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Water savings at M/s Vansal Narayan Engineering Works in SIIDCUL IIE Haridwar

Rinsing tanks at facilities of M/s Vansal Narayan Engineering Works in IIE Haridwar

Summary of the success

A consortium of experts in the field of resource, energy and water efficiency in industrial processes, led by the German consultancy, Adelphi, visited 50 companies in the Integrated Industrial Estate (IIE) at Haridwar to undertake rapid assessments of their production facilities. Companies interested in increasing their resource efficiency and reducing pollution caused by production were selected for a detailed assessment, given there is a potential for implementation of efficiency measures. 

M/s Vansal Narayan Engineering Works, one of the companies selected for detailed assessment, is a manufacturing company within the Integrated Industrial Estate (IIE) of the State Infrastructure and Industrial Development Corporation of Uttarakhand Ltd. (SIIDCUL) in Haridwar producing and assembling electric fans. Whilst the detailing of measures is currently ongoing, significant water savings and reduction of wastewater produced could be achieved at the plant after the assessment of resource used and implementation of suggested measures. These no-cost measures were identified by an Indo-German expert team of Adelphi.

About the problem

The River Ganga, with its cultural and religious significance, provides a 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 the habitat for many plant and animal species. Despite numerous rejuvenation efforts over the past 30 years, environmental pressure on Ganga has only increased.

IIE Haridwar is an industrial estate located in the catchment area of the 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. Nearly 4.5 million litres of wastewater is discharged from the industrial estate, which finds its way to River Ganga. Increasing resource efficiency and reducing pollution load in individual industries could be an option to prevent further pollution. The industries often lack knowledge and expertise to implement such improvement measures. 

Actions initiated

To systematically improve the situation, IIE Haridwar was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project of the Indo-German Development Cooperation. Jointly with SIIDCUL, a public agency owning the industrial estate, the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has been implementing the SEIP Project since 2016.

Under SEIP, a German consultancy (Adelphi) was hired to audit and assess the potential of environmental improvements in companies. On the one hand, end-of-pipe solutions, i.e. an improvement in the treatment of wastewater and waste are being considered. On the other, however the main focus lies on increasing resource, water and energy efficiency in the companies’ processes since tackling pollution at the source is generally a more economical solution. The objective is to reduce environmental impacts of industrial operations at the same time also to reduce costs of waste treatment and disposal.

Expert of Adelphi visits production facility of M/s Vansal Narayan Engineering Works

The approach is to target technological modifications as well as optimisation of manufacturing processes. The latter usually do not require large investments, but rather entail changes in the production steps, change of input materials, or the training of workers. These measures tend to build the trust of companies in the viability of efficiency measure and lay the basis for larger interventions requiring substantial investments.

Water efficiency

Vansal Narayan Engineering Works with an annual revenue of around INR 35 crore, manufactures and assembles fans. The consultants noticed an excessive use of water in the pre-treatment section of the company’s powder coating plant which could be easily avoided. The water flow in the rinsing tanks was not set according to actual measurements and hence, water was used regardless of its requirements. The GIZ’s consultants suggested adjusting the water flow in the rinsing tanks to match the actual requirements which can be determined through conductivity measurements of rinse water leaving the tanks or through trials for in-house quality requirements.

Rinsing tank at M/s Vansal Narayan Engineering Works

Since water flow meters are not installed at these process steps, instantaneous water flow rate measurements were