WELCOME

THE QUALITY CIRCLE FORUM OF INDIA, HYDERABAD CHAPTER

PRESENTATION ON

“WATER EXCELLENCY AWARD”

National Awards and Sustainability-2030 Vision & Excellence

Conclave of Indian Cement Industry

On Dated: 15 & 16 Oct-2018

FOR: HEIDELBERGCEMENT INDIA LTD.

NARSINGARH, DAMOH, M.P.

BY: MR. SANDEEP KUMAR TIWARI

HeidelbergCementGroup :

In around 60 countries across the world, HeidelbergCement stands for competence and quality. For 145years since its founding in 1873, HeidelbergCement has grown from a regional cement manufacturer, withone plant in Heidelberg, to one of the world’s leading building materials groups. With the takeover of

Italcementi, HeidelbergCement has become the number 1 in aggregates production, number 2 incement, and number 3 in ready-mixedconcrete worldwide.

HC India:HeidelbergCement entered India in 2006 and is currently one of the top ten Cement Players. The Group

acquired majority stakes in Mysore Cements and Cochin Cements as well as the Indorama Cement (joint-venture), which was converted to a full acquisition in 2008. Following the merger with Indorama Cement,

Mysore Cements was renamed as HeidelbergCement India Ltd. (HCIL) in 2009. HCIL expanded its capacityby way of a brownfield project in Central India from 2 million tonnes to 5 million tonnes in early 2013.

With the acquisition of Italcementi in 2016, HeidelbergCement further strengthened its presence in India.Italcementi had entered the Indian market in 2001, through acquisition of Zuari Cement (joint-venture), which

had an integrated cement plant in Andhra Pradesh and subsequently acquired Sri Vishnu situated inTelangana. Italcementi acquired full control of Zuari Cement in 2006 and expanded its capacity in AndhraPradeshby way of a brownfield project in early 2010.

Currently, HeidelbergCement India has production facilities at: Damoh (Madhya Pradesh), Jhansi

(Uttar Pradesh), Solapur (Maharashtra), Sitapuram (Telangana), Yerraguntla (Andhra Pradesh),Ammasandra(Karnataka),Chennai (Tamil Nadu) and Cochin (Kerala).

HeidelbergCement markets its products across 12 States and 2 Union Territories under the brand names“Mycem” and “Zuari”.

ABOUT THE GROUP/COMPANY

Number 1 in aggregates, number 2 in cement,

and number 3 in ready-mixed concrete in World

HeidelbergCement

Italcementi

HeidelbergCement and

Italcementi

Company Profile- HeidelbergCement India Ltd

63000 no. of employees

3000 locations in more than

60 Countries

Our Presence in India

INTRODUCTION OF ORGANISATION

HEIDELBERGCEMENT INDIA LIMITED

❖ PLANT’S LOCATION

❖ PRODUCT

❖ PRODUCTION CAPACITY

❖ PLANT PROCESS

LOCATION

Clinker Plant, Narsingarh

HEIDELBERGCEMENT INDIA LIMITED (HCIL) NARSINGARH, DAMOH, M.P.CAPACITY: 3.1 MTPA CLINKER

CERTIFIED: ISO-14001, ISO-9001 & OHSAS-18001 & WATER POSITIVE (+6.37)

MILESTONE - HCIL

Unit-1 1982 1500

TPD

NGH

Unit-2 1989 2200

TPD

NGH

Unit-3 2013 5000

TPD

NGH

WHRPP 2015

15

MW

NGH

OPERATIONS OF CLINKERISATION UNITS

Following activities are involved in operation of Clinkerisation units:-

❖ The limestone requirement for producing clinker is met from Patharia Lime stone

mines.

❖ The limestone is received at Narsingarh plant by Covered Over Land Belt Conveyor

(OLBC).

❖ The lime stone received is further sized in crusher and transported through covered

conveyor belt equipped with dust collectors & water sprinklers to a longitudinal

stock pile in the plant from where, it is reclaimed for finer grinding.

❖ Lime stone & Laterite/Bauxide mix in raw mill make raw mix, store in Raw mill silo.

❖ Raw mix enters the kiln from the Pre-heater. Clinkerisation reaction occurred at

high Temperature between 350 to 1450 degree Celsius in Kiln and finally Raw mix

converted into Clinker.

❖ Clinker cool in Cooler and stock in Clinker silo.

❖ Clinker transported to Grinding unit by rope way/road for cement production.

❖ Clinker, Gypsum and Fly ash are ground in Cement mill and cement is produced

which is being transported by truck and Railway to the end user.

