflocculation Sand Filtration Chlorination Activated Charcoal Treatment Demineralization De-aeration Chemical Treatment