3Outline Vision Business challenges HCCB Strategy Next Steps… AvailabilityRegulatoryHCCB StrategyWater ConservationStewardship through Public Private PartnershipNext Steps…
4Vision Be a recognized leader in water stewardship Develop sustainable solutions for the company and community water management.Inclusive business growth
5India Water Scenario Water demand is expected to double by 2050 Line of Stress1700Source : “India Water Scenario – Macro level picture” by Bharat Sharma, International Water Management Institute, New DelhiSource : National commission for Integrated Water Resources development plan, Ministry of Water resources India,Water demand is expected to double by 2050Agriculture will continue to dominate – accounts for ~ 70% of water demand.Industrial Water demand expected to Increase from 6 to 10% by 2050Improved agriculture practices is key to sustainable Water Management.
6…India Water Scenario (cont..) AbundantAdequateMarginally StressedSeverely StressedWater allocation priorities(National Water Policy -2002)Drinking waterIrrigationHydropowerEcologyAgro industries and non- agricultural industriesNavigation and other uses.Source – TCCC Water Risk SurveyDefine Water Stress~85% of India Volumes comes from Water Scarce AreasWater Allocation for Industries- A Low Priority
7Challenges in Water Availability…. Surface waterRequires approvals and is regulated through permitsChanges in permit is a challengeCommunity – Key player in the approval processPerceptions- a key influence on decisionsGround WaterIncreasingly Stringent abstraction lawslimits water withdrawal in water stressed areas.Requires to recharge water more than the permit to withdrawal.Increasing Ground water abstraction permitHigh on Control, Low on GovernanceMunicipal SupplyContinuous availability – a challengeThe Onus is on Industries to Champion Water Sustainability…
8…..And Wastewater Disposal “ZERO Wastewater Discharge Condition” for Plant operationNecessitates 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/ dayChallengesAvailability of land for disposal of waste waterIncrease in Total Dissolved Solids (TDS) Concentration in Wastewater and compliance to Wastewater requirement.- Government regulations regarding discharge volumes and TDS are rapidly becoming restrictiveConditions necessitate control on usage and disposal
9The Key Drivers of Water Management AvailabilityQuantity and Quality is a challengeCostBeyond Money …… Business ContinuityHCCB StrategyWork Proactively to be “Beyond compliance” with constantly evolving regulatory frameworkVisualize Future Requirements and build for itObtain “Social License” to operate business in harmony with local communityRecognized as a Leader in water managementSustained thru continuous engagement with the local communityThe Key Drivers of Water Management
10HCCB – Our Water conservation strategy ReduceReplenishReuseImplementing 3 R policy on water conservation….
11HCCB – Our Water conservation strategy ReduceReplenishReuseImplementing 3-R policy on water conservation….
12HCCB Water Management- How have we evolved…. HCCB has one of the largest returnable glass mixIn 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
13Internal Controls and Processes to “Reduce” Create AwarenessWater Resource Management trainingSelf Assessment Tool kitDrive benchmark utilization of recoveries-90 %Maintenance & upkeep of recovery systemsEstablish a Dry Floor CultureIt is possible to have World Class Water Usage even in High RGB scenarios !!!
14Internal Controls and Processes to “Reduce” ReengineeringAutomate and Regulate Water flow thru flow control valvesOptimize Bottle Washer Jet sizeOptimize Flow PressureReplicate Best Practices across plantsIt is possible to have World Class Water Usage even in High RGB scenarios !!!
15Internal Controls and Processes to “Reduce” Process optimizationCorrecting Leaks as a Process not a projectOptimizing Frequency of BackwashValidating and Converting to 3-Step CIPUse of more water Efficient valvesReplicate Best practices across plants
16HCCB – Our Water conservation strategy ReduceReplenishReuseWater Reuse for Non-product , non –package contact applications only…..
