This is a presentation from Chaibasa Cement Works,ACC Limited 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. Water Management System at CCW
Venue :CII- Godrej GBC Hyderabad
Date :16.12.2008
Name of the Presenter :A.K. Srivastava
Head Plant Operations
Chaibasa Cement Works
This report is solely for the internal use. No part of it may be circulated, quoted, or reproduced for distribution outside the company organization without prior written
approval from ACC Limited. This material was used during an oral presentation; it is not a complete record of the discussion.

2. Company Profile
Established in 1947.
Part of ACC/ Holcim, a
national and global l d
ti l d l b l leader
Expansion & modernization
in 2005.
1.2 MTPA integrated
cement plant
Situated i “K lh
Si d in “Kolhan region
i
– A hard core tribal belt” ,
80 Km. from Jamshedpur.
QMS & EMS established as
per IS/ISO 9001 & 14001.
OHSMS established as per
Reliable and respected Holcim OH&S pyramid. 2
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

3. Process Details
Highly sophisticated and modern plant with state of the art
technology.
Semi d process (up to 23% enriched slurry feed in VRM)
S i dry ( t i h d l f di
Raw mat. extraction Raw material preparation
Pyro processing
Raw meal preparation
Shipping Cement Grinding Shipping 3
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

4. Roadmap for meeting the Environment goals
2008 2009 2010 2011
Stack emissions
50 30 30 30
(mg/nm3)
Fugitive Emission SPM
5000 4000 3000 2000
(µg/nm3)
Kg of CO2/ ton of
650 634 618 602
Cementitious Material
CEMS Installation on 1 kiln
Kiln Stack
Water Consumption -30% -20% -15% -10%
Environment
Road Map Power Consumption 88.7 86.4 84.3 82.2
KWh / ton
Tonnage of alternative
8400 14024 15150 22201
fuels & raw mat. (tons)
Thermal Substitution
0.53 1.43 1.62 1.99
Rate (%)
AFR Installation
0.95 2.8 5.0 0.5
Capex Rs. Cr
Total GAV (Savings) Rs.
0.29 3.47 4.30 5.89
Cr
4
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

5. Water Conservation Initiatives
Annual Water Investmen
Year of Savings t made Payback
Sl. Water conservation
Implemen period
No. initiatives
tation Rs.
R (months)
m3 Rs. Lakhs
Lakhs
Strengthening of water
monitoring system by
g y y
1 installation of water 2005-06 - - 2.22 -
meters at source
points
Recycling of Effluent by
rerouting of reject pit
2 2006-07 165000 4.85 2 5
discharge to
abandoned mine pit
Zero effluent d h
ffl discharge
by providing
3 sedimentation tanks 2007-08 330000 9.7 12.1 15
and reutilization of
effluent
ffl
5
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

6. Specific Water Consumption
3.00
3 00
2.50 2.40
2.28
2.02
2.00 5%
m3/MT
1.50
1.21
1.00
0.70
0.50
0.00
0 00 0.00
0 00
0.00
2004 – 05 2005 – 06 2006 – 07 2007 – 08 Benchmark 6
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

7. Road map to achieve global benchmark
Objective & targets Plan of Action Expected Technical justification
Date of
Completion
Strengthening of water Installation of Dec. 2009 Water recycled from reject pit is
monitoring system at water meters at collected in mines abandoned pit
user end user end (A block) for further use in
plant, this reutilized water is
again counted as fresh water
due to lack of monitoring
system.
At present, water meters are
installed only at sources and we
are unable to take initiatives
department wise.
d t t i
To achieve specific installation of Dec. 2011 At present water consumption in
water consumption 700 modernized floatation process is about 950
ltr./ MT of Clinker from Filtration Floatation ltr. per tonnes of clinker. By
present level of 1519 Plant (FFP)
(FFP). implementing this proposed
ltr./ MTof Clinker project dry cake will be fed to
VRM and 130 ltr. water per
tonnes of clinker will be
consumed in this process.
7
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

8. Sustainability Indices
8
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

9. Environment Performance Index (PEP)
Systematic monitoring and evaluation of environmental performance
Identification of strengths and weaknesses (self-assessment)
Supporting tool in (environmental) business planning
Environmental programs, CAPEX projects, budgeting etc.
Database for communication purposes
Group and Group company internal benchmarking
85 Enval Performance Indicator Atmospheric Emission: PM
80
80
75 76
75 73
70
66
EPI (% )
65
62
60
55
50
2005 2006 2007 2008 2007 2006
Year
CCW Performance CCW Target
ACC Avg. Performance HOLCIM Avg. Performance 9
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

