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Improvements in ETP operations lead to pollution reduction & water savings at M/s Kwality Polythreads Pvt. Ltd.

                               Pic: Consultants of GOPA Infra visit M/s Kwality Polythreads Pvt. Ltd. in IIE Haridwar

Summary of the success

M/s Kwality Polythreads Pvt. Ltd. is a producer of polythreads located within the Integrated Industrial Estate (IIE) of the State Infrastructure and Industrial Development Corporation of Uttarakhand Ltd. (SIIDCUL) in Haridwar. M/s Kwality Polythreads Pvt. Ltd. was able to improve the performance of its Effluent Treatment Plant (ETP), reduce its consumption of water, decrease the input of chemicals and the production of sludge whilst simultaneously, making cost savings.

The German consultancy GOPA Infra, assigned by GIZ, visited the industry in summer 2017, and after auditing the Effluent Treatment Plant (ETP) operations, suggested measures for improvement and upgradation. With support from GOPA Infra and GIZ, M/s Kwality Polythreads Pvt. Ltd. was able to successfully implement the first round of measures. Besides direct tangible environmental and economic benefits, the measures also created better awareness and eagerness to invest in new technologies and to apply better techniques for wastewater treatment.

About the problem

The Ganga river provides livelihood to more than 500 million people. It is the source of drinking water and many economic and agricultural activities. The river and its surroundings form habitat for many plant and animal species. Ganga is well known for its tremendous cultural and religious significance. Despite numerous rejuvenation efforts over the past 30 years, environmental pressure on Ganga has only increased.

As stated on the homepage of SIIDCUL, IIE Haridwar is an industrial estate located in the catchment area of River Ganga spreading over an area of 2,038 acres. It comprises of 15 sectors of which 12 are occupied by more than 550 industrial units, mainly pharma, electrical and electronics, packaging, food production, metal processing, plastic and rubber moulding, and cosmetics. In total, there are 473 operational units in the estate generating industrial and domestic wastewater. The effluent streams are collected and are treated at the industrial estate’s Common Effluent Treatment Plant (CETP).

GIZ closely looked into removing difficulties faced by industries in meeting the inlet norms of the CETP by improving the operations of ETPs so that all the pollutant parameters such as COD, and the wastewater volume discharged are well within the permissible ceiling.

Actions initiated

To systematically improve the situation, IIE Haridwar was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” and “Support to Ganga Rejuvenation” (SGR) projects within the Indo-German Development Cooperation. In cooperation with SIIDCUL, a public agency owning the industrial estate, both projects are being implemented by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH to find solutions to improve the efficiency and efficacy of wastewater treatment plants and reduce pollution.

The SEIP Project is aiming at mitigating environmental problems caused by industrial production focusing on industrial wastewater and solid waste management. Since the project’s initiation in 2015, technical solutions as well as business and management models to reduce acute environmental pollution and to improve resource efficiency in industrial production are piloted in a total of five Indian industrial estates. Implemented since 2015, one of the aims of the SGR project in the state of Uttarakhand is to demonstrate that the pollution caused by municipal wastewater and industrial effluent can be reduced by efficient management of wastewater and functionality of treatment plants.

Pic: Consultants of GOPA Infra visit M/s Kwality Polythreads Pvt. Ltd. in IIE Haridwar

Pic: Consultants visit M/s Kwality Polythreads Pvt. Ltd.

A German consultancy GOPA Infra was hired by aforementioned SGR project to assess the ETPs installed in 16 industries. In July 2017, national and international experts from GOPA Infra visited the 16 industries as well as the CETP in IIE Haridwar to collect data and samples in order to do preliminary assessments. Nine industries with ETPs were chosen to undergo a detailed assessment for improvements. Regulatory pressure, economic motivations as well as the wish to act more responsibly and sustainably were drivers for the companies to invite the consultants to undertake the assessments and to subsequently implement the solutions.

