Organization- Emirates Aluminium

Project- By-Product Utilization

Project Started- October’2009

Project End-July’2011

Team-GREEN BED

Plant Greenery with every drop of water at EMAL

New dreams to fulfill

To grow 25 square feet of GREEN BEDS with the waste water,

by products of the chillers, in and around CAST HOUSE premises,

with 4 marked water drain trenches.

And with other potential tapping points we can make GREEN BEDS

of 250 square feet At CAST HOUSE itself.

Finally if implemented all over Emirates Aluminium it will be

1000 square feet of areas with GREEN BEDS.

EMAL “Largest Producer of Aluminium with GREEN BEDS around”.

Emirates Aluminium located at Al Taweelah, Abu Dhabi, UAE.

EMAL CORE VALUES:

•Safety, first, last and always

•Protection of the Environment

•Investing in Today, for Tomorrow

•Everything Can Be Improved

•We Respect Individuals & Their Differences

Protection of the Environment

Explanation:

Our world is small and it is precious, and it is entrusted into our care only for a short period

of time. Our environment is our children’s inheritance.

You and I can minimise the environmental impact of everything we do.

Aluminium production doesn’t have to cost the earth.

Behaviours:

Use best available technology (B.A.T) as part of our Environmental strategy.

Encourage all employees and contractors to behave consistently with the requirements of

the EMAL Environmental, Health & Safety (EHS) Policy.

Create a culture of environmental awareness in all EMAL business activities following best-

practice.

Reduce waste and energy-use every day and re-use and recycle every day.

Think before you act.

Participate in events that promote environmental care.

Opportunity

Currently depending upon humidity and running time,

every air conditioner condensate drain in Gulf

countries produces 2-10 litres of water everyday.

This currently ends up as waste water.

The business opportunity

•Environment is in the core of EMAL

•Aluminium production doesn’t have to cost the earth

•Create a culture of environmental awareness by following best-practice

•Develop a culture that promote environmental care

•Gurner more acceptability from our valued customers and to compete

with immediate business competitors.

Preliminary Research

•During POV activities measured quantity of water drain from four

small AC’s in EMAL project site.

•“Cooling off Global warming”- An article published in October’2009

EMAL today.

The SUCCESS of PILOT project

A GREEN BED at Ingot Caster

MCC Room AC water trench

GREEN BEDS at Cast House

Maintenance building.

GREEN BEDS at Cast House

Maintenance building.

GREEN BEDS at Cast House

Maintenance building.

Tools Used to accomplish the idea

Brainstorming

•Individual Brainstorming

•Group Brainstorming

There will be no green in the desert without irrigation, it is very

difficult to carry out sand land irrigation.

various alternative of sand land irrigation

•Moistube irrigation system

•Micro Reservoir irrigation system

•smart irrigator gardener series

•Flooded irrigation system

Moistube irrigation system

Advantages

•Large land of ground can be irrigated and gets greenery.

Disadvantages

•Initial investment, regular maintenance cost is very high.

Micro Reservoir irrigation system

Advantages

•Large area’s of field covered with the irrigation system.

Disadvantages

•Initial investment & regular maintenance cost is very high.

Smart Irrigator Gardener Series

Advantages

•Domestic irrigation system with minimum

investment and very effective in Gulf regions.

Disadvantages

•Sweet water utilisation cost and regular manual

irrigation.

Advantages

•Autogeneous Irrigation system.

•No maintenance cost.

•No wastage of opportunity.

Disadvantages:

•Limitation of choice of plantation, to

grow very near to a chiller drain point.

Flooded irrigation system for Green Bed

Team Group:

•Aknath Mishra Leader

•Rodolfo Cano Member

•Manoj P V Member

•Saeed Mohammed Khalifa Member

•Kamal Member

Facilitator: Mr.Amit Parikh

Management Support:

•Environment is in the core of EMAL policy. The idea was recognized

through publishing in the internal magazine “EMAL Today” and then

granting permission to carry out the pilot project inside plant periphery.

•Accepting as one of the nominee for best Suggestion of EMAL.

Sponsorship

•Provide all resources from Men, Material and Machinery to make the

pilot project a success story.

Budget

•Pilot project cost was about 100 AED, which has been borne by

team itself.

•Final budget for company wide application has been taken care by

EMAL Environment department.

The feasibility study was evaluated by EMAL business Systems

department. A detailed report through Suggestion scheme submitted for

implementation and has been accepted for plant wide implementation. In

2nd phase, just started, the “GREEN BED” concept will be placed in the

tender paper for implementation during commissioning phase through

vendor.

A concept similar to Quality Project’s to be launched plant wide ,where

group of people will be judged as per best practices in “Green Bed”

project in the respective operational area’s.

The departments like Business System, Corporate communication ,

Environment has been informed and chalk out a plan for implementation.

The concept will be monitored by EHS coordinators of the respective

departments and the award judgment will be taken care by Environmental

department.

Results

•Planned to convert 25 square feet barren land into Green Bed but

actual achieved 20 square feet Green Bed’s.

•Accepted the idea to implement from beginning in 2nd phase.

Benefits

Tangible

•AED 100 x 20= AED 2000.

•20 square feet of Green Beds.

•Savings through Sweet water cost: approx AED 50 per square feet of

greenery per year; AED 50 x 20= AED 1000.

Intangible

•EMAL active participation in sustainability plan.

• Respect the environment.

• Reuse every drop of water.

•Promoting environmental awareness among employees.

•Enhancement of quality working environment.

•Proactive approach to fulfill ISO 14000 standards.

Feedback

•Positive feedback received from higher management through awards

like EMAL Employee of the month and EMAL EHS employee of the

month.

Perception

•Global warming is not added by air-conditioning; has been changed

after our dream project “GREEN BED”. The perception has been

changed and due accolades were showered for the work.

•In EMAL we can not reduce drastically greenhouse gas emission but by

initiating some sort of green approaches might down the rise of

temperature and sea level, it will reduce the damage to ecosystems and

human health.

•Individual action does not work for large changes, so it for collective

action to make green bed’s around EMAL.

Learning lessons

The impacts of Aluminium production are air pollution, climate change, liquid effluent likely

to have an impact on the patch coral reef and generation and disposal of industrial waste.

The environmental impacts of our smelter will not harm the society.

As we can anticipate, By the next few year, our earth will become 4 degrees hotter than

what it is now. Our glaciers are melting at rapid rate. So let all of us lend our hands to fight

the WARMING.

-Plant more Trees.

-Don't waste Water & Electricity.

-Don't use or burn Plastics.

It costs 38 Trillion dollars to create OXYGEN for 6 months for all Human beings on earth.

"TREES DO IT FOR FREE"

"Respect them and Save them

Although the idea took some time across rest of EMAL to get recognized and replicated in

rest part of EMAL but now such improvements are getting recognized regularly & getting

replicated.

Way Forward

Team members recognized through:

•Publication of the Article.

•EMAL Employee of the month.

•EMAL EHS employee of the month.

•Nominated for best suggestion of EMAL.

Parallel deployment of the concept:

Future development of the idea into automobile condensate utilization in

preserving tyre treads life, minimize road accidents due to tyre burst and

best utilizations of the waste water from auto air conditioner.

Q & A

Thank You