Profitability

Profitability

Water’n Idea

During a recent Waste Walk discussion at South Ferriby with Production Operator Maintainer, Russ Baker, Russ highlighted an opportunity regarding water usage and the fact he had recently noticed an overflowing of the main process water tank into the Plant overflow lagoon.

As the discussion progressed, it became apparent that a considerable amount of water was unnecessarily being extracted from the local river; far more than was needed by the Cement making process. As a result, it had become necessary to triple handle the water to remove it from the overflow lagoon. Not only were several of the eight CI wastes now present in the new current state of the operation, which had started a few days earlier after a pump was changed, but there were environmental impacts too.

Following standard CI methodologies, a solution was proposed for a cost-free software modification to prevent the overflow; which led to the lagoon level being lowered by 1ft in 24 hours. A rough calculation based on the size of the lagoon suggested we were over processing and unnecessarily transporting around 100,000 litres of water a day.  Thanks to Russ’ prompt action and rapid collaboration from the electrical department; the South Ferriby team was able to address the issue before further waste could occur.