This is a presentation from Kankroli Tyre Plant, 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. CII - Sohrabji Godrej Green Business Centre, National Award for
” Excellence in Water Management – 2008”
2008”
Presentation By
Kankroli Tyre Plant (KTP)
A UNIT OF
I
Team Members
Mr. DR Pai
Mr. A K Pamecha
Mr. M P Sharma
Special Guidance
Mr. A K Makkar (Unit H ead )
Slide No . 1
UNIT PROFILE
JK TYRE AND INDUSTRIES
Banm ore (MP ) Kankroli (Raj asthan) Vikrant Tyres, Mys ore
KANKROLI TYRE PLANT
KTP – MISSION
• Established at Kankr oli - 1976
• Initial capacity – 55 Ton/ Day, KANKRO LI TY RE PLANT
• Curre nt capacity – 210 Ton/ Da y TO BE
• Water Demand – 1200m3 (Max)
ZERO LEAK P LANT
Slide No . 2
1

2. PROCESS OUTLINE
Duri ng ma nufacturi ng, w e use Compressed Air, Steam, Water & Oil at
v arious applications of pr ocesses.
At KTP w e thought for a consolida te policy and pr ogram for
identi fication and c orrection of leaks, Zero Drai n and Water Pr ocess
efficienc y impr ov ement, Zero Leak mission w as started in J un -2008
Slide No . 3
Industry Benchmark
3T n
m/ o
Avg. – 8.4 Our Plant
3.04
2 nd Best – 4.8
C nu pi n
o s m to
Wtr
ae
Data Source : CII Study, Conducted by : Forbes Marshal
Future Plans to “BETTER THE BEST”
Slide No . 4
2

3. WATER CONSERVATION STRATEGIES
WATER CONSERVATION STRATEGIES
1. Work for ZERO Discharge
2. Develop Hydrophobia for water in unwanted places
3. Eliminate all open drains
4. Optimize and load cooling towers to their 100%
capacity to reduce evaporation losses
5. Reduce evaporative cooling to the extent possible.
6. Explore radiator / air cooling
7. Recover / remove heat to the extent possible from water
before sending it to cooling tower
8. Eliminate Flash losses in steam usage
9. Identify wastage and eliminate them.
10. Deploy concepts of Multiple recycling / recovery and
reuse
Slide No . 5
Initiatives
Ø Prize for water efficient family block (8 quarters).
Ø Prize for every received sugge stion, 15 No s/month Accepted
sugge stions, Every implemented sugge stion for water con servation /
Leak.
Ø Solar Water Heater For Canteen
Ø Solar Water heater for Ca rbon area Workmen bath
Ø Water con se rvation by recycled water for Air Wa sher in Plant
Ø FRP Sheet s for abundant daylight utilization
Ø Push cock water tapings.
Ø Dist rict Level Children Poster competition
Ø Steering committee formed comprising of Unit Head, BU/SSU Head s,
Asset Managers & Workmen.
Ø Health Check up & Medical add to surrounding residing.
Slide No . 6
3

4. E.M.S. INITIATIVES AT KTP
Ø Discharge Elimination
Ø Leakage Elimination
Ø Air Emission Reduction
Ø Effluent Discharge Reduction
Ø Adoption of clean Processes
Ø Energy Conservation
Ø Optimization of Fuels and Oils
Ø Recycling, recovery and reuse
Ø Process Waste reduction
Ø Enhancing Green Belt
Ø Resource Conservation
Slide No . 7
Water Conservation Efforts
Water Conservation Efforts
VISI ON, M ISSI ON
& GUIDANCE
Recycle &
Rain Water Waste
Harvesting Apex
Apex Treatme nt
ING
Level
RE
Lev el
E-U
CL
- S
Cooling Unit Level Water
CY
Towers Unit L evel
Q uantificatio n
E
E
Eliminatio n
RE
Business Uni t Level
Busin ess Unit Lev el
Sav ing
Sewerage Task For ce / Small Gr oup s
Droplets
Recycling
SG Projects
RECOVERY
Slide No . 8
4

