This is a presentation from Tata Chemicals Ltd, 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. Presentation on
“Excellence in Water Management – 2008
16 & 17 December 2008: CII- Sohrabji Godrej Green Business
Centre, Hyderabad
TATA CHEMICALS LIMITED - BABRALA
The Glorious Tatas
v Group Turnov er > $62.5 Billion
v Group’s 27 publicl y listed compa nies hav e
Market Capitaliza tion $ 60 Billion
v Operations in m ore than 40 countries across
6 contine nts
v Total Number of Em ployees : >350,000
v Conglomerate of 116 compa nies in 7
Business Sectors:
• Materials
• Energy
• Chemicals
• Serv ices
• Consumer Pr oducts
• IT & Com munications
• Engineeri ng

2. Tata Chemicals
v Tata Chemicals Established in 1939 at Mithapur, Gujarat
v Urea complex at Babrala commissioned in Dec, 1994
Urea
D el hi
Bab rala
Mith apur
Hald ia
Mumbai
DAP
NPK
Salt
Soda A sh
Fertilizer Complex - Babrala
Single train A mmonia Plant
Capacity – 1520 MTPD
Haldor Topsoe Technology
Two trains Urea Plant
Capacity – 2620 MTPD
Snamprogetti Technology
State-of-th e-ar t T echnology
Most En ergy Efficient Plan t
Most Env ironmentally Effic ien t
32% of entire area is under green cov er
Zero Discharge of Efflue nts
Lowest M anpower Operated
DCS Control Sy stem
Single Control Room for Complex
SA P – R/ 3 ERP Pack age
Referenc e Plant for Technology Supplier s

3. Urea Manufacturing Process
HB J Pipeline
H ydro carbon s Ammonia storage
Stea m Air
NH 3 Urea
Ammon ia Plant Urea Plant
Ammonia Urea Bagging
CO2
Bagge d
Urea
Power & Steam Cooling to wers Dispatch
Road:
15%
De-mineral isation Instrument air Inert gas Rail: 85%
Our APPROACH …….
Three pronged st rategy for achieving excellence in
water management
v Water Efficient Design
v Efficient Operations to conserve water
v Continuous identification of new opportunities and
integrate them with the processes / operations
through suitable modifications

4. Water Efficient Design
Efficient Design : Selected Unique concepts at the design
stage.
v Though the river Ganges is near by w e selected
bore-w ell w ater as fresh w ater supply source.
v Earlier borewell w ater w as com ing to the plant after
getting accum ulated in a p ond. Now it is com ing t o
the plant directly through pipeline.
v Effluent treatment at the source to conserve w ater
and am m onia
v Boiler blow dow n is used as m ake up to coolin g
tow er.
v All innocu ous treated effluents are used for green
belt developm ent and m aintenan ce w ithin the
prem ises. TCL, Babrala is a ‘Z ERO’ effluent
discharge unit.
Water Efficient Operation
Efficient Operation : Our strategy is continuous monitoring
and optimization of operation
v Continuous vigilance and monitoring at the source
(i.e at the tube well discharge)
v Maximum possible recycling of process/steam
condensate
v Cooling water treatment optimization to operate with
high cycle of concentration.
v Boiler water treatment optimization to minimize blow
down quantity.
v Controlled use and monitoring at all consumption
points

5. Find new opportunities and integrate
Efficient Modification : Our strategy is to involve maximum
people and continuously search for new opportunities and
optimization of operation
v All em ployees and tow nship residents are m ade
aw are of w ater conservation
v People find new opportunities and suggest
v Suggestions are evaluated by con cerned
department follow ed by process engineering dept
for benefits and suitability
v Schem e m ade and detail design done
v Schem e im plem ented and evalu ated for actu al benefits
v Suggestor is rew arded
Driving Excellence through People Involvement,
Driving Excellence
Teamwork and efficient methodologies
Six-Sigma
Benchmarking
Process
Improvement RC A F MEA RCM KM
Techniques
5S SPC Suggestion Scheme Manthan C O Q
Process
Balanced Scorecard BSC model - SHE
Framework
Integrated Management Systems
(ISO 9001, ISO 14001, OHSAS 18001, ISO 27001 and RC14001)
Tata Business Excellence Model

