Mandatory Water Audit for Domestic and Industrial Water Supply

IWW Technical Session on

“Mandatory Water Audit for Domestic and Industrial Water Supply”

FICCI Interventions in Pulp & Paper Sector for Reduction in Freshwater Consumption and Treatment of Coloured Effluent-A Case Study Karishma Bist

Dy. Director FICCI - Resource Conservation & Management Group Email: karishma.bist@ficci.com 1

About Resource Conservation & Management (RCM)

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Introduction ••FICCI FICCI conducted conducted aa scoping scoping study study supported supported by

by WWF WWF & & HSBC HSBC under under ‘Living ‘Living Ganga Ganga Program’ Program’ for for Pulp Pulp & & Paper Paper Sector Sector in in Ganga Ganga Basin.

Basin.

••ItIt was was observed observed that that about about more more than than 80% 80% of of the the Pulp Pulp & & Paper Paper units units operate operate on on medium medium & & small small scale scale and and majority majority of of them them lack lack adequate adequate water water & & wastewater wastewater management management practices. practices.

••Under Under the the study study detailed detailed water water audits audits were were conducted conducted in in selected selected units units and and ‘Best ‘Best Practices’ Practices’ for for Water Water & & Wastewater Wastewater Management Management were were identified/evolved identified/evolved and and also also implemented implemented in in demonstration demonstration pulp pulp & & paper paper unit unit Resource Conservation and Management Group

ACTIVITIES OF THE STUDY •• Mapping Mapping of of Pulp Pulp & & Paper Paper Units Units in in Ganga Ganga Basin Basin •• Selection Selection of of Representative Representative Units Units for for Detailed Detailed Studies Studies •• Conduction Conduction of of Detailed Detailed Water Water Audits Audits ,, Monitoring Monitoring and and Sampling Sampling •• Identification Identification of of Water Water & & Wastewater Wastewater Management Management Problems Problems & & Issues Issues •• Evolving/Identifying Evolving/Identifying Water Water & & Wastewater Wastewater Management Management Best Best Practices Practices •• Implementation Implementation of of Some Some Selected Selected Best Best Practices Practices in in the the Demonstration Demonstration Unit Unit •• Monitoring Monitoring the the Results Results & & Cost Cost Benefit Benefit Analysis Analysis

DETAILS OF STUDIED UNIT (DEMONSTRATION CASE STUDY)  The mill is producing 80 tons/day of Paper which includes: Creame Wove Paper, Construction Paper, Activity Paper, Newsprint, MG PosterPaper, Colored Paper. The mill was producing around 28000 TPA of Paper Products from 35000 TPA of Waste Paper.

DETAILS OF PULP & PAPER UNIT

Mill Operating Capacity Raw Water Source No. of Borewells Total Water Quantity Drawn

80 TPD Groundwater 3 6264 KL/day

PROCESS EMPLOYED IN PULP & PAPER UNIT

1. Unloading / Conveying

5. Filtered Pulp

2. Pulper

3. Screen

4. Poly Disc Filter

6. Paper Machine

9. Cutting Machine

7. Pigment Coating

8. Dryer

10. Final Products

DETAILS OF STUDIED UNIT WATER SOURCING & DISTRIBUTION SYSTEM

DETAILS OF STUDIED UNIT WASTEWATER COLLECTION SCENARIO FROM DIFFERENT SECTIONS OF THE UNIT

FLOW MEASUREMENTS CONDUCTED USING ULTRASONIC FLOWMETER

Flow Measurement at Borewell

COLORED DRAINS AT PULP & PAPER MILL

COLORED DRAIN SAMPLES TESTED FOR HYPO-DOSING

Colored Wastewater Samples from different drains

Bleaching with addition of Hypo Solution

EXISTING ETP SCHEME AT PULP & PAPER UNITS

WASTEWATER SAMPLE COLLECTION

pH meter

Thermometer

BOD Sample Bottle

Wastewater Sample Collection

MAIN PROBLEMS IDENTIFIED  Lack of water storage facility

 Old Pulping technology having higher loss of fiber in the effluent  Non-segregation of highly concentrated effluent streams  Non- Recovery of fibers from the process water  Lack of Water Efficient Showers  Difficulty in reuse/recycle of colored effluents in the process  Poorly Maintained Effluent Treatment Plants  Lack of Good Housekeeping Practices

PROBLEMS IDENTIFIED & RECOMMENDATIONS

1. Lack of water storage facility

Direct Supply of Fresh Water to Process from Bore-well

Proposed Scheme: Installation of Freshwater Storage tank with level indicator before distribution freshwater to process and other sections.

Supply of Fresh Water to Process from Storage Tank

PROBLEMS IDENTIFIED & RECOMMENDATIONS

2.Old technology having higher loss of fiber in the effluent : The low consistency screening technology of pulping can be replaced by medium consistency (2-3%) screening technology which uses less water for pulping and have less fiber losses in the wastewater.

Proposed Scheme: Installation of Modern Pulp Screening Technology with finer screens for more fiber recovery.

3. Non-segregation of low concentrated effluent stream from highly concentrated effluents

Collection of Wastewater for Treatment without Segregation

Proposed Scheme: Segregation of different types of streams based on their quality followed by suitable treatment before sending to ETP.