IN THE WAY OF WATER EXCELLENCEIN HCIL

❖ WATER POLICY

❖ ROADMAP

❖ COMPLIANCE

❖ PUBLIC DISCLOSURE

IMS POLICY

GROUP SUSTAINABILITY COMMITMENTS -2030

Driving Economic Strength and Innovation

Achieving excellence in Occupational Health and Safety

Reducing our Environmental Footprint

Enabling the Circular Economy

Being a Good Neighbour

Ensuring Compliance and creatingTransparency

REDUCING OUR ENVIRONMENTAL FOOTPRINT : WATER

Reducing our Environmental Footprint

“We are committed to fulfilling our share of the global responsibility to keep temperature rise below

2°C, and we will continue to reduce our impacts on air, land and water.”

GOALS - Water:

✓ Reduction of water consumption at all sites to the economically and technologically feasible

level.

✓ All sites located in water scarcity areas will have a Water Management System as well as a

Water Reduction Master Plan

✓ Implementation of a Global Strategic Water Consumption Reduction Plan

KPIs

➢ Water consumption compared to 2015

➢ Percentage of sites in water scarcity areas using water management plans

➢ Percentage of sites having implemented an efficiency oriented water recording system

➢ Global water reduction target from 2030 onwards

Tools and Measures (How to achieve):

➢ A Binding Water Reduction Master Plan as a Part of the Water Management plan for Each site

location in water scarcity areas, describing water quantities handled, their origin and use rate,

consumption reduction potentials, water recycling opportunities and possibilities of a close

cooperation with surrounding communities.

➢ The 2030 Global Strategic Water consumption Reduction Plan.

➢ Appropriate Managers will have water conservation related improvement objectives.

COMPLIANCE

• All Statutory rules and regulations for Environment is being

complied.

• Time to time, it is being reviewed by HeidelbergCement Group

• Group Audit is being conducting once in a three month

Our aim ZERO harm

PUBLIC DISCLOSURE

• Six monthly compliance report of Environment Clearance and

monthly report is available at our company website.

• Digital Display board showing online monitoring data is displayed

at plant main gate and its online data is available at CPCB &

MPPCB website.

• Disclosure of the hazardous material used, effluents released for

public at plant main gate.

• MSDS is disclosed for all users

Our aim ZERO harm

APPROACH TO WATER MANAGEMENT

Augmentation

of Water Resources

Reduce

Reuse & Recycle (Zero Liquid Discharge)

100% Use of

STP water

A Three

Pronged Approach

SPECIFIC WATER CONSUMPTION & REDUCTION

❖ IN CLINKERISATION PLANT

❖ IN PLANT COLONY

0.153

0.059 0.056

0.000

0.020

0.040

0.060

0.080

0.100

0.120

0.140

0.160

0.180

2015-16 2016-17 2017-18

Water Consuption /Tonne of Clinker (KL/Mitric Tonne)

SPECIFIC WATER CONSUMPTION IN CLINKER PLANT

❖ Replaced the Water Cooled Compressors with Air Cooled Screw Compressors/Blower.

❖ Installation of Waste Heat Recovery Power Plant (WHRPP) for utilization of Waste Heat in Power

generation, therefore, water consumption in Clinker Cooler and Gas Conditioning Tower (GCT) / PH

down comer duct was reduced.

❖ Replaced the underground old & corroded pipe lines with new one to arrest even the small leakage

of water from the pipe lines (Work under process).

❖ Utilization of STP treated water in plant process.

❖ Rain water checked in small channel by making a small check dam and utilized the same water in

processduringrainy season.

ACTION TAKEN TO REDUCE WATER CONSUMPTION IN PLANT

Screw Compressor Water Cooled Compressor

SPECIFIC WATER CONSUMPTION IN COLONY

1905

1375

1687

0

500

1000

1500

2000

2500

2015-16 2016-17 2017-18

Water Consuption (KL) per Day

* It is included the total domestic water utilised in Plant colonies (60% approx.)

and Near by village area (40% approx.) under CSR activity

❖ Training andAwareness programs organized for water savings.

❖ Optimization of water supply timings in Colonies and nearby Village area.

❖ Installation of Water sprinkling and Drip irrigation system.

