“Responsible Care - A Global Initiative for Environment, Health, Safety & Security "

Project#1: Reduction of Water consumption in Cooling Tower Operations

Project Presentation By Project Presentation By Mr. Vrishank MenonMr. Vrishank Menon

What did I do?

• During the summer of 2014, I interned at Dorf Ketal Chemicals, a chemical manufacturing plant in Taloja, Maharashtra and took part in two projects (related to Responsible Care) as part of two teams at the plant. This presentation deals with the reduction of blow down quantity of a cooling tower at the plant.

• http://www.dorfketal.com/

IndexIndex Responsible Care (RC) – What & Other details ? RC – Way forward @ Dorf Ketal Project Selection Basis Project Details – Project # 1 (Reduction in Water consumption in

cooling tower operations) Cooling Tower – What & How it operates Project Scope Diagnosis Solution Identification Event Transition Action Plan Achievements Supporting Reference documents

Responsible Care (RC) – What ?Responsible Care (RC) – What ? RC is a world-wide initiative developed by the chemical industry that drives continuous improvement in

health, safety and environmental (HSE) performance, together with open and transparent communication with stakeholders. How did responsible care come about?

The Responsible Care initiative was initiated after the tragic gas leak in Bhopal, India in

1984 and was officially launched in 1985 by the Chemistry Industry Association Of Canada. The association, after the incident, revisited and amended the already-present CAER (Community Awareness and Emergency Response) plan and integrated into the more holistic Responsible Care initiative. The initiative was later adopted by chemistry councils from other parts of the world and soon enough, adopted by India in .

On signing of this global charter, the respective CEO and company commit to continuous improvement in the fields of health, safety, security and environmental performance and open and frank communication with the industrial community and society. The Responsible Care commitment is essential to building trust and confidence within the industry and subsequently, bettering the living standards and quality of those involved in and around the industrial process (stakeholders, neighboring communities, employees,etc.)

  While the presence of chemical industry does pose its risks to the environment and the While the presence of chemical industry does pose its risks to the environment and the public, these chemicals are needed for the running of all other industries and are essential public, these chemicals are needed for the running of all other industries and are essential parts of everyday life. Thus, the idea of sustainable chemistry arises, an idea, which is parts of everyday life. Thus, the idea of sustainable chemistry arises, an idea, which is fully encapsulated by the Responsible Care initiative. fully encapsulated by the Responsible Care initiative.   There are two things the chemical industry must do to adhere to this idea,There are two things the chemical industry must do to adhere to this idea,

1. Improve the level of environmental, health, safety and security performance in all 1. Improve the level of environmental, health, safety and security performance in all aspects of chemical operations, to eliminate the basis for concern.aspects of chemical operations, to eliminate the basis for concern.

2. Communicate, in detail, of the proceedings to the public and to the government, and 2. Communicate, in detail, of the proceedings to the public and to the government, and demonstrate that the industry is sensitive and responsive to public concern.demonstrate that the industry is sensitive and responsive to public concern.

Responsible Care - What’s it in Chemical Industry?

1. To recognize and respond to community concerns about chemicals and the operations. 2. To develop and produce chemicals that can be manufactured, transported, used and disposed off safely. 3.To make health, safety and environmental considerations a priority while planning for all existing and new products and processes. 4. To report promptly on information on chemical related health hazards and to recommend protective measures to officials, employees, customers and the public, 5.To counsel customers on the safe use, transportation and disposal of chemical products. 6. To operate plants and facilities in a manner that protects the environment and the health and safety of the employees and the public. 7. To extend knowledge by conducting or supporting research on the health, safety and environmental effects of products processes and waste materials. 8. To work with others to resolve problems created by past handling and disposal of hazardous substances. 9. To participate with government and others in creating responsible laws, regulations and standards to safeguard the community workplace and environment. 10. To promote the principles and practices of Responsible Care by sharing experiences and offering assistance to others who produce, handle, use, transport or dispose off chemicals

The Guiding Principles of Responsible The Guiding Principles of Responsible CareCare

Codes under Responsible Care®Codes under Responsible Care®

PROCESS SAFETY

POLLUTION PREVENTION

PRODUCT STEWARDSHIPDISTRIBUTION

EMERGENCY RESPONSE

EMPLOYEE HEALTH & SAFETY

SECURITY CODE (APPLICABLE IN

US)

Benefits of Responsible Care®:Benefits of Responsible Care®:1. Improvement of Environment, Health, Safety & Security

performance Fewer people getting hurt Less adverse impact on the environment, More understanding amongst stakeholders,

2. Insurance & financing cost savings3. Reduction in legal liabilities4. Pollution prevention - cost savings5. Crisis management - Better prepared in case of crisis.6. Improved product development7. Marketing advantage - added sales tools.8. Workers Compensation - lower premiums.9. Exchange of ideas – less redundancy of ideas.10. Pride!!!

