This is a presentation from ACC Limited Damodhar Cement Works, 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.
9548086042 for call girls in Indira Nagar with room service
Water Conservation through re-cycle and re-use, presented by ACC Limited Damodhar Cement Works
1. Excellence Through Teamwork
Water conservation through
recycle and reuse
Presented By
ACC Limited
Damodhar Cement Works
Dam odh ar Ce men t Works
Damodhar at a glance ….
• DCSL comme nce d commercial production in October 1990 as a
joint ve nture project of WBID C a nd Ce me nt C orporation of I ndia
Ltd
• In Se pte mber 1996 A CC Ltd. took ov er the ma na ge me nt of the
Company a nd it be ca me a Subsidiary of the A CC Ltd. With
WBIDC as a partner
• Capa city e nhance ment from 2.70 to 5.25 LTPA of Portland Sla g
Cement in the y ear 1998 was taken up by A CC
• A n ISO 9001 : 2000 and I SO 14001:2004 certified unit
Dam odh ar Ce men t Works
2. Our Strategic Vision
Dam odh ar Ce men t Works
Our Environmental Policy
Dam odh ar Ce men t Works
3. Cement Manufacturing Process
Wet Slag sto rage at
Ropewa y Loading Ball Mill-2
Station 16 T/H
Cove red
Ropewa y 2.6 KM, storag e H all Ball Mill-3
Capa city 13 5 TPH 15 TPH
Clinker
180 00T
Dry Sl ag
Open Wet Slag Clinker 500 0T
Storag e And Ce ment Sto rage Silo
Capa city 35 KT Gypsum Gypsum
2 x 3 80 0 T
800 0T
Slag Dr ye r Wagon Tippler 600
TPH Ball Mill-1 Bagging
60TP H
49 TPH 100 T C ap.
2 nos Roto
Pac ke r
Coal
Coal Mill Storag e
3 TPH 800 MT
Dam odh ar Ce men t Works
Drinking Water Consumption
Water consumption in Water Consumption in
Factory Colony
300 300 262.39
Lit /Person /Day
Lit /Person /Day
242.36
250 198.21 185.93 250 196.48 200.22
184
200 166.25 200
150 150
100 100
50 50
0 0
'04-'05 '05-'06 '06-'07 '07-'08 '04-'05 '05-'06 '06-'07 '07-'08
Year Year
•2005-06 water con sumption high •2007-08 water con sumption high
due to fly ash silo and cement silo due to new construction of quarters
project
Dam odh ar Ce men t Works
4. Bench Marking
156.183
180 0.6
135.173
160
122.285
0.5 0.5 0.5 0.5
119.526
0.5
140 113.009
Consumption (K m3)
Consumption (m3/T)
Specific Water
93.233
120 0.4
91.962
0.28
0.28
78.734
0.28
0.28
100
0.3
80
43.174
40.791
41.94
60 30.323 0.2
0.081
0.085
0.078
40
0.06
0.1
20
0
0
'04-'05 '05-'06 '06-'07 '07-'08
'04-'05 '05 -'06 '06-'07 '07-'08
Yea r Year
Industrial DCW
Drinking/Domestic Use National Benchmark
Total International Benthmark
Dam odh ar Ce men t Works
Water Flow Diagram
Damodhar Riv er
FM FM
Process
Drinking Water
Water
FM
Process
w ater
Plant Colony Village
Ta nk
Drinking
Water
Over Head
Tan k Drinking Water
Process Reserv oir
Plant Water
Dam odh ar Ce men t Works
5. Sewage Treatment Plant
SWE AGE
COLLECTIO N
SUMP
OXIDIZATIO N
PLANT
BACK
CIRCULAR WASH
TANK WATE R
TANK
FILTE R
TRE ATE D SUPPLY
WATE R FOR
RESERVOIR IRRIG ATIO N
Dam odh ar Ce men t Works
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
Dam odh ar Ce men t Works
6. Project -1 : Reuse of Domestic Waste Water
The previous system of domestic waste water
treatment having following demerits :
• The Dome stic Wa ste water including the kitche n a nd
washroom dischar ge is trea te d at sew age trea tme nt pla nt
• A fter the pla nt expa nsion, filtration ca pa city of STP was not
suffi cie nt to take the increase of waste water day to day due
to incre ase of population a nd quarters in colony
Idea Generation
• Disconne ction of Kitche n a nd ba throom line of A-Block &
Hutme nt buildings from main STP line
• Wa ste water from kitche n a nd bathroom colle ct in a pond after
gravitation f iltration proce ss and this w ater use f or garde ning
and bre eding fish
Dam odh ar Ce men t Works
Project - 1 : Reuse of domestic waste water
Kitche n and Was hroom Water Collecte d into Pond
Plantati on at Col ony
Dam odh ar Ce men t Works
7. Project - 1 : Reuse of domestic waste water
600
Volume (Lit.)