ACTION TAKEN TO REDUCE WATER CONSUMPTION IN COLONY

WATER FLOW METERING FOR ALL MAIN SOURCES - NARSINGARH

Flow meter

Pump

Power plant

ABBRIVATIONS / MARKS DESCRIPTIONS

Valve

Online flow meter

HEIDELBERG CEMENT INDIA LIMITED

UNIT - NARSINGARH, DAMOH (MP)

PLANT WATER DISTRIBUTION SYSTEM

Filter plant

Line- 1 & 2

Line- 3

FM 15

WORKERCOLONY

Mahuna Pump

Pit No. 2

Areator

Clarifier

Unfiltered waterTank

Filtered waterTank

P P PFM1

FM 24

FM 23

PPP

FM 3

FM 4

CT TANKLINE - 1

CT TANKLINE - 2

DRINKING WATER TANK

RAW WATER TANK FOR PLANT

Chloronisation tank

P PP

P

P

LINE - 2CIRCULATING LINE - 1

CIRCULATING

ROLLER PRESS

P P P

ADM

NARSINGARH

STAFFCOLONY

Press

filter

Press

filter

Press

filter

Press

filter

BACK WASH BACK

WASH

FM 13

FM 14

OverheadTank

PLANT DRINKING

WATERFM 12

COMPRESSOR HOUSE

FIRE POINT

Soft water tank1

Soft water tank2

Fire tank1

Fire tank1Drinking

water tank

1

Drinking water tank

1

Raw water tank1

Raw water tank2

Press

filter

Softner 1

Press

filter

Softner - 2

P

P

P

PP P P P P

FM10

FM 11

FM 5

FM 6

FM 7

RAW MILL

COALMILL

COOLER

PH-1

RAW MILL

RABH BAG HOUSE

PREHEATER

COAL MILL

KILN

COOLER

Cooling Tower-1

Cooling Tower-2

P

P

FM 17

BACK WASHBACK WASH

DRINKING WATER

FM 16

P

FM20

FM2

FM 8

PH - 2FM 9

P

P

FM 18

P

FM

P

FM 25

FM 25

CST Tank

SW Tank

DMWTank

Softing

DM Process

COOLING TOWER

SNCR TANK FARM AREA

FM

FM DRTank

ALL BOILERS

GARD POND

DM Process

STP PLANT

process

Gardning

FM30

FM29

FM 28

FM

GEUST HOUSE

HOSTEL

process

Gardning

FM27

GEUST HOUSE

FM19

WATER MANAGEMENT

❖ SEWAGE TREATMENT PLANT (STP)

FOR PLANT & COLONIES

❖ PERCENTAGE OF RECYCLED/FRESH

WATER USED IN PROCESS & OTHER

UTILITIES

❖ AMOUNT OF WATER GIVEN TO

COMMUNITIES

SEWAGE TREATMENT PLANT (600 KLD)

STP of Capacity 600 KLD has been installed at Clinkerisation unit Narsingarh based on Activated

Sludge Process (ASP) technology. The Inlet source of Waste water from plant & colonies and thetreated water is being used for plantation and dust supresstion.

PERCENTAGE OF RECYCLED WATER USED IN PROCESS & OTHER

UTILITIES:-

100% STP treated water is being utilised in plant process, dust suppression

and plantation. Approx. 50% of total treated water is being utilised for

gardening and remaining 50% in plant process and dust suppression (i.e.

Percentage may vary on seasonal basis).

PERCENTAGE OF FRESH WATER USED IN CLINKER MANUFACTURING:-

In Clinker manufacturing process, we are using 88% Rain water, which is

being conserved in mines pit. Apart from this, we are using surface water,

received from Sonar river in case of water unavailability in pit and 12%

water from STP.

WATER MANAGEMENT

AMOUNT OF WATER GIVEN TO COMMUNITIES FOR DRINKING,

DOMESTIC USE & IRRIGATION PURPOSE :-

HCIL is being supplied domestic water to the near by village Narsingarh

under CSR. The total amount of water being supplied to the Narsingarh

village is approx. 40% of our total domestic water demand.

Apart from this, we have been converted our mine out area as a waterreservoir and near by villagers are being used the water reservoir for

Irrigation & other purposes.

WATER MANAGEMENT

WATER HARVESTED QUANTITY

❖ ROOF TOP RAIN WATER HARVESTING

❖ SURFACE WATER HARVESTING

SYSTEM

❖ RAIN WATER CONSERVATION

IN POND

❖WATER CONSERVATION IN MINES PIT

SN. Location Area ( m2 )

1 Roof Top Rain Water Harvesting by Recharge Bore well 12720

2 Surface Rain Water Harvesting System 62000

3 Water Reservoir (pond) at east colony 5256

Total 79976

ROOF TOP RAIN WATER HARVESTING THROUGH RECHARGE BORE

WELL AT NARSINGARH PLANT & COLONIES

*Annual Average Rain Fall for Damoh location is 1173 mm.