6. MONITORING……Measure , Analyze & Improve
Measuring
Flow m eters are provided at the discharge of tube w ells to
m easure at source
Major consum ption points have separate flow m eters
Sum of production and sum of consum ptions are balanced on
daily basis. Variation ( <2.0 %) ensures accuracy of
m easurem ent.
Daily Reporting
Daily w ater consum ption inform ation is sent to Senior
Managem ent
Daily Environm ent perform ance is reviewed by senior
m anagem ent
Every year reduction of specific w ater consum ption target is
taken and the sam e is m entioned in MD’s Green Goal sheet
Environm ent incident Reporting System
Monitoring consumption of domestic water
To monitor and reduce per capita consumption
v Flow m eters installed in the dom estic supply lines
to tow nship
v Treated effluent is being used in place of fresh w ater
for tow nship green-field m aintenance
v Aw areness sessions on natural resource
conservation and Quiz contest are conducted regularly
for tow nship (ISO-14001 certified) residents, school
students and nearby com m unity
v Tow nship sew age w ater is treated and used for
horticulture purpose
v Regular Preventive Maintenance of w ater
taps/netw ork at public places by using checklists

7. Water Conservation Projects 2004-2008
Sr Year of Descriptio n Inv estmen t
No Imple men tati on (Rs La cs)
Use of partially de-cationed water as am monia cooling tower ma ke-up
1 2004-05 5.50
(annual wate r saving: 284,0 00 m3)
T o provide tapping points (5 -6) at cooling towe r Blow dow n heade r for
2 2004-05 0.35
horticulture purpose.
2" b ypass line provided with I/V f rom ring h eader to fountain wate r
3 2004-05 0.00
pump discharge line
Recycling of D M plant analyse r effluents to FWST (annu al water
4 2005-06 0.85
saving: 10000 m3 )
T o provide flow met res in tubewells at drinking w ater o/l line going to
5 2005-06 3.00
township
T o provide wate r cooler in rec ycle line of HSD pump to cont rol HSD
6 2005-06 temp in the day t ank a nd thus eliminating use of water spra y on th e 1.00
tank du ring summer (annual wate r saving: 5000 m3)
Recyling of CPS GP steam condensate to D M Plant (Annual wate r
7 2006-07 4.00
saving: 25000 m3 )
Recycling of inter-stage condensate f rom compressors to cooling wate r
8 2006-07 4.50
return he ader (annual wate r saving: 250 00 m3)
9 2006-07 Installation of additional pH meter at the inlet lines to Guard po nd-1 2.00
T o provide horticulture water ta pping near Fire and safet y lawn an d
10 2006-07 1.00
IGGP area
T o prime the floor washing pumps using effluent wate r and eliminate
11 2006-07 0.30
the consumption of utility water.
T o provide tappings at the 55 -P-05A/B/ C reciculation line for irrigation
12 2007-08 0.25
near NBS security guard cabin
Water Conservation Project - 1
Installation of a water cooler for to control HSD
tank temperature
v HSD pump runs continuously as a ready available
stand by fuel for Gas turbine and Boiler to avoid
unwanted trips
v We used to spray water on tank surface to cool
down the HSD tank in day time of hot summer
v A water cooler was installed to cool the recycled
HSD at pump discharge so that temp remain
below flash point of HSD
Annual w ater sav ing : 5000 M 3
Benefits
Inv estment : Rs 1.5 lacs

8. Water Conservation Project-2
Rain Water Harvesting system in residential complex for
water conservation
v Water harv esting Pond -1
v Capacity : 100X30X0.5 m3
v Water coll ected and r ec harg ed during rai ny seas on: 4500 m3
v Cos t of pr ojec t: Rs 10,000
v Water Harv esting Pond – 2
v Capacity: 20X30X1 m3
v Water coll ected and r ec harg ed during rai ny seas on: 900 m3
v Cos t of pr ojec t: Rs 25,000
Annual w ater charged : 4500 M 3
Benefits
Inv estment : Rs 35,000
Water Conservation Projects - 3
Rain Water Recycling project in
residential complex for water
conservation
v A pit of 10 M3 capacity cons truc ted
v Auto star t pump w ith capaci ty of
50m3/hr
v Recycle to raw w ater body
Annual w ater sav ing : 50000 M3
Benefits
Inv estment : Rs 100,000

9. Set the benchmarks
Sp. Wa ter Consumption* (M 3 / M T of Urea)
Ben chm ar k in F ert ilizer in dustr y
for w ater con su mption
4.4
CPCB Sta ndar d = 10 M 3/MT Impact of e xces s
blo w d ow n from
FAI be nchmark = 5.26 M 3/MT (TCL) Co oli ng To w ers
due t o hi gh er
* Excludi ng to wns hip wa ter co nsu mp tio n alk anity
Set the Benchmarks
Waste Water Ge neration (M 3 / M T)
Fir st comp an y to get BSC 5 st ar r ating
for EM S in th e W orld
Only co mpan y to g et N akheel Su st ain abilit y Award
From BSC for EM S
1.19
1.1
0.95 0.94
0.9 0.85
0.74
0.7 0.67 0.62 0.70
0.5
01-02 02-03 03-04 04-05 05-06 06-07 07-08
Impact of e xces s
CPCB Standard = 5.0 M3/MT blo w d ow n from
F AI benchmark = 0.78 M 3/MT ( TCL) Co oli ng To w ers d ue
to hig he r alk an ity

