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HCCB – Sustainability through Water Conservation

HCCB – Sustainability through Water Conservation. Outline. Vision Business challenges Availability Regulatory HCCB Strategy Water Conservation Stewardship through Public Private Partnership Next Steps…. Vision. Be a recognized leader in water stewardship

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HCCB – Sustainability through Water Conservation

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  1. HCCB – Sustainability through Water Conservation Classified - Internal use

  2. Outline • Vision • Business challenges • Availability • Regulatory • HCCB Strategy • Water Conservation • Stewardship through Public Private Partnership • Next Steps…

  3. Vision Be a recognized leader in water stewardship Develop sustainable solutions for the company and community water management. Inclusive business growth

  4. India Water Scenario Line of Stress 1700 Source : “India Water Scenario – Macro level picture” by Bharat Sharma , International Water Management Institute, New Delhi Source : National commission for Integrated Water Resources development plan, Ministry of Water resources India, • Water demand is expected to double by 2050 • Agriculture will continue to dominate – accounts for ~ 70% of water demand. • Industrial Water demand expected to Increase from 6 to 10% by 2050 Improved agriculture practices is key to sustainable Water Management.

  5. …India Water Scenario (cont..) a • Water allocation priorities • (National Water Policy -2002) • Drinking water • Irrigation • Hydropower • Ecology • Agro industries and non- agricultural industries • Navigation and other uses. Abundant Adequate Marginally Stressed Severely Stressed Source – TCCC Water Risk Survey • ~85% of India Volumes comes from Water Scarce Areas Water Allocation for Industries- A Low Priority

  6. Challenges in Water Availability…. • Surface water • Requires approvals and is regulated through permits • Changes in permit is a challenge • Community – Key player in the approval process • Perceptions- a key influence on decisions • Ground Water • Increasingly Stringent abstraction laws • limits water withdrawal in water stressed areas. • Requires to recharge water more than the permit to withdrawal. • Increasing Ground water abstraction permit • High on Control, Low on Governance • Municipal Supply • Continuous availability – a challenge The Onus is on Industries to Champion Water Sustainability…

  7. …..And Wastewater Disposal • Conditions necessitate control on usage and disposal • “ZERO Wastewater Discharge Condition” for Plant operation • Necessitates disposal of treated wastewater within the plant premises. • Wastewater to be disposed thru development of “Green Belt” • 18 out of 33 HCCB plants are classified “ZERO Discharge” • Treated wastewater disposal rate varies from 55 to 25 m3 /hectare/ day • Challenges • Availability of land for disposal of waste water • Increase in Total Dissolved Solids (TDS) Concentration in Wastewater and compliance to Wastewater requirement. - Government regulations regarding discharge volumes and TDS are rapidly becoming restrictive

  8. The Key Drivers of Water Management • The Key Drivers of Water Management • Availability • Quantity and Quality is a challenge • Cost • Beyond Money …… Business Continuity • HCCB Strategy • Work Proactively to be “Beyond compliance” with constantly evolving regulatory framework • Visualize Future Requirements and build for it • Obtain “Social License” to operate business in harmony with local community • Recognized as a Leader in water management • Sustained thru continuous engagement with the local community

  9. HCCB – Our Water conservation strategy • Implementing 3 R policy on water conservation….

  10. HCCB – Our Water conservation strategy • Implementing 3-R policy on water conservation….

  11. HCCB Water Management- How have we evolved…. • HCCB has one of the largest returnable glass mix • In 2010 Returnable packs accounted for 58 % of the Physical case volume • ~ 36 % Improvement in Water Usage over last 3 years. • We produced an additional 25 MM Physical cases in 2010 with the quantity of water used in 2009. Classified - Internal use

  12. Internal Controls and Processes to “Reduce” Create Awareness • Water Resource Management training • Self Assessment Tool kit • Drive benchmark utilization of recoveries-90 % • Maintenance & upkeep of recovery systems • Establish a Dry Floor Culture It is possible to have World Class Water Usage even in High RGB scenarios !!!

  13. Internal Controls and Processes to “Reduce” • Reengineering • Automate and Regulate Water flow thru flow control valves • Optimize Bottle Washer Jet size • Optimize Flow Pressure • Replicate Best Practices across plants It is possible to have World Class Water Usage even in High RGB scenarios !!!