Whilst the detailed assessments are still ongoing, some suggestions on improvements were already given by the experts during initial site visits and based on the preliminary assessments of M/s Kwality Polythreads Pvt. Ltd.

ETP improvement

M/s Kwality Polythreads Pvt. Ltd. is operating on an 8,000m² industrial plot in IIE Haridwar and employs 150 people. The annual turnover of M/s Kwality Polythreads Pvt. Ltd. ranges between 60 and 70 crore INR.

Before the intervention, the wastewater generated by M/s Kwality Polythreads Pvt. Ltd. occasionally surpassed the ceiling value of the CETP inlet. The implemented measures led to the reduction of sludge by half and realisation of water savings of about 20 percent. Also, these improvements were achieved with zero cost investment.

Problems identified

Solutions

Costs

Results

Inappropriate operation of sludge treatment procedure since lime was directly charged to the treatment plant

- Soaking of lime in water before charging it to the treatment plant instead of direct charge (which leads to an increase in sludge).

- Dividing the tanks for ferrous-sulphates and lime of the wastewater treatment plant, so that these substances do not neutralize each other, become ineffective and end up as sludge.

- Installation of mixing mechanisms and constant water flows in the tanks

No cost

About 25 percent sludge reduction

Low quality raw materials and chemicals and application of wrong concentration resulted in overuse of chemicals

- Customize inputs according to requirements of wastewater.

- Use of ferrous-sulphates of at least 80 percent purity and lime with minimum of 75 percent purity.

No cost. Chemicals of higher quality and increased purity are now purchased at the same supplier for the same price as the chemicals of inferior quality.

About 25 percent sludge reduction

Treated wastewater was unnecessarily disposed

Reuse of treated water in the dyeing process of dark colour yarns which do not require high water quality.

No cost

About 15 to 20 percent of total fresh water used for dying of black shades, saved (reduced 80 KLD to 50 KLD; 1 KLD CETP treatment price is approximately 55 INR)

Total costs:

No cost

Total savings:

Alternative 1:  75,000 INR per year

(considering 50 percent reduction of sludge and cost of 25,000 INR per ton) 

Alternative 2:  96,000 INR per year

(considering sludge can be re-classified as landfill recharge which costs of 18,000 INR per ton)

Estimated payback period:

0 months

Environmental benefits

Economic benefits

Operational benefits

Reduction of:

- water use

- input of chemicals

- generated sludge

Annual cost saving of respectively 75,000 INR per year or 96,000 INR per year

Improved ETP performance

Pic: Sludge Reduction and improvement in treated wastewater quality (Test was done on 25th May 2017)

Pic: Wastewater sample taken on 25th September 2017

Pic: Disposed sludge was reduced by 50% after intervention

The success – The benefits!!

In total, the implemented measures led to annual cost savings of around 75,000 INR per year to 96,000 INR per year, depending on the selected calculation alternative. Further, the implemented solutions yielded to a noticeable reduction in the use of water, the input of chemicals and the amount of generated sludge. The interventions were no cost measures of operational, managerial or technical nature.

Before the intervention, there was a general lack of knowledge and awareness regarding the topic of wastewater treatment, its economic and environmental benefits, as well as technologies and techniques available. Whilst many companies were apprehensive before the implementation of the measures, the readiness for change towards more sustainable methods as well as the openness for and the trust in new technologies and techniques has substantially increased within the industry. They would invest and/or engage in the interventions again.

As a matter of fact, the interventions have increased the company’s awareness regarding the importance of proper ETP operation. They are also more eager to improve the performance of their plant even further: Next steps, such as the set-up of pilot plants testing new technologies were mentioned. M/s Kwality Polythreads Pvt. Ltd. would like to share their experiences with other companies to promote the improvement of ETP efficiency and performance.

Pic: M/s Kwality Polythreads Pvt. Ltd.’s efforts towards industrial and social responsibility recognised through award presented by the State of Uttarakhand (Award presented by Trivendra Singh Rawat, the Chief Minister of Uttarakhand)

 

 
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