PROBLEMS IDENTIFIED & RECOMMENDATIONS

4. Non-recovery of fibers from the Effluent Proposed Schemes: Recovery of fibers using Saveall or Krofta Sedicell technology.

Use of Save-all for Fiber Recovery and wastewater recycling

Use of Krofta Sedicell before ETP for Fiber Recovery

PROBLEMS IDENTIFIED & RECOMMENDATIONS

5. Conventional Effluent Treatment Plants

The convention ETP scheme in the Pulp & Paper Units

Proposed Scheme: Modify existing ETP by adopting advanced treatment technologies.

Modified ETP scheme in the Pulp & Paper Units

BEST MANAGEMENT PRACTICES FOR IMPLEMENTATION IN DEMONSTRATION UNIT

 Installation of Medium Consistency Screening for Pulping to replace low consistency screening Use of modern Fan Jet Spray Showers and Wide Angle Spray Showers in Paper Machines instead of inefficient hole showers Segregation & Treatment of colored wastewater before ETP for reuse/recycling in the process Following Better Housekeeping Practices and proper training to the workers.

Installation of Medium Consistency Screening technology

BEFORE & AFTER SCENARIO Before Implementation

After Implementation

Freshwater (1000KL/day) (now not required)

Pulp Inlet Line Pulp Inlet Line

Pulp Outlet Line

Rejects

Rejects Pulp Outlet Line

Low Consistency Pulp Screen consuming more water

Medium Consistency Pulp Screen consuming less water.

WATER & ENERGY SAVINGS BY MODERN PULP SCREEN

Water & Energy Savings by Modern Pulp Screen Installation Water Energy Consumption Consumption (KL/day) Details Borewell Modern (H.P./day) Pulping Screen KWh/day Before 3000 720 990 (60 HP) Installation After 2000 480 490 (32.8 Installation HP) Savings 1000 240 500 (33.5 HP)

Use of modern Fan Jet Spray Showers and Wide Angle Spray Showers

BEFORE & AFTER SCENARIO

Before Implementation

After Implementation

Inefficient Hole Showers consuming more water

Water Efficient Wide Angle Spray Showers

WATER SAVINGS & REDUCTION IN EFFLUENT GENERATION BY MODERN WATER EFFICIENT SHOWERS

Water Savings & Reduction in Effluent Generation by Modern Water Efficient Showers Details

Water Consumption (KL/day)

Effluent Generation (KL/day)

Before Installation

1200

600

After Installation

720

360

Savings

480

240

Segregation & Treatment of colored Effluents

BEFORE & AFTER SCENARIO Before Segregation and Treatment of Colored Effluent

BEFORE & AFTER SCENARIO (Continued) After Segregation and Treatment of Colored Effluent Newly Constructed Channels & Pits for segregation & treatment

Hypo-dosing for colour removal

Treated Colored Effluent after Hypo-dosing

BEFORE & AFTER SCENARIO After Segregation and Treatment of Colored Effluent

Effluent Discharged to common pit New Storage Tank to provide Retention Time to treated colored effluent

Training of Employees

Training to Middle Management at Pulp and Paper Unit

COST BENEFIT ANALYSIS OF IMPLEMENTED BEST PRACTICES S. Best No Management .

Practices

Operational & Environmental benefits

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Uses less fresh water and energy and also, less energy would be required to pump the fresh water from the borewells Uses less water and - Water Saving enable backwater 1,440,00 KL recycling leading to - Reduction in less effluent backwater generation & generation savings in effluent 720,00 KL treatment SUB-TOTAL

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Replacement of Conventional Pulp Screen with Modern Pulp Screening Equipment having consistency 2.5% Replacement of conventional hole showers with modern wide angle & fan jet spray Showers at Paper Machines

Annual Resource Investm Annual Savings ent (Rs. Monetary In lakhs) Savings (Rs. In lakhs) Water Savings 9.5 12 3,000,00 KL Energy Savings 226050 HP

Simple Payback Period (Years) 0.8

1.4

1.7

0.8

15.4

18.9

0.8

COST BENEFIT ANALYSIS OF IMPLEMENTED BEST PRACTICES

S.No Best Operational & .

Managemen Environmental t Practices benefits

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Segregation of colored effluents for colour removal before treatment & reuse

Annual Resource Savings

Increased efficiency of existing ETP and improved quality of final Effluent.

TOTAL

Investmen Annual t (Rs. In Moneta lakhs) ry Savings (Rs. In lakhs)

Simple Paybac k Period (Years) --

4.1

Operatin g Cost (-7.5)

19.5

11.4

1.7

REDUCTION IN FRESHWATER CONSUMPTION UPTO 50%

REDUCTION IN EFFLUENT GENERATION UPTO 22%

REDUCTION IN SPECIFIC WATER CONSUMPTION UPTO 56%

 The mill was consuming around 6000 KL/day of Freshwater and was producing 80 TPD of paper. SWC of the mill KL/Ton before Intervention.

was 75 FICCI

 After intervention SWC is 33 KL/Ton (Mill consuming around 3000 KL/day of Freshwater and has also increased its production capacity to around 90 TPD).

We are here to serve you Karishma Bist

Dy. Director FICCI - Resource Conservation & Management Group Email: karishma.bist@ficci.com

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