National Award for :CII Sterlite Industries India Ltd- Silvassa
OVERVIEW STRUCTURE p A leading producer of key commodities Group turnover FY 06-07 $ 6.7 bn p Listed on the London Stock Exchange p 25,000+ Employees Aluminium Copper Zinc Copper Zinc Aluminum p US$ 2.2bn pipeline of brown and greenfield projects KCM (Copper) Sterlite (Copper) HZL (Zinc) Vedanta Alumina (Alumina) Balco (Aluminium) Malco (Aluminium)
REFINERY ANODE CC ROD ELETRO REFINING CATHODE CASTING ROLLING CC ROD COIL
PROJECTS WITH ZERO INVESTMENTS: q Modification in Thermoshypon cooling water arrangement. Savings : 4380 m3 : Rs. 1.4 Lacs. q Condensate Recovery of RVD for Filter Press Backwashing. Savings : 1284 m3 : Rs. 0.41Lacs q Process modification in Leaching section reduced steam consumption Savings : 2160 m3 : Rs. 0.69 Lacs q Modification of Nozzles in ASWM Resulted in better drying & reduction in water consumption. Savings : 770 m3 : Rs. 0.23Lacs q Reuse of collected condensate water generated by anode casting cooling water. Savings : 655 m3 : Rs. 0.21 Lacs
PROJECTS WITH INVESTMENTS: q Rain water harvesting. Savings : Year - Water Savings 2004-1577 m3 (Rs. 0.50 Lacs) 2005-4158 m3 (Rs. 1.25 Lacs) 2006-6225 m3 (Rs. 1.86 Lacs) 2007-9475 m3 (Rs. 2.84 Lacs) Total - 21435 m3 (Rs. 6.45 Lacs) Investment : Rs. 10 Lacs Payback Period : 72 months
PROJECTS WITH INVESTMENTS: q Conversion of Gland Packing Pumps into Mechanical Seal Savings Investment Payback Period : 1728 m3 Water (Rs. 0.55 Lacs) : Rs. 3.0 Lacs : 65 months q Provision of Electrolytic Cell covers in Refinery Savings Investment Payback Period : 3703 m3 Water (Rs. 1.18 Lacs) : Rs. 1.0 Lacs : 14 months q Lube Cooled Heat Exchanger for Compressors with recirculation Savings Investment Payback Period : 1200 m3 Water (Rs. 0.38 Lacs) : Rs. 1.5 Lacs : 46 months
WATER CONSERVATION PROJECTS - SUMMARY: Total no of projects implemented = 9 Projects implemented without investments = 5 Projects implemented with investments = 4 Savings : 37315 m3 Water Total Investments made : Rs 15.5 Lacs Total Savings Achieved : Rs 11.5 Lacs
WATER SHARE - SILVASSA 20% 2% 2% 18% 58% RFNY CCRC CCRP PMP ACP
WATER CATHODE (M3/MT) Sp. Water Consumption 0.70 0.60 0.50 0.40 0.30 0.20 0.10 0.60 0.67 0.54 0.49 0.00 2003-04 2004-05 2005-06 2006-07 Fiscal Year Reduction in Specific Water Consumption = 18.97 %
WATER CC ROD (M3/MT) 0.50 0.44 0.47 0.41 0.35 Sp. Water Consumption 0.40 0.30 0.20 0.10 0.00 2003-04 2004-05 2005-06 2006-07 Fiscal Year Reduction in Specific Water Consumption = 20.45 %
Waste Water Details : Industrial Waste Generated ( M3 ) 12000 10000 8000 6000 4000 2000 0 9500 10308 8260 5544 2003-04 2004-05 2005-06 2006-07 Fiscal Year
Waste Water Details : Domestic Quantity Generated (M3) 8000 7000 6000 5000 4000 3000 2000 1000 0 7440 7093 7054 5838 2003-04 2004-05 2005-06 2006-07 Fiscal Year
BENCHMARKING q Our ultimate objective of our plant is to be 0.4 m3/mt of copper cathode. q CII water audit and implementing the same for further improvement. q To sustain as a ZERO discharge plant in copper industry. ROAD MAP FOR THE FUTURE q Regular Water Audits & Identification of new projects. q SPC techniques in Water Monitoring. q Utilization of waste condensate water. q Conversion of all gland seal pumps into mechanical seals. q Exploring the possibility of Air Cooled heat exchangers in place of normal cooling towers.
TQM PROJECT KEY FACTOR 1: FOR WATER SUCESSFUL CONSUMPTION IMPLEMENTATION REDUCTION Problem Statement : Consumption of water is on higher side @ 1,10,400 m3 per year which is costing around Rs. 35.3 Lacs per year. Mission Statement : Reduce the Water consumption from 1,10,400 m3 per year to 92,000 m3 per year thereby leading to conservation of natural resource & a saving of approx Rs 6.0 Lacs per year.