What Responsible Care programs is Dorf Ketal What Responsible Care programs is Dorf Ketal Chemicals involved in?Chemicals involved in?

What Responsible Care programs is Dorf Ketal Chemicals involved in? Reduction in water consumption Reduction in waste generation Zero Liquid Effluent Discharge Solid waste reduction Energy Conservation Reduction / Mitigation of Volatile Organic Content (VOC)

releases Electricity Generation through Solar energy Electricity saving by installation of VFDs’ & energy efficient

motors. RC 14001 Certification

I was involved in the Project highlighted in Red

On what basis was the project selected?On what basis was the project selected? WHAT:

Reduction of water consumption in cooling tower operations. (Relates to Responsible Care code of Pollution Prevention)

WHY:

The project helped me learn about cooling tower operations at the plant. The project aimed to reduce water consumption and conserve natural resource,

which is scarce.

WHERE:

Dorf Ketal Chemicals Manufacturing Plant at Taloja, Navi Mumbai, in Utilities Section

WHEN:

The Project commenced in the month of July 2014 (on start of my internship) and therefore this project was selected amongst other projects which were either in-process or planned at a later date.

Please insert Team Photo Here

Project Team - The Warriors ChampionUdayan Thite

Team LeaderShantanu Banerjee

Team MemberSudam Karpe

Mallikarjun MalgatteSandeep Patwardhan

Vikram NimbalkarVrishank Menon (Student/Intern)

Resource / MentorKaushik Biswas

StakeholderDorf Ketal Chemicals (I) P. Ltd.

Team Name: The Warriors Process Area: Utility

Project #1 : Reduction of Water consumption in Cooling Tower Operations

Background : The need for a water saving project arises mainly due to the scarcity of water, which is a natural resource and an overall commitment toward bettering environmental performance. It was identified that there was an opportunity for water saving in cooling tower operations as the blow-down given to the cooling tower was based on weekly frequency instead of any scientific / calculated method.

How I went about the project I studied about cooling tower operation. The team and I defined the scope of the project and the potential of saving. Site Visit by the project team to understand the actual cooling tower operations at

the plant. The team and I went through technical literature survey to identify potential for

water saving and the water quality requirements in cooling tower operations Brainstorming with the Project team about

◦ Identification of water usage & losses◦ Identification of critical parameters which affect the losses (blow-down quantity,

blow-down frequency, TDS of make up & circulating water) Data collection for the critical parameters by Project team After data collection, we brainstormed and analyzed the data to identify the solutions

for reduction in water consumption/losses. We identified the actions to be taken to monitor the reduction in blow down quantity. We evaluated the risks associated with the change in operations. We did a trial run of the proposed and monitored the results. The new method was implemented. Monitoring on regular basis continued.

What is a cooling tower?What is a cooling tower? Cooling Tower is an utility equipment in any plant which provides

cooling water as a cooling media to the reaction vessels and plant heat exchangers.Water is readily used a coolant in most chemical processes and

is extensively used in most chemical plants. It is transported through pipelines to machinery (reaction vessels & heat exchangers) to absorb excess heat that is produced during the reactions or for removal of heat provided from the boilers and heaters to the chemical media inside the plant equipments.

As a result, the water in itself becomes very hot after absorbing the heat of the reaction or from the heat exchangers and needs to be cooled.

Here, the cooling tower comes in, where hot water is circulated through the cooling tower, cooled down to an acceptable limit for reuse as a coolant again.

DiagramDiagram

Boiler

Reactors

HOT

How does it work?How does it work?A cooling tower functions by spreading the

water over a basin towards an open roof. Here there is a fan that allows for the water to

evaporate and thus reject heat from the systemHowever, this evaporation means that there is a

loss of water and thus a ‘make-up water 'needs to be added

Certain ‘blow down quantity’ of water needs to be removed from the bottom in order to reduce the amounts of accumulated solids which is due to evaporation of water.

Project Scope

Problem Statement :

Blow Down Quantity of cooling tower at Taloja Manufacturing location was high and was done once a week unscientifically which led to the wastage of scarce natural resource. This needs to be reduced by 30% as a part of continual improvement program.