5. Water Conservation Projects By Employees
A THEMES
Pro jects Im lemente d
p T eam
Maintain in g ZERO Disch arg e M CS
E lo y ees awa rene ss impro v ement p ro grammes
mp M CS
Pu sh co ck in place o f n o rm l tap es
a M CS B THEMES
Toilet flu sh water v olume red uc tio n b y inse rtin g
M CS
brick P rojects Implemented Team
Twin ty p e T oile t flu sh water tan k in trod u ctionall cooling water lines
Clos e looping of M CS MCS
Reco very In creas e in plant & colo ny was te water &
Use o f b ack wa sh water in Air recycling g Sy stems M CS
Han dlin MCS
Tren ch water recov ery
Boiler b low-d own re du ction by con d uc tiv it y
M CS
Improve s team co ndensate recovery
MCS
MCS
C THEMES
con tro l o f DM Wat er
Coo lin g to wers elimin ation andRain po ration lo ss
eva water harves ting us ing natural Pro ject s Implof Terrain
gradian t emen te d MCS Team
M CS Emp loy ye inv o lve men t t hrou gh sp ecific s ug ges tio ns fo r w ate
redu ctio n Wo rk men & St aff
co n serv at ion
Dra in co rrec tio n s an d maint ain ing s water harves ting
Rain torm wa ter us ing Plant roof water collection MCS
M CS Drin kin g w ater su pp ly pressu re red u ctio n Wo rk men & St aff
drain s d ry
Red uc tio n in n umbe r o f w ater t aps Wo rk men & St aff
Us e of radiator cooling (A CF C) inplace of cooling towers MCS
24 x 4 Leak mon ito rin g sys tem
2 Wo rk men & St aff
Us e o f b ack wash wat er fo r Flo or & Road cle anin g Wo rk men & St aff
Cooling to wer recons truction for efficiency Stea m re du cti on in bo iler de -aerat or by wa y o f p re -
W at er for improvements MCS
Wo rk men & St aff
h eat ing u sing wa ste hea t
A CILOL Chemical s prayning in neig hbouring st eam i nst ead of lea vin g in o pe n a tmo sp he re
Us e o f Flash world Wo rk men & St aff
MCS
famous Lake RA JSA MA ND for evoporation wat er u sag eatio n sp ra y b y use of b ack-wash
Sto p fre sh minimis in co al
Wo rk men & St aff
wa ter
Us e o f au to st op v alve s wit h time s fo r sto pp in g w ate r
Wo rk men & St aff
circu lat ion in idle m/ cs
Ferrul es in sertio n fo r wa ter co nse rv ati on Wo rk men & St aff
Sto pp ag e o f se con d circ ula tio n p u mps in cert ain pl aces Wo rk men & St aff
Slide No . 9
SUSTAINING : LEAK FREE PLANT
Awareness Among People Leakage is Direct Loss of Resources
gok i k cpk l s cpr k /ku ,
uh us •NEW TAG DES IGNED FOR
c<rk m i knu [ k' k j gr k eu!
R q THIS MISSION.
d gr dch l q sH l k/kk ,
j uk kbZ s • THE TAG HAS 3 FOLDS:
ok i kuh dk l c fey ck/k !
"i s Wks • 1ST FOLD TO TIE ON LEAK
gok i k dk ugh d k Zeky
uh b s
s
• 2ND TO CORRECTING
gj l e; dsfy ; s ; sgs vueks !
y AGENC Y
COST OF LEAK:
AIR@6KG/CM2 IN 3/8PIPE=Rs:2.6 0/Min • 3RD FOR REGISTRATION /
OIL=ONE DROP /PER Day =Rs:6.85 MONITOR ING
Ac tive P ersons
• ANY PERSON CAN
11
98
IDENTIF Y ANY LEAK AT
112 ANY PLACE.
Ar ea Identified Corrected % Correction
350
300
306 320
BU1 208 173 83%
250 233 2 6
4
BU2 173 146 84%
200
89 150 92 BU3 363 259 71%
70 104 94
68 10
5
0
0 Warehouse 4 4 100%
0
St ea m Air Oi l w ter
a
Ut il ity 86 73 85%
B U1 BU2 BU3 SSU1 WH Ident f ed
i i Corre cte d Grand Total 834 655 79%
Slide No . 10
5