  14. Internal Controls and Processes to “Reduce” • Process optimization • Correcting Leaks as a Process not a project • Optimizing Frequency of Backwash • Validating and Converting to 3-Step CIP • Use of more water Efficient valves • Replicate Best practices across plants

  15. HCCB – Our Water conservation strategy Water Reuse for Non-product , non –package contact applications only…..

  16. Recovery Header Sediment Tank Backwash Water from Process Clear Water well Backwash Recovery Tank Chemical Addition Garnet Filter Raw Water Storage Tank Infrastructure Investments to “Reuse” Schematic- Back Wash Recovery • WATER REUSE – BACKWASH RECOVERY • - Back Wash accounts for 6-8 % • of total Water usage • - Potential Recovery of ~ 98 % thru • optimal usage • Filtration and Chlorination for microbial control • Water collected in Raw Water Tank • Replicated across >90% of HCCB Locations 100 kl 98 kl Opportunity for reduction in Plant Water demand - ~ 50 -100 m3/day

  17. Infrastructure Investments to “Reuse” Schematic of Vacuum Pump Recovery VACUUM PUMP WATER REUSE - Potential of ~98 % water recovery thru optimal usage -Closed Loop System ensures minimal contamination risks & high reuse -Replicated across all HCCB locations. Vacuum line to equipment Glycol returned to hot Glycol line equipment Vacuum Pump Paramix Glycol from line equipment Fresh soft water make up Holding tank Recirculation Pump Drain Valve Opportunity for reduction in Plant Water demand - About 24 m3/day

  18. Infrastructure Investments to “Reuse” • Schematic- Decaustisizer Recovery • System • BOTTLEWASHER RECOVERY • Bottle Washer Accounts for 40 - 60 % of water used in RGB Lines • Recovery potential of > 75 % of water use. • -Water reused in pre-final rinse of bottlewashing and utilities, if any excess. • - Replicated across >90 % locations of HCCB. 100kl Cl2, FeSO4 Water from B/W s Pre final compartments PHE Sedimentation Tank Clear Water Tank Carbon Filter Degasser Tower Decaustiziser Sand Filter pH Correction Tank 5u Decaustizised Water Storage Tank 75kl B/W final rinse Except the last Jet Chlorine 4 ppm Opportunity for reduction in Plant Water demand - ~130-150 m3/day

  19. New Technologies Enabling HCCB to move “Beyond Compliance” System Unique to HCCB • Schematic- Advance Waste • Water Recovery thru UFRO • UF – RO BASED ADVANCE WASTEWATER RECOVERY • Accounts for 8 – 10 % of water used in the plant • -Overall process recovery > 60 %. • -Treated Water meets drinking water standards • -Water Reuse for all utilities , process area cleaning etc.. • - Available at ~50% Locations of HCCB. 100kl Coagulation Multimedia Filter Duel Media Filter Micron Filtration Ultra Filtration Reverse Osmosis Non Process Application (Boilers,Cooling Towers ) Degasser 60kl Solar Pond 40kl Opportunity for reduction in Plant Water demand - ~ 50–100 m3/day

  20. New Technologies Enabling HCCB to move “Beyond Compliance” System Unique to HCCB • TOTAL DISSOLVED SOLIDS MANAGEMENT IN EFFLUENT • - 2 Stage RO for 85% wastewater recovery. • RO reject >10% solids is concentrated through evaporation plant. • Treated Water meets drinking water standards • Crystallizer plant Separate the salt. • Salt disposed to “Approved Site”. Schematic of 2 pass RO Secondary Treated Wastewater RO water for Non product contact use (Utilities usage) 100kl ~85kl Wastewater Tertiary treatment RO - 1 RO - 2 High TDS RO Reject to evaporation plant ~15kl Mechanical Vapor Recompression Evaporation (MVRE) & Crystallizer ~14kl Recovered water TDS < 150 ppm (Conveyor Lubrication, Floor Cleaning in process areas) 5mg/l Salt (Approved Landfill Sites) Potential technology for 100% Water reuse and Zero discharge in future…..