10. India’s Best – Sp. water consumption (M3/MT)
TCL Indo Gulf CFCL ECPL KSF
03-04 4.96 _ _ 6.55 _
04-05 4.68 5.23 _ 5.97 6.62
05-06 4.70 _ 5.12 6.26 _
06-07 4.50 5.2 5.4 6.15 -
07-08 4.66# 5.75 - -
# fig ur e is 4.40 excl uding i mpact of CPCB Standard = 10 M3/ MT
al kali ne water blow down
F AI benchmark = 5.26 M 3/MT ( TCL)
Inter national Benc hmar k is not availabl e for si mil ar plant in si milar g eogr aphic al c onditi ons.
Also, Benc hmar king r eport in the area of water c ons er vati on is not publis hed by any agenc y.
India’s Best – Sp. Effluent generation (M3/MT)
TCL Indo Gulf CFCL KSF
03-04 0.94 _ _ _
04-05 0.74 -- _ 0.82
05-06 0.67 0.80 _ _
06-07 0.62 0.71 1.0
07-08 0.85# 0.73 - _
# f igur e is 0.70 excluding i mpact of CPCB Standard = 5.0 M3/MT
al kali ne water blow down
F AI benchmark = 0.78 M 3/MT ( TCL)

11. Way Forward…….never rest on your laurels
Deep recharge Rain water harvesting
Use of treated domestic effluents for toilet
flushing in township
All new building to be constructed as Green
buildings concept
Assessment of carbon Foot Prints of Tata
Chemicals
Life Cycle assessment of Urea Business
To establish model Eco-friendly villages in near
by community
Certifications / Memberships
• ISO 9001, ISO 14001, OHSAS 18001, RC14001 and ISO 27001
• ISO 14001 and OHSAS 18001 certificati on for Tow nship
• Signator y to Responsible Care – A public Com mitme nt
• Member of CoRE – Corporate Round Table on Env ironme nt

12. AWARDS & ACCOLADES
v 5 Star rating for E nv ironmental Sustaina bility fr om BSC, UK :
2004, 2005, 2006
v Sw ord of Honour from British safe ty council consecutiv ely four
times in a row . :2007-08
v ICMA, SHE Excellence Aw ard : 2005
v Aditya Birla best Responsible Care Aw ard : 2004
v Greentech Env ironment Excellence Platinum Aw ard for year :
2003-04, 2004-05.
v Golden Peacock Env ironment Mana gement Aw ard for the year :
2005
v Aw ard for “Excellence in Natural Gas Conserv ation” Firs t Prize in
Fertiliser Sector, ins tituted by GAI L : 2004, 2005.
AWARDS & ACCOLADES
v Env ironment pr otecti on aw ard fr om Fertiliser Associati on of
India : 2005-06
v Aditya Birla aw ard for the best Responsible Care compa ny” and
“Cor porate Social Responsi bility aw ard” : 2005-06, 2007-08
v Aditya Birla aw ard for “ Corporate S ocial Responsi bility” for the
year : 2005-06
v The Sarv a Shreshtha S uraksha Puraskar (Golde n Tr ophy and
Certi ficate) fr om Na tional Safety Council of India (NSCI ) for year
2006-07.
v The best Tec hnical Innov ation Aw ard (2006-07) fr om Fertilizer
Association of India (FAI)
v Nakheel Sustaina bility aw ard (Special Aw ard) by Britis h safety
council in year 2007-08

13. At Babrala We are Proud of….
Our Benc hmark S HE
B ein
te o f Ar t BSC g B
Ou r Sta y
Stand ards :
th e est i
ith man o u r W o r ld
n
Plan t w Swords of Honor T ec
e atu res h no f o r
N o vel F consecutively 4 Su p
p l ie
lo g y
times in a row rs
Our Highest
Being India’s Employee Our High CSR
Best in SHE Productivity in standards
perfor m ance Fertiliz er Indu str y
t
Our Mo s
E nv a’ s
S ta n iron I n di te r
p l an
d ar
ds me n
t B ein
g W a er
>> F Our Greenest & y& z
t ir
g et i n W o r s t Best Land scaped E ner g nt ferti l i
B SC ld to
Indust rial Facilit y E ffi ci e pl ex
5 st
ar co m
BEING WORLD
CLASS
THANK YOU