This is a presentation from Ashok Leyland, Hosur II one of the finalists at the 5th CII-GBC National Award for Excellence in Water Management in 2008 The awards are in 2 categories, Within the Fence for work done on minimizing the organisations water footprint, and Beyond the Fence for work done in the community around the industry. This presentation was in the "Within the Fence" category. We thank CII and the respective companies for giving us permission to upload these presentations on the India Water Portal website for dissemination to a wider audience.

1. Ashok Leyland : A Brief History
§ 2nd Largest Commercial Vehicle Manufacturer in India
and market leader in technology
§ Established in 1948
§ Six Manufacturing facilities across India and joint
ventures abroad
§ Annual Turnover of Rs. 8300 Crores
§ About 12000 employees
§ All manufacturing plants in India are certified for
ISO14001 & TS16949
§ Vehicles and Engines - Complying to Euro Norms
§ Launching First hybrid electric vehicle of India
§ Market leader in CNG Powered bus
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2. Ashok Leyland, Hosur – II
Ø Established in 1994
Ø Spread over 197.15 acres
Ø Manpower – around 1250
Ø Annual turnover of 1597
Greene ry:
crores Ø No of Trees – around 19500
Ø TS 16949/ ISO 14001 Certified Ø Garden Area – 1,70,000 Sq.m.
Rain Water Harvest ing :
Ø Total storage capacity 70,000
KL/season
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Plant Block Diagram
FRAME CABIN AXLE
FR AME PRES S FR AME P AIN TING C AB WELD C AB P AIN T AS S Y. &
SHOP & ASS Y SHOP SHOP P AIN TING
OTHER UNIT
CAB TRIM & CHASSIS ASSY
SUPPLIES
ASSEMBLED
VEHICLE
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3. Comparison with Global norms /
benchmark
Inefficent water us e by indus try
The ratio of water consumption and eco nomic value creatio n
in Indian industry is poor. Fo r every cubic metre o f water t hat
Indian industry uses, it generat es merely US $7.5
eco nomic pro duct ivity
Indust rial
Industrial water
water use Industrial pro duct ivity At Ashok Leyland, Unit II
(billio n cubic productivity (US $ / cubic
Country metres) (millio n US $) metre)
Total Indu str ial W ater : 71213 C u Mt.
Argentina 2.6 77171 30
Produ ctivit y : US $879007
Brazil 9.9 231442 23.4 Indust rial water pr oduct ivit y : 12.3
India 15 113041 7.5 (US $ / cub ic m etre)
Ko rea, Rep. 2.6 249268 95.6
Norway 1.4 47599 35
Sweden 0.8 74703 92.2
Thailand 1.3 64800 48.9
Unit ed
Kingdom 0.7 330097 443.7
Sourc e: World Bank, 2001
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Specific Process Water
Consumption
Specific Process Water Consumption
8
7 6.9
6.3
6 5.7
Cu Mt per Vehicle
5 6.00 4.8
4 5.60
3 4.20 4.20
2
1
0
04-05 05-06 06-07 07-08
A ctual Projected
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4. Water Saving Projects
Project: I
Zero Discharge Effluent Project
Objective:
To recycle effluent (through Effluent Treatment
Plant +Reverse Osmosis Plant) to use for
Paint Process like:
1. Rinse water in paint line.
2. Feed to hot water generator.
3. Cooling circuits in compressor house & weld
shop.
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Before Zero Discharge Project:
Process Flow of Industrial Effluent
Efflue nt fro m
Equalization tank
Process
Us age of
Treat ed
Effluent
for To Garden
Flocculation Tank
Reaction *
Ph Correc tio n
Clarifier
PSF ACF
Thicke ner
Sludg e Dr yi ng (Clarifier ) Leg end:
Bed PSF : Pr essur e Sand Filt er
ACF : Activat ed C arb on F ilt er
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5. Zero Discharge Reverse Osmosis (R.O.)
Plant Process Flow
TO ETP 25 KL 10 KL 6.5 KL
PRETRE 75 KL REVE RSE 15 KL REVE RSE 3.5 KL
REVE RSE
ATMEN T OSMOSIS-I OSMOSIS- OSMOSIS-III
(85% ) (75 %) II (60%) (35 %)
FEED FROM ETP PRETR EATE D
WATER FEE D
100 KL
93.5KL
PERME ATE MULTIPLE
DRY SL UDGE SLUDGE 6.17 KL 6.5 KL
DRYI NG WATER EFFECT
TO SLF BED S STORAGE EVAPO RATO R
(99.6 7% )
99.67KL 0.33 KL
LEGEND :
FEED FILTERATE
FILTERATE WATE R TO TO THE PAINT PERME ATE SLUDGE
ETP PROCE SS& COOLING
REJE CT BA CKW AS H
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Zero Discharge Reverse Osmosis (R.O.)