MINES PIT FOR RAIN WATER HARVESTING IN NARSINGARH MINES (CLOSED)

S.N. Pit No.Pit Area (m2)/

Roof top Area (m2)Catchment Area (m2)

1 Pit-1 in Area-1 205650 3550000

2 Pit-2 in Area-2 82720 950000

3 Pit-3 in Area-3 88970 650000

4 Pit-4 in Area-3 115800 1650000

5 Pit-1 in Madia 25640 100000

6 Pit-3 in Chainpura South 103000 750000

7 Pit-3 in Chainpura East 10470 250000

8 Pit-2 in Barkhera 16200 240000

9 Pit-3 in Barkhera 101400 100000

10 Pit-4 in Barkhera 300800 1450000

Total 1050650 9690000

*Annual Average Rain Fall for Damoh location is 1173 mm.

RAIN WATER HARVESTING SYSTEM

Roof top Rain Water Harvesting System at plant

Surface Rain Water Harvesting System at colony Water Reservoir at plant Colony

RWH Filter

RWH Filter installed at HCIL Colony

RWH System installed at HCIL School Building

RAIN WATER HARVESTING SYSTEM

RAIN WATER HARVESTING IN MINES PITS

RAIN WATER HARVESTING IN MINES PITS

HCIL / ZCL - SGU

SPRINKLER/DRIP IRRIGATION SYSTEM

WATER POSITIVE INITIATIVES

WATER POSITIVE (+6.37)

CERTIFICATE

FROM TUV SUD

RECOGNITIONS AND AWARDS

Water Positive Certificate from TUV

SUD in 2018

National Energy Conservation Award 2014

received from BEE through Honourable Energy

(Cabinet) Minister

ACHIEVEMENTS

Green Manufacturing Excellence Award 2013 from

Frost & Sullivan

“Golden Peacock Occupational Health

& Safety Award” 2018

Controller General,IBM Facilitating Mines team

with the 5 star recognition award during MEMC

final day function-2018

ACHIEVEMENTS

❖ Green School Program Award

through Honourable HRD (Cabinet)

Minister

Green School Programme -2017

All India Rank -4

Green School Programme -2018

All India Rank -1 (Water sub Category)

❖ Green School Program Award by Dr.

Bhure Lal, Head- Environment

Pollution Control Authority (EPCA)

CARPORATE SOCIAL RESPONCIBILITY (CSR)

Deepening of pond - Singhpur Construction of Culvert -Patheria

Construction of Check Dam - SatparaConstruction of Check Dam - Narsingarh

CSR ACTIVITIES

CSR ACTIVITIES

Water tanker for villages

Water Solution for Damoh at Rajnagar

Construction of Culvert at village

Mara nearby Imlai Plant

Construction of Ghat on Sonar River

AWARENESS

WATER SAVING AWARENESS PROGRAM FOR COLONY FAMILIES

SAVE WATER SIGNAGE DISPLAYED AT WATER TAP

BEST PRACTICES

Covered Over Land belt Conveyor (OLBC) (22 km.)

between Lime Stone Mines, Patharia & Clinkerisation Unit, Narsingarh

Rope way (13 km.) between Clinkerisation Unit, Narsingarh

& Grinding Unit, Imlai

BEST PRACTICES

Waste Heat Recovery Power Plant (15 MW)

Scrap Storage Yard

Plantation by Director TechnicalPlantation by Managing Director

Mass Plantation

PLANTATION❖ Total area of Clinkerisation Unit: 191.77 Ha

❖ Total area of Green Belt Development: 74.635 Ha❖ % of green belt development: 38.92%

GREEN BELT

Door to door collection Shredder & ComposterSegregation of waste

Curing system Domestic Waste Processing Facility

DOMESTIC WASTE MANAGEMENT SYSTEM

CELEBRATION OF WORLD ENVIRONMENT DAY & INTERNATIONAL OZONE DAY

Incineration of Narcotic (Opium) in Kiln by Police Department of Madhya Pradesh

Incineration of Plastic waste in Kiln by Madhya

Pradesh Pollution Control Board

INCINERATION

Environment Emergency Mock drill

CAAQMS- COLLECTORATE CAMPUS DAMOH INSTALLED BY HCIL FOR LOCAL PUBLIC UNDER DIRECTION OF MPPCB

ENVIRONMENT MAGAZINE

Safety is our foremost priority