Objective :

Reduction in Cooling Tower (CT) Basin Blow Down quantity from 8 KL to 5.6 KL per month.

MACRO MAP OF THE PROCESS

Input of water to cooling tower

Operation of cooling tower

Process Cooling thro circulation

 Make-up water operations

Blowdown operations

Note : Project Scope

Completion Target : Sept 30th, 2014

DiagnosisDiagnosisSite Visit :

1.We found out at the site that the water for the cooling tower came from Maharashtra Industrial Development Corporation (MIDC) treatment plant and the Dorf Ketal Reverse Osmosis (RO) plant.2. We learnt that the loss of water from the cooling tower is caused by (i) Evaporation (ii) Drift and (iii) Blow down.3.As the water is lost, the dissolved salt concentration increases. The loss is made up for by adding water, which is called “Make-up water”4.We found out that the operators at the cooling tower removed a certain blow down quantity 1 kL ever week without checking the concentration of the dissolved salts and making appropriate calculations.

Technical Literature/manual survey :

1.The concentration of the dissolved salts is measured by a parameter called “Total Dissolved Solids” (TDS)2.We found the recommended value of TDS for the cooling tower.3.We found out the relationship between the TDS values and COC values (Cycle of concentration)

Data collection :

1.We Recorded the Make Up Water quantity added to the cooling tower from MIDC supply and RO Plant. 2.We checked and recorded the TDS values of the water of the cooling tower regularly.3.We checked and recorded value of TDS from the water that was being added.4.We noted the Quantity of Blow down given from each cooling tower basin and the frequency of Blow down.5.The data was collected over a period of two months (July and August)

Data Analysis :

1.The quantity of make-up water was found to be approximately the value of water lost through evaporation. 2.Using the upper limit of the maximum permissible TDS value in circulating value of 2200 mg/L, a COC of 36 was found. (Recommended by Chembond Ashland Water Technologies Ltd)3.After calculation, it was found out that the actual blow down quantity was much lower than the theoretical value. 4.In spite of the lower blow down quantity, the TDS value never exceeded the theoretical permissible limit of 1500 mg/L. The maximum value at cooling tower 1 was 1436 mg/L and the maximum value at cooling tower 2 was 1184. However, it was concluded that there was a further scope for reduction of blow down.

DiagnosisDiagnosis

Solutions that were identified.Solutions that were identified.1. Blow Down water was not to be removed until the TDS reaches and/or

exceeds 2200 mg/L.2. When the TDS value does exceed 2200 mg/L, give a Blow Down of 2 KL and

make up with Fresh MIDC Water of 50 TDS ( Max.)3. Volume of Water Saved :

M = Initial make-up water volume C1 = Initial Cycles of concentration number , C2 = Final cycles of

concentration no.The potential water saving in CT-1 would be 1.7 KL (42.5%) & CT-2 would be 1.22 KL (30%)

The final decision was that the Total Dissolved Salt value would be monitored on a daily basis with effect from September to determine an accurate blow down quantity for effective running of the cooling tower. A Management of Change (MOC) request was raised and was to be approved after one month of monitoring the system with the implementation of the proposed solution.

Event Transition Action PlanEvent Transition Action PlanTransition Owner: Utility Operator

Plan Date: 01.09.2014

Actions Required for CompletionActionOwner

Initials ScheduledCompletion

ActualCompletion

1 Monitor the TDS of circulating water QC Continual Being done

2Update the TDSresult in excel sheet and log book

Utility Operator

Continual Being done

3Discuss with HOD when TDS goes beyond 1500 mg/L

Utility Operator

Continual Being done

4Give Blow-down at TDS of 2200 mg/L

Utility Operator

ContinualWill be monitored

5

6 Identification of Consequence Matrix & Tracking Shantanu 31.12.2014

AchievementsAchievements

CT-1 (Till 30th Sept, 2014) CT-2 (Till 30th Sept, 2014)

TDS TDS

TDS in both the towers have not crossed 2200mg/L and therefore no blowdown given in September 2014. This saved 8 KL of water in the month of September 2014.

Supporting Project DataSupporting Project Data

Literature Reference : Literature on Bureau of Energy Efficiency Cooling Tower Selection & Sizing by KLM Technology Group Water Conservation in Cooling Tower – The Australian Institute of

Refrigeration, Air Conditioning & Heating. Refer description for document 1 (monitoring sheet till september)

and document 2 and 3 about TDS.

Microsoft Word 97 - 2003 Document

Microsoft Word 97 - 2003 Document

Monitoring sheet

THANK YOUTHANK YOU