Plant
R.O.Plant Multiple Effect Evaporator
UF
R.O. -3
R.O. -2
R.O.-1
Compr es sor
Boiler
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6. Quality of Effluents
Sl. Para meter TNPCB Af ter Af ter
No Tol erance Treatment Treatment
limit Through Through
ETP R.O.
1 pH 5.5 – 9.0 6.5 – 8.5 7.0
2 TSS (mg/l) 100 < 10 <1.0
3 TDS 2100 < 1000 52.0
4 BOD 30 < 15 <1.0
5 COD 250 < 100 <1.0
6 Copper (as Co) mg/l 3 < 1.0 <0.05
7 Zinc (mg/l) 1 < 0.5 <0.01
8 Chlorides (as Cl) mg/l 1000 < 500 13.0
9 Oil & Grease 10 <3 <1.0
10 Sulphates (as SO4) mg/l 1000 < 500 <0.2
11 Dissolved phospate mg/l 5 <3 <0.05
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Investment in Zero Discharge Project
PA RTICULA RS COST IN RS. LA KHS
RO PLA NT 85
MECHA NICAL EVA PORA TOR 98
CIV IL CONSTRUCTIO NS 48
STEA M BOILER 8
PIPING WORK 13
ELECT RICA L WORK 23
TOTAL COST OF PROJECT 275
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7. Benefits of the Zero Discharge
Project
The occurred savings :Rs. 12.6 lakhs/annum.
Ø The entire treated w ater is being us ed for the plant paint
process and cooling circuits(100 kl /day present volume) .
• Rinse w ater in paint line.
• Feed to hot w ater generator.
• Cooling circu its in com pressor house & weld shop.
Ø Being 3 stage R.O. Plant, the membrane recovery achieved
is 90-94%.
Ø Lesser the reject quantity the operation of Multiple Effect
Evaporator ( Tr iple Effect) evaporator is less.
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After Zero Discharge Project: Process
Flow of Industrial Effluent
Effluent from Oth er
Equalization tank
Proc es s Proc es s
Cab Paint
Pro cess Zero Discharge R.O.
Plant with Multip le
Cooling
Effect Evapor ator
Circuits
Flocculation Tank
Reaction *
Usage of
RO
produ ct for
Ph Correc tio n
Clarifier
PSF ACF
Thicke ner
Sludg e Dr yi ng
Bed
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8. Project - II
Project description
To reduce soft water consumption in Paint process
Objective:
To reuse pre treatment Rinse-I water to Rinse-II there
by reduce the soft water consumption in paint
process.
Target :
To reduce soft water consumption by 5% / day in
pretreatment line.
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Problem identification :
HIGHER SOFTWATER USAGE IN PT LINE
Additi on of 2KL
Level drop of 2KL/day due Rinse water to
Degrease fres h Soft water
to evaporation & Spray loss
Level drop 0.75KL/da y`
DIP Degrease Sof t Water
Bath temp. - 55-65°C Rinses 1
Level drop
Spray Degrease
- 1.25KL/da y` Discard of 80KL water / month Sof t Water
In Rinses 2 Rinses 2
Weakly one time drain
WHY REDUSE THE BATH LEVEL IN PT TANK ?
WHY REDUSE THE BATH LEVEL IN PT TANK ? 16
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9. R E D U S ET H EB A T HL E V E L
Current situation analysis:
PRO CESS C ARR Y O VER
P
The carry over solution
Is in Rinses 1&2
EV APOR ATI ON
X
Bath temp. - 55-65°C
EV APOR ATI ON
SP AR Y L OSS ES
X
Through exhaust fan
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Re use of Rinse 1& Rinse 2 discarded Water:
Rinse water to Degrease
Spray & dip degrease Level make up Additi on of 2KL
From R1 & R 2 fres h Soft water
Level drop
- 0.75KL/da y`
DIP Degrease Sof t Water
Bath temp. - 55-65°C Rinses 1
Level drop
- 1.25 KL/da y` Discard of 40KL water / month Sof t Water
Spray Degrease In Rinses 2 Rinses 2
15 days one time drain
Water conservation per month, 40 KL
Water conservation per month, 40 KL 18
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10. AFTER THE MODIFECATION IN P T LINE
Rinses 1
Dip Degrease
Spray & dip degrease Level make up
From R1 & R 2
Rinses 1
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Spray Degrease
Benefit to Environment
• Soft water saving of 480 KL/annum by reusing Rinse
water
• Soft water Plant regeneration reduction by appx. 2
times/annum
• Reduction in regenerating chemicals by 400kg
i.e.Rs.1800 / annum
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11. Tangible Benefits:
Process Tank Before Pr oject After Pr oject
Rinse 2 draining 7 days once 15 days once
frequency
Rinse 2 water 80 KL 40 KL
requirement/month
Cost Saving
Source Quantity,/annum Rs./annum
Water 480 KL Rs. 24000
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Tangible Benefits:
Water conservation per annum: 480 KL i.e. Rs. 24000
Water conservation per annum: 480 KL i.e. Rs. 24000
Reduction in Effluent generation: 3080 KL i.e.Rs.27104
Reduction in Effluent generation: 3080 KL i.e.Rs.27104
Intangible Benefits:
1. Improv ing Env ironme nt by Conserv ing Resources & Re ducing
Efflue nt to E TP
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12. Project - III
Project description
Elimination of water softener usage.
