CONNECT. COLLABORATE. RE-APPLY.
HCCB – Sustainability through Water Conservation
Classified - Internal use
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
Develop sustainable solutions for the company and community water management.
Inclusive business growth
India Water Scenario
5177
22091820 1628
1340
1140
0
1500
3000
4500
6000
1951 1970 2000 2010 2025 2050
m3/
an
nu
m /
per
son
year
Per Capita Water - Availability Water Demand projection
0
400
800
1200
1600
Year
Bill
ion
Cu
bic
Me
ter
(BC
M)
Irrigation 460 536 688 1008
Others 25 115 174 291
Industry 34 42 80 143
1990 2010 2025 2050
• 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
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,
1700
Improved agriculture practices is key to sustainable Water Management.
Line of Stress
…India Water Scenario (cont..)
Source – TCCC Water Risk Survey
~85% of India Volumes comes from Water Scarce Areas
a
Abundant
Adequate
Marginally Stressed
Severely Stressed
Water allocation priorities
(National Water Policy -2002)
1. Drinking water 2. Irrigation3. Hydropower4. Ecology5. Agro industries and non-
agricultural industries6. Navigation and other
uses.
Water Allocation for Industries- A Low Priority
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…
Challenges in Water Availability….
“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
o Availability of land for disposal of waste watero 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 Conditions necessitate control on usage and disposal
…..And Wastewater Disposal
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
The Key Drivers of Water Management
The Key Drivers of Water Management
Reduce
Replenish
Reuse
Implementing 3 R policy on water conservation….
HCCB – Our Water conservation strategy
Reduce
Replenish
Reuse
Implementing 3-R policy on water conservation….
HCCB – Our Water conservation strategy
Classified - Internal use
0
1
2
3
4
3.58 3.272.71 2.34 2.1
YearW
UR
- L
/L
HCCB WUR Trend• 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.
HCCB Water Management- How have we evolved….
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 !!!
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 !!!
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
Internal Controls and Processes to “Reduce”
Reduce
Replenish
Reuse
HCCB – Our Water conservation strategy
Water Reuse for Non-product , non –package contact applications only…..
Opportunity for reduction in Plant Water demand - ~ 50 -100 m3/day
Infrastructure Investments to “Reuse”
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
Backwash Water from
Process
Recovery Header
Backwash Recovery
TankChemical Addition
Garnet Filter
Raw WaterStorage
Tank
Sediment Tank Clear
Waterwell
Schematic- Back Wash Recovery
100 kl
98 kl
Opportunity for reduction in Plant Water demand - About 24 m3/day
Infrastructure Investments to “Reuse”
Vacuum line to equipment
Glycol returned to hot Glycol line equipment
Holding tank
Paramix Vacuum Pump
Recirculation Pump
Glycol from line equipment
Fresh soft water make up
Drain Valve
Schematic of Vacuum Pump RecoveryVACUUM 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.
Opportunity for reduction in Plant Water demand - ~130-150 m3/day
Infrastructure Investments to “Reuse”
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.
pH Correction Tank
Water from B/W s Pre final compartments
Cl2, FeSO4
DegasserTower
5u
Sand Filter
Sedimentation Tank
Clear Water Tank
Carbon Filter Decaustiziser
Decaustizised Water Storage
Tank
Chlorine4 ppm
B/W final rinseExcept the last Jet
PHE
Schematic- Decaustisizer Recovery System
100kl
75kl
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.
Coagulation
Multimedia Filter
Duel Media Filter
Micron Filtration
Ultra Filtrati
on
Degasser
Reverse
Osmosis
Non Process Application
(Boilers,Cooling Towers )
Solar
Pond
Schematic- Advance Waste Water Recovery thru UFRO
100kl
60kl
40kl
Opportunity for reduction in Plant Water demand - ~ 50–100 m3/day
System Unique to HCCB
New Technologies Enabling HCCB to move “Beyond Compliance”
New Technologies Enabling HCCB to move “Beyond Compliance”
Wastewater Tertiary treatment
RO - 1
Secondary Treated Wastewater
RO water for Non product contact use (Utilities usage)
High TDS RO Reject to evaporation plant
Mechanical Vapor
Recompression
Evaporation (MVRE) &
Crystallizer
Recovered water TDS < 150 ppm (Conveyor Lubrication, Floor Cleaning in process areas)
Salt (Approved Landfill Sites)
RO - 2
Schematic of 2 pass RO
100kl ~85kl
~15kl
~14kl
5mg/l
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”.
Potential technology for 100% Water reuse and Zero discharge in future…..
System Unique to HCCB
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
Pretreatment and
MBR based
Biological Treatment
RO - 1
Bottle washer &CIP wastewater
Water for product contact Application
High TDS RO Reject to evaporation plant
Evaporation and
Crystallization Plant
Salt (Approved Landfill Sites)
RO - 2
Medium Pressure
Ultra violet
system
Makeup water
Schematic of Pilot Water Reuse Project
HCCB has invested over Rs 5.0 MM USD in Water recovery schemes over the last 5 years
UF - RO
Tertiary
Decausticizer
Backwash
PET rinse
Vacuum pump
Condensate
0 10 20 30 40 50 60 70 80 90 100
46
71
91
96
100
100
100
Water Recovery Scheme Coverage
% CBO Operation
Re
co
ve
ry S
ch
em
es
Investment in Water Recovery Schemes Across India…
Water Usage Trends @ Multi Line Plant- Bangalore (COE Location)
2007 2008 2009 20100
1
2
3
2.83 2.77
2.091.78
Focus Area- Optimum Usage of Recovery Systems to deliver WUR
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
Reduce
Replenish
Reuse
Public Private Community Partnership
HCCB – Our Water conservation strategy
2010 Target 2011
82
100 +
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
Water Replenishment Status & Plan …..
Before
After
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 .
Leading a sustainable partnership in water replenishment…
Water Recharge Project in 2010De-silting of a 100 Acre Nemam Lake
Safe Drinking water and Sanitation projects are integral part of Source Vulnerability Assessment study
• Dedication of water storage tank for Indiranagari
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.
Drinking Water & Sanitation Projects
• Installation of RO plants for the household in Goblej
Drip irrigation projects with State Govt & farmers at Kaladera in Rajasthan
• Completed 331 projects covering165.5 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 of200,000 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
Promoting Efficient Agricultural Practices
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
Next Steps
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
In Conclusion & In Conjunction with the Vision…