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

Be a recognized leader in water stewardship

Develop sustainable solutions for the company and community water management.

Inclusive business growth

india water scenario
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.

india water scenario cont
…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

slide6

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…

slide7

…..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

slide8

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
slide9

HCCB – Our Water conservation strategy

  • Implementing 3 R policy on water conservation….
slide10

HCCB – Our Water conservation strategy

  • Implementing 3-R policy on water conservation….
slide11

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

slide12

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 !!!

slide13

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 !!!

slide14

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
slide15

HCCB – Our Water conservation strategy

Water Reuse for Non-product , non –package contact applications only…..

slide16

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

slide17

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

infrastructure investments to reuse
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

slide19

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

new technologies enabling hccb to move beyond compliance
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…..

slide21

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)

slide22

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

water usage trends @ multi line plant bangalore coe location
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

slide24

HCCB – Our Water conservation strategy

  • Public Private Community Partnership
slide25

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
slide26

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…

slide27

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

slide28

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

slide29

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
slide30

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