  21. Exploring Next Steps in Water Reuse • Partnering with Corporate Quality, Legal, PAC, Technical teams on Water reuse PILOT Project. • Closed loop water reuse for Bottlewasher and CIP wastewater. • Captured ahead of discharge to waste water plant • Water reuse for Product Contact application (Not yet approved for product use). • Multi-barrier Design closed loop system with cutting edge technologies combining Ultra Filtration Reverse Osmosis (UFRO), evaporation & Ultra Violet treatment • Benefits • Increased Water Availability (~15 %) • Waste water plant load reduced (~50%) • Reduction in land for waste water discharge Schematic of Pilot Water Reuse Project Makeup water Bottle washer & CIP wastewater Pretreatment and MBR based Biological Treatment RO - 2 RO - 1 High TDS RO Reject to evaporation plant Evaporation and Crystallization Plant Medium Pressure Ultra violet system Water for product contact Application Salt (Approved Landfill Sites)

  22. Investment in Water Recovery Schemes Across India… HCCB has invested over Rs 5.0 MM USD in Water recovery schemes over the last 5 years

  23. Water Usage Trends @ Multi Line Plant- Bangalore(COE Location) • Recoveries at • Back Wash • Decaustisizer • PET Rinse • Vacuum Pump • 3 step CIP for Juice - Optimize Recoveries - 2 stage UF-RO Waste Water Recovery - Evaporation & Salt Crystallization Focus Area- Optimum Usage of Recovery Systems to deliver WUR

  24. HCCB – Our Water conservation strategy • Public Private Community Partnership

  25. Water Replenishment Status & Plan ….. HCCB Water Replenishment Status • HCCB Currently is at a Water Neutrality of 82 % • HCCB looks at Water neutrality accounts as Total Water Used for beverage production • Sensitivities around water usage requires focus on total water instead of Beverage water usage

  26. Water Recharge Project in 2010De-silting of a 100 Acre Nemam Lake Nemam Lake • In Partnership with Local Government , NGO and community • Partial de-silting completed • Completion planned in 2011 • Creates a Water Recharge potential of 154,000 m3/ annum • Improves Percolation • Increases storage area • Benefits 200 farmers and 600 families in the area . Before After Leading a sustainable partnership in water replenishment…

  27. Drinking Water & Sanitation Projects • Drinking Water Projects • ‘Elixir of Life’ project • Drinking water to over 100 Government Schools benefitting over 30,000 children in Chennai • Community based drinking Water projects • Benefiting over 350 households across Gujarat • Improving Sanitation • Construction of 200 toilets in the state of Gujarat, Assam and Tamilnadu. • Dedication of water storage tank for Indiranagari • Installation of RO plants for the household • in Goblej Safe Drinking water and Sanitation projects are integral part of Source Vulnerability Assessment study

  28. Promoting Efficient Agricultural Practices Drip irrigation projectswith State Govt & farmers at Kaladerain Rajasthan • Completed 331 projects covering 165.5 hectares of agricultural land • Estimated water conservation of 198,600 m3 / yr • Plan for 170 hectares of area for drip irrigation in 2011 • Projected water conservation of 200,000 m3/annum. Benefits to farmers • 40-50% water saving under drip over conventional irrigation method. • In absence of flooding - Eliminates soil salinity issues • Higher crop yield resulting in higher income. Drip irrigation project at Jaipur

  29. Next Steps • Water Stewardship • At HCCB, we will become water positive (100% +) by end of 2011 at national level thru • Optimizing Inhouse water use • Restoration & revival of Community Water Bodies • Rain water harvesting • Drip Irrigation • Ensure green field locations have • Surface water & Municipal water as the primary source • Creation of land based reservoir to cater peak demand • Focus on • Safe Drinking Water • Sanitation • Vocational Training on Water Conservation for local community

  30. In Conclusion & In Conjunction with the Vision… • HCCB will continue the journey to become most efficient converter of Water into Beverage with best water balance practices. • Will strive to reinforce Social goodwill – by building empowered communities around operations, growing acceptance as responsible corporate citizen, and being recognized a leader in Water management among the community through – • Efficient Irrigation Practices, • Safe Drinking Water Initiatives, • Sanitation Projects, etc

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