10. Commitment towards reduction in GHG Emission
Our objective is to reduce by the year 2010 the average
specific net CO2 emission by 20 % from the reference year
1990, l l
1990 calculated per WBCSD CO2 protocol.
d l
Clinker Factor Specific Net CO2 Emission
75.0
75 0 73 900.0
900 0
876.0
880.0
Kg. CO2/ MT of Cem. Mat.
69.5
70.0 860.0
840.0
65.0
65 0
820.0
804.0
%
800.0
60.3 800.0
60.0 781.0
780.0
55.9
55.0 55.0
55.0 760.0
. 740.0
50.0 720.0
2005 2006 2007 2008 2007 2006 2005 2006 2007 2008
Year Year
CCW Performance CCW Target CCW Performance CCW Target
ACC Avg. Performance HOLCIM Avg. Performance 10
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

11. Commitment towards reduction in GHG Emission
This reduction will be achieved through improving the four key eco-efficiency
parameters:
clinker factor
specific thermal energy consumption
specific electrical energy consumption
thermal substitution rate
Specific Thermal Energy Consumption Specific Electrical Energy Consumption
1050.0
1050 0
110.0 995.0
106 1000.0
kWh/ MT of Cement
105.0 950.0
KCal/ Kg. of Clinker
900.0 876
100.0
C
850.0
95.0 800.0
91.9 91.42 755.0 750.0 748.8 751
90.0 89.0 750.0
85.6
85 6 85.0
85 0
K 700.0
700 0
85.0
650.0
80.0 600.0
2005 2006 2007 2008 2007 2006 2005 2006 2007 2008 2007 2006
Year
Yea Year
CCW Performance CCW Target ACC Avg. Performance HOLCIM Avg. Performance
11
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

12. Water Conservation Initiatives
Phase 1st :Strengthening of water monitoring system
Phase 2nd :Recycling of Effluent
Phase 3rd :Zero effluent discharge
12
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

13. Phase 1st :Strengthening of water monitoring system
Objectives
Compliance with environmental legal requirements
To improve Environmental Performance Indicator (EPI) of the plant
Regular monitoring of water consumption
Conservation of natural resources
Project Mission
Installation of water meters at source level
Project Organization
Client: Mr. A. Roy Choudhary, Vice President
Project Manager: Mr. A.K. Srivastava, Manager Engineering
Project Member: Mr. S.K. Mazumdar
Mr S K Mazumdar, HOD Water Supply
Mr. Pradeep Singh, HOD Environment
Mr. P.K. Bhattacharya, Asst. Officer, WS
13
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

14. Phase 1st :Strengthening of water monitoring system
Identified Risks in planning phase
Sr. Identified Risks Remedial Actions
No.
1. Unavailability of layout drawings (plant established Study and develop water line layout
in the year 1947)
2. Procurement of the water meters in the time frame Adherence with delivery schedule.
Attributes Action plan
Att ib t & A ti l
Planned Actual date
Sr. Accomplished Planned date of Actual date of
Activity date of of
No. by commencement commencement
completion completion
Study of existing lay out
HOD: Water
1. and generate requirement 05.04.2005 05.04.2005 15.04.2005 10.04.2005
Supply
for water meters
Procurement of water
2. HOD: Purchase 15.04.2005 10.04.2005 30.06.2005 10.08.2005
meters
Installation of water HOD: Water
3. 01.07.2005 12.08.2005 31.07.2005 25.09.2005
meters Supply
Establishment of system
4.
4 for daily water Mgr. Engee.
Mgr Engee 01.08.2005
01 08 2005 01.10.2005
01 10 2005 Cont.
Cont Cont.
Cont
consumption monitoring
14
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

15. Phase 1st :Strengthening of water monitoring system
Out come of Team Work
Monitoring of water consumption started on daily basis.
Monitored water consumption was double than derived from formula on
monthly production basis.
Source End user
Quarry
Abandoned
Quarry Pit M
(G Block) Clinkerisation
Plant
Active
Quarry Pit M Captive P
C i Power
Plant
Check Dam
M
(River) Floatation
Plant
Abandoned
Quarry Pit Cement
(A Block) M
Grinding &
Packing Plant
Domestic 15
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

16. Phase 2nd :Recycling of Effluent
Objectives
To improve life of reject pit
To improve stability of reject pit
To improve Environmental Performance Indicator (EPI) of the plant
Conservation of natural resources
Project Mission
Recycling of Effluent by rerouting of reject pit discharge to abandoned
mine pit
Project Organization
Client: Mr. A.K. Srivastava, GM (Tech.)
Project Manager: Mr. KRK Prusty, Manager Mining
Project Member: Mr. P.K. Nanda, Jt. Manager Mining
Mr. Rajesh Kumar, Jt. Manager Mining
Mr. Y Kumar, Dy.
Mr Y. Kumar Dy Manager CSR
16
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