Objective:
Reduction of Effluent generation by
eliminating softener usage.
Target :
To reduce effluent generation by 4380 KL / annum
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Feasibility study
Soft water usage
Soft water is being used for our
1. Paint process
2.Hot water Generators,
3.Cooling circuits in Compressors
Chiller Plants,weld guns
Daily requirement of soft water is 75 KL.
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13. Feasibility study
Quality of soft water required
Sl Application water Remarks
No Hardness in
ppm
1 Paint pre treatment <5 Sensitiv e
process rinsing to quality
2 Cooling circuits in <5 Sensitive
Compressor, weld to scale
guns,
3 For hot water <5 Sensitive to
generators in paint scale
shop
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Feasibility study
Quality of R.O.water available
Sl Critical water Conclusion
No Parameters quality in
ppm
1 pH 7 R.O. water
qua lity is
2 TDS 52 super io r t han
3 Hardness <2 soft water.
Action taken
• Taken approval from Paint process team
•Laid pipeline for inter connecting R.O.treated water
piping and soft water storage sump .
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14. Results - BENIFI TS FROM THIS P ROJE CT
Effluent reduction by eliminating softener per day
• The daily rinsing +regeneration water: 12 KL
Net water saving / annum is =4380 KL
Tangible benefits per annum:
• The softener regeneration
Chemical cost / annum Rs. 46800/-
• The water cost : Rs. 13,140/-
• Cost of avoidance at ETP+R.O. : Rs. 672768/-
Total cost saving/ annum in Rs- 732708/-
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Project - IV
Project :
Ne w Liquid s urface c ondit ione r P L-X
Proj ect - II
Objective :
Water Co nservation through a lternat ive s urface
activatio n chem ica l
Present stat us :
Water co nsumption in surface act ivatio n pro cess
present ly 3,120 m 3/year
Ta rget :
To re duce the wate r c ons umpt io n to
620m 3/year,res ulting in net saving of 2,500m 3/year
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15. Aging durati on: Solid v s Liquid S ur face Conditi oner
v Solid Surface Conditioner
Chemical Nipaf in ZS
Type Solid
Draining f req. Weekly
Water used 60 KL
v Liquid Surface Conditioner
Chemical PL - X
Type Liquid
Draining f req. Month ly
Water used 60 KL
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Conv entional Sur face Condi tioner Ba th
Surf ace conditioning Water rinsing
Degreasin g Phosphati ng
Helps to ac hieve low temperatur e and
Helps to ac hieve low temperatur e and
high paint perfor mance phosphate
high paint perfor mance phosphate
System.
System.
The stability of the Ti colloid is poor
The stability of the Ti colloid is poor
& ititrequires draining & replenishment
& requires draining & replenishment
of bath
of bath
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16. Com parison of S olid & liqui d Sur face Condi tioner
PL ZS PL X
Solid type Liquid type
Shorter bath life Longer bath life
Good Phosphate coating Superior phos phate c oati ng
Fine Crystal mor phol ogy Finer crystal morphol ogy
Longer phos process ti me Shorter phos process time
Auto drain required Auto drain not required
Hash marks c an be s een Hash marks c annot be s een
Poor phos phatibiliy on hard to react steel Good phosphatibili y on hard to react
steel
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Results and Sta ndar dization
Water s aved thr ough the project ((Raw + DMW): 2706 KL
Water s aved thr ough the project Raw + DMW): 2706 KL
Waste w ater reduction through the pr oject: 2706 KL
Waste w ater reduction through the pr oject: 2706 KL
Sludge c ontent reduction: Approx. 1125 kg per annum
Sludge c ontent reduction: Approx. 1125 kg per annum
DM water con sumption @ Rs. 150 / KL Rs. 3,60000 per annum
Water con sumption @ Rs. 20 / KL Rs. 6120 per annum
Wa ste wate r treatment @ Rs. 7 / KL Rs.18942 per annum
Energy savings @ Rs. 3.67 / unit Rs. 14006 per annum
Chemical consumption @ Rs. 69 / kg Rs.103170 per annum
Potential savings per annum, Rs. 3.89 lakhs
Potential savings per annum, Rs. 3.89 lakhs
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