TQM PROJECT 1: WATER CONSUMPTION REDUCTION Cause And Effect Diagram based on Brain Storming : OTHERS No NRV in water transfer line No calibration of flow meters No recycling of STP water Evaporation Losses Overflow of quenching,sintex CCR BOILER Blowdown Emulsion leakages Leakages no recyclinfg of Casting Cooling Improper data recording Lack of awareness of SOP Tank overflow in ETP More B/W REGENERATION/ BACK WASHING REFINERY Leakages High frequency of regeneration Drift Losses Evaporation Losses COOLING TOWER Contact cleaning Poor water quality Leakages Seepage to ground Low COC Excessive Blowdown Excessive heating of equipment Poor condition of drift eliminators HIGH WATER CONSUMPTION
TQM PROJECT KEY FACTOR 1: FOR WATER SUCESSFUL CONSUMPTION IMPLEMENTATION REDUCTION q Recycling of water q Overflow and leakages q Evaporation losses in cell house q Excessive regeneration and backwashing q Efficiency of cooling tower [ the cycle of concentration to 5-7 (COC) ] q Alternate source to raw water. Formulation of Theories
TQM PROJECT KEY FACTOR 1: FOR WATER SUCESSFUL CONSUMPTION IMPLEMENTATION REDUCTION Results & Benefits Water Consumption (M3) 10000 9000 8000 7000 6000 5000 4000 9200 8916 8569 Before TQM 9021 8838 8402 7109 7006 6956 6924 7123 6802 6823 2005-06 May-06 Jul-06 Sep-06 Nov-06 Jan-07 Mar-07 Month After TQM Reduction in Water Consumption : 16.2 % ( Rs. 5.73 Lacs )
TQM PROJECT KEY FACTOR 2: WATER FOR SUCESSFUL CONSUMPTION IMPLEMENTATION REDUCTION IN PMP De-Te Cost is 29 % of the Total Slime Plant Cost Steam / Water - 91 % We targeted reduction in steam consumption which in turn resulted in water consumption reduction. Leaching Cost, 35% Steam/Water -91 % Detellurisation Cost, 29% Packing Cost, 6% We increased the no. of baskets, increased the basket cleaning frequency & provided additional steam lines. Utilities, 6% Stores & Spares Cost, 11% Manpower Cost, 4% Replacement Cost, 9% After completion of the project water consumption reduced by 70 %.
Employee & Community Involvement TOP DOWN APPROACH APPROACH BOTTOM UP APPROACH Policy Deployment Continuous Improvement Daily Management PEP Mechanism Water Month
SUGGESTION CATEGORY COP Reduction 18% System Improvement 16% Quality 10% Process Improvement 14% Water Conservation 17% Safety Environment 25%
Water Month Celebration q Celebrated Water Month on March 2007. q Celebrated World Water Day on March 22 nd 2007. q Each year carries a particular theme on WWD like 2007 : 2006 : Water and Culture 2005 : Water for Life 2004 : Water and Disasters 2003 : Water for the future etc. q Organized various events related to water awareness.
WATER MONITORING & REPORTING SYSTEMS: q Whole Plant is divided into 5 areas and Water Consumption for each plant is monitored. q Water norms 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 is getting prepared by the Water Manager and is getting reviewed by the Head Operations in presence of Sectional Heads. q The Water report consists of Water Share, Specific Consumption, Trend analysis, Internal & External Benchmarking, Concerns and Action plan for the next month.
LIST OF KEY MAJOR FACTOR ENVIRONMENT FOR SUCESSFUL IMPLEMENTATION IMPROVEMENTS 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)
AWARDS KEY FACTOR & CERTIFICATION FOR SUCESSFUL IMPLEMENTATION q ISO 9001,14001 and 18001 (OHSAS) Certification by DNV q Sterlite brand Copper cathode registered in LME in Dec- 01 q Awarded Commendation certificate RBNQA of IMC in March 2007 q Sterlite bagged IMEA - Silver corporate award of M/s Frost and Sullivan in Nov 2006 q Won First Prize at Qualtech 2005 in Improvement Manufacturing Category. q Won finalist award at ASQ team competition-2006 held in Milwaukee, USA. q NABL accreditation on chemical, electrical & mechanical testing in Aug-2003. q Central lab recognized as R&D centre by Govt., of India
AWARDS KEY FACTOR & CERTIFICATION FOR SUCESSFUL IMPLEMENTATION q Won 3rd Prize for Unique Employee Involvement by INSSAN May 2007 q Appreciation letter from Gujarat safety council for excellent safety practices q Won INSSAN Meritorious award Feb-2007 q Bagged consecutive prizes for best suggestor in INSSAN at Visakaptnam in July 2007 q Corporate award for Creative workplace q Safety Innovation award by Institute of Engineers Sept 2007 q Short listed for Platinum Band in IMEA NABL q Awarded by CII as Excellent Energy Efficient Unit in Sept 07 q Won First Prize at Qualtech 2007 in Innovation Manufacturing Category.