RESULTS :
Discharge
water (KL)
–Recycling of waste
water and optimum
usage of resource
0
0
0
0
–Smooth and efficient
'03-'04
'04-'05
'05-'06
'06-'07
'07-'08
operation of STP
–Ensure ZERO discharge Year
Dam odh ar Ce men t Works
Project – 2 : Reduction of river water usage
The previous water supply system (sur face water
from Damodar river) had the fo llo wing demerits :
• Unhy gie nic w ater quality specially during monsoon.
• During summer and w inter, 10 nos. la bor use d daily for
channeling the wa ter to the pumping point
• 18 KW pumps use d for lif ting the wa ter a nd 7.5 KW pump
use d f or pressure f iltration
• High trea tme nt cost of Rs. 4000.00 per month
The Cost of production was Rs. 5.50 per KL .
Dam odh ar Ce men t Works
8. Project – 2 : Reduction of river water usage
IDEA GENERA TION :
• Elimination of the surface w ater supply a nd associa te d
filtration syste m by installation of a dee p bore we ll
pumping unit a t middle of riv er be d
• Drawing the subsoil wa ter w hich is much more hy gie nic
and av aila ble throughout the ye ar
Dam odh ar Ce men t Works
Project – 2 : Reduction of river water usage
A ctions I mple mente d
ü 40 feet deep bore well pump has be en installe d
ü Wa ter treatment pla nt operation ha s bee n stoppe d
Dam odh ar Ce men t Works
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. 1.20 per KL
Rs.
• Hence annual saving is Rs. 2.40 Lakhs
Rs.
Dam odh ar Ce men t Works
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.
Dam odh ar Ce men t Works
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%
Dam odh ar Ce men t Works
Awareness
• DCW sent repre se nta tive to De lhi for training on Wa ter
Manage me nt syste m
• Mass aw areness of taking hygienic water through distribution of
leafle ts & ele ctronic me dia a mong the ne arby community &
colony inhabita nts
• Providing hy gienic w ater to the ne arby v illa gers
• Periodic che cking of qua lity of w ater by internal a s w ell a s
exter nal authority
• Distribution of leaf lets for a wareness towards w ater borne
diseases
• A rrange draw ing competition on ‘Conservation Of Na tura l
resour ces’ a mong the colony & ne arby inha bita nts’ childre n
ces’ nts’
• ‘Suggestion Sche me’ for new idea ge neration
me’
• Envir onmental Q uiz C ompetition conducte d by DC W club
Dam odh ar Ce men t Works
11. Sustainable Development
• Rain Water Harvesting: C onstructed
earthen pond a t Colony & concrete
reservoir inside pla nt
• Use of Treate d water from Se wa ge
Treatme nt plant for pla nt & colony
pla ntation & garde ning
• Reserve shower & kitche n water into
pond for pla nta tion
• Complete Looping of proce ss w ater f or
recirculation
• Optimizing the water distribution
cycle freque ncy towards colony &
near by inhabita nts
• Installation of floa t valv es to a ll the
water reserv oirs (ta nks) a t all the
colony buildings
Dam odh ar Ce men t Works
Our Future Plan……..
Plan……..
• Integration with OSHAS 18001
• Annual external audits through authorized auditing
agencies
• Involvement of people through small group activities
• Developing In-house expertise for audits
In-
• 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
Dam odh ar Ce men t Works
12. We can do no great things ;
only small things with great love.
- Mother Teresa
Dam odh ar Ce men t Works
Dam odh ar Ce men t Works