6. Pro ject – 1 : Co oling Tower Efficiency I mprov ement
Cooling Tower # 3 & 4
Before After
CT# 4 Compressors
&
VAM Chille r
CT# 3 Cooling BU-1
Mills
• Cooling Tow er#1 capacity enhanced from 600 m3/hr to 1000
m3/hr, Cr oss Flow , Less drift loss (< 0.05%), more efficient .
• Sav ings: Water @ 22 KL/ Day, Electrici ty 12 kW/Hr.
• Cooling Tow er # 3 & 4 Eliminated
Slide No . 11
Wo rk
Project-2 : Cooling Tower # 2 & 5 (PCW + Tren ch)
Addition al PHE pro vid ed
Trenc h
Trenc h for Heat utilization o f
CB D
CB D tren ch wat er
Tank
Tank
ACFC cap acity in creas ed
Pump
Trench No . 1
Trench No . 2
Trench No . 3
Trench No . 4
Trench No . 5
25 HP for d elta 1 5 deg ree C,
X3 from wat er cool ed to ai r
cool ed type.
PHE PHE
Filter I II ACFC
Curing
Curing Pump
CB D
CB D 125 HP
PC W / H ydraulic Supply Storage
Storage
Tank
Tank
After
GAIN : Saving of Water= 11.5 KL/Day
Slide No . 12
6

7. Pro ject – 3 : Sewag e Trea tmen t Plant
Water R ecycled to Process K L/Da yy
Water R ecycled to Process K L/Da
Key Acti on Taken 282
1. STP installed to treat w ater for 167
recycling to process 139
120
148
2. Repair a nd prov iding of bottom
03-04
04-05
05-06
06-07
07-08
lining to prev ent seepage from
tanks. Recycling Yield in %
Recycling Yield in %
3 Treat and rec ycle plant domestic
4 8.6 2
w aste w ater for process use. 5
4 2.1 3
Cantee n & domes tic plant w aste
div erted to S TP. 34 .81
05-06
06-07
07-08
Trad eeEfflu ent Gener ation
Trad Efflu ent Gener ation
249 253
193
63 61
03-04
04-05
05-06
06-07
07-08
Slide No . 13
Ongoing Project : Curing Main Trench L ea k Co rrection
We are correcti ng all the headers / return lines of 135 m long curing
main trenc h for leak, heat insula tion a nd fl oor for eas y identificati on
and maintenance of all the pipe lines.
It w ill help us to sav e w ater up-to 50KL/Da y.
BEFORE AFTER
Slide No . 14
7

8. Water Consumption Per Capita Consumption
Ltrs./Kg. Ltrs./Kg.
7.36 6.96 7.22
6.56 6.63 6.44 216 213 205
219
5.37 206 201
196 199
3.59 Ind ustrial water co nsumption 142
2.806 2.547 C olony water consumptio n
123
03-04
04-05
05-06
06-07
07-08
99-00
00-01
01-02
02-03
03-04
04-05
05-06
06-07
07-08
Oct-08
Power Cons umptio n (Kwh. /Kg .) Air Consumption ( m3 /Kg.)
0 .851 0.69 0.686 0.689
0.823 0 .676
0.816
0 .795
0.776 0.651
0.764 02-03
0.644
03-04
04-05
05-06
06-07
07-08
02-03
03-04
04-05
05-06
06-07
07-08
Slide No . 15
RAINWATER HARVESTING (KL)
70000 66349
62747
60000
50000
40000 36588
30000
20000
20000
10000 10000
10000
199
0
2002 2003 2004 2005 2006 2007 2008
Slide No . 16
8