17Infrastructure Investments to “Reuse” BackwashWaterfromProcessRecoveryHeaderTankChemicalAdditionGarnetFilterRaw WaterStorageSedimentClearwellSchematic- Back Wash Recovery100 kl98 klWATER REUSE – BACKWASH RECOVERY- Back Wash accounts for 6-8 %of total Water usage- Potential Recovery of ~ 98 % thruoptimal usageFiltration and Chlorination for microbial controlWater collected in Raw Water TankReplicated across >90% of HCCB LocationsOpportunity for reduction in Plant Water demand - ~ m3/day
18Infrastructure Investments to “Reuse” Vacuum line to equipmentGlycol returned to hot Glycol line equipmentHolding tankParamixVacuum PumpRecirculation PumpGlycol fromline equipmentFresh soft water make upDrain ValveSchematic of Vacuum Pump RecoveryVACUUM PUMP WATER REUSE- Potential of ~98 % water recoverythru optimal usage-Closed Loop System ensuresminimal contamination risks & high reuse-Replicated across all HCCB locations.Opportunity for reduction in Plant Water demand - About 24 m3/day
19Infrastructure Investments to “Reuse” pH CorrectionTankWater fromB/W s Pre finalcompartmentsCl2, FeSO4DegasserTower5uSandFilterSedimentationClearWaterCarbonDecaustiziserDecaustizisedWater StorageChlorine4 ppmB/W final rinseExcept the last JetPHESchematic- Decaustisizer RecoverySystem100kl75klBOTTLEWASHER RECOVERYBottle Washer Accounts for % of water used in RGB LinesRecovery 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.Opportunity for reduction in Plant Water demand - ~ m3/day
20Schematic- Advance Waste Water Recovery thru UFRO New Technologies Enabling HCCB to move “Beyond Compliance”System Unique to HCCBCoagulationMultimedia FilterDuel Media FilterMicron FiltrationUltra FiltrationDegasserReverse OsmosisNon Process Application (Boilers,Cooling Towers )Solar PondSchematic- Advance WasteWater Recovery thru UFRO100kl60kl40klUF – RO BASED ADVANCE WASTEWATER RECOVERYAccounts 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.Opportunity for reduction in Plant Water demand - ~ 50–100 m3/day
21New Technologies Enabling HCCB to move “Beyond Compliance” System Unique to HCCBTOTAL 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 standardsCrystallizer plant Separate the salt.Salt disposed to “Approved Site”.Wastewater Tertiary treatmentRO - 1SecondaryTreatedWastewaterRO water for Non product contact use (Utilities usage)High TDS RO Rejectto evaporation plantMechanical Vapor Recompression Evaporation (MVRE) & CrystallizerRecovered water TDS < 150 ppm (Conveyor Lubrication, Floor Cleaning in process areas)Salt(Approved Landfill Sites)RO - 2Schematic of 2 pass RO100kl~85kl~15kl~14kl5mg/lPotential technology for 100% Water reuse and Zero discharge in future…..
22Exploring 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 plantWater 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 treatmentBenefitsIncreased Water Availability (~15 %)Waste water plant load reduced (~50%)Reduction in land for waste water dischargePretreatment and MBR based BiologicalTreatmentRO - 1Bottle washer &CIP wastewaterWater for product contact ApplicationHigh TDS RO Rejectto evaporation plantEvaporation and Crystallization PlantSalt(Approved Landfill Sites)RO - 2Medium Pressure Ultra violet systemMakeup waterSchematic of Pilot Water Reuse Project
23Investment in Water Recovery Schemes Across India… TDS factor in deciding on recovery schemes to be addedHCCB has invested over Rs 5.0 MM USD in Water recovery schemes over the last 5 years
24Water Usage Trends @ Multi Line Plant- Bangalore (COE Location) Recoveries atBack WashDecaustisizerPET RinseVacuum Pump3 step CIP for Juice- Optimize Recoveries- 2 stage UF-RO Waste Water Recovery- Evaporation & Salt CrystallizationFocus Area- Optimum Usage of Recovery Systems to deliver WUR
25HCCB – Our Water conservation strategy ReduceReplenishReusePublic Private Community Partnership
26Water Replenishment Status & Plan ….. HCCB Water Replenishment StatusHCCB Currently is at a Water Neutrality of 82 %HCCB looks at Water neutrality accounts as Total Water Used for beverage productionSensitivities around water usage requires focus on total water instead of Beverage water usage
27Water Recharge Project in 2010 De-silting of a 100 Acre Nemam Lake In Partnership with Local Government , NGO and communityPartial de-silting completedCompletion planned in 2011Creates a Water Recharge potential of 154,000 m3/ annumImproves PercolationIncreases storage areaBenefits 200 farmers and 600 families in the area .BeforeAfterLeading a sustainable partnership in water replenishment…
28Drinking Water & Sanitation Projects Drinking Water Projects‘Elixir of Life’ projectDrinking water to over 100 Government Schools benefitting over 30,000 children in ChennaiCommunity based drinking Water projectsBenefiting over 350 households across GujaratImproving SanitationConstruction of 200 toilets in the state of Gujarat, Assam and Tamilnadu.Dedication of water storage tank for IndiranagariInstallation of RO plants for the householdin GoblejSafe Drinking water and Sanitation projects are integral part of Source Vulnerability Assessment study
29Promoting Efficient Agricultural Practices Drip irrigation projects with State Govt &farmers at Kaladera in RajasthanCompleted 331 projects covering165.5 hectares of agricultural landEstimated water conservation of198,600 m3 / yrPlan for 170 hectares of area for dripirrigation in 2011Projected water conservation of200,000 m3/annum.Benefits to farmers40-50% water saving under drip over conventional irrigation method.In absence of flooding - Eliminates soil salinity issuesHigher crop yield resulting in higher income.Drip irrigation project at Jaipur
30Next Steps Water Stewardship At HCCB, we will become water positive (100% +) by end of 2011 at national level thruOptimizing Inhouse water useRestoration & revival of Community Water BodiesRain water harvestingDrip IrrigationEnsure green field locations haveSurface water & Municipal water as the primary sourceCreation of land based reservoir to cater peak demandFocus onSafe Drinking WaterSanitationVocational Training on Water Conservation for local community
31In 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