17. Phase 2nd :Recycling of Effluent
Identified Risks in planning phase
Sr. Identified Risks Remedial Actions
No.
1. During project bund may be collapsed and lead to Strengthening of bund.
flood in near by areas.
Dewatering of reject pit.
Attributes & Action plan
Planned
l d Actual date
ld
Sr. Accomplished Planned date of Actual date of
Activity date of of
No. by commencement commencement
completion completion
Strengthening of bund by
1. Mgr. Mining
g g 10.10.2006 07.10.2006 15.11.2006 23.11.2006
dumping overburden soil
Dewatering of reject pit
2. Mgr. Mining 15.11.2006 23.11.2006 30.11.2006 07.12.2006
through diesel pump
Laying of pipe with valves
y g pp
& strainer in bund for
3. regular dewatering of Mgr. Mining 20.11.2006 27.11.2006 30.11.2006 05.12.2006
clean water through
gravity.
Development of natural
4. drain for the recirculation Mgr. Mining 20.11.2006 29.11.2006 31.01.2007 20.02.2007
of mine discharge water
17
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

18. Phase 2nd :Recycling of Effluent
Source End user
Q
Quarry
y
Abandoned
Quarry Pit M
(G Block) Clinkerisation
Plant
Active
Quarry Pit M Captive Power
Plant
Check Dam
M
(River) Floatation
oatat o Reject
j Abandoned Evaporation/
p /
Plant Mine Pit Natural
seepage
Abandoned
Quarry Pit Cement
(A Block) M
Grinding &
Packing Pl t
P ki Plant
Domestic
18
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

19. Phase 2nd :Recycling of Effluent
Out come of Team Work
Pit life increased by 1 year.
Dewatering pump operation not required ( Rs 10 Lakhs/ annum)
Rs. annum).
Stability of bund increased.
Clean water is being recycled (approximately 2000 KL per day) in ‘A’ block pit
for reutilization in cement plant
plant.
Water
Silica
19
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

20. Phase 3rd :Zero effluent discharge
Objectives
Conservation of natural resources (water & energy)
Control of water pollution
To improve Environmental Performance Indicator (EPI) of the plant
Project Mission
To achieve ‘Zero effluent discharge’
Project Organization
Client: Mr. I.M. Sharma, Plant Head
Project Manager: Mr. A.K. Srivastava, GM (Tech)
Project Member: Mr. P Singh, Asst. Manager Environment
Mr.
Mr J N Prasad Jt Manager Civil
Prasad, Jt.
Mr. Y Singh, Dy. Manager CR-RM
Mr. M Singh, Asst. Engineer CR-RM
Mr. P K Bhattacharya, Asst. Officer WS
20
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

21. Phase 3rd :Zero effluent discharge
Attributes & Action plan
Planned Actual date
Sr. Accomplished Planned date of Actual date of
Activity date of of
No. by
y commencement commencement
completion completion
Dy. Manager &
Initial Cleaning & Asst. Engr. CR-
1. 12.09.2007 12.09.2007 30.09.2007 25.09.2007
Arresting leakages RM, Asst. Mgr
Env.
Construction of effluent
collection sump Jt. Mgr. Civil
2. (1mX1mX1m) to collect Asst. Officer 12.09.2007 12.09.2007 30.09.2007 25.09.2007
compressor cooling water WS
& pump installation
Revamping of old settling
Dy. Manager &
tank and procurement &
3. CR-RM, Jt. Mgr. 01.10.2007 26.09.2007 31.01.2008 31.01.2008
installation of recycle
Civil
pump.
Minimising water Asst
Asst. Officer
4. consumption in Wet WS, Asst. Engr. 12.09.2007 12.09.2007 30.09.2007 30.09.2008
grinding & thickening. CR-RM
Recycling effluent in wet
Asst. Mgr Env.,
grinding & stopping river
5. Asst. Officer 01.02.2008 01.02.2008 15.02.2008 15.02.2008
water consumption in the
WS
same.
21
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

22. Phase 3rd :Zero effluent discharge
Source End user
Quarry
Abandoned
Quarry Pit M
(G Block) Clinkerisation
Plant
Active E
Quarry Pit M Captive Power
Plant
ST F
F
Check Dam
M L
(River)
(Ri ) Floatation
Plant
ST U
Abandoned E
Quarry Pit Cement
(
(A Block)
) M ST N
Grinding &
Packing Plant T
Domestic
22
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

23. Phase 3rd :Zero effluent discharge
Out come of Team Work
Conservation of water (approx. 1000 KL per day)
Conservation of energy
energy.
Control of pollution
Pump installed to recycle effluent. Pumping facility installed to recycle effluent.
23
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008

24. HAND IN HAND - TOGETHER EACH ACHIEVE MORE
Thank you for your benign presence & support
y y g p pp
24
ACC Limited CII ‘Water Excellence Award 2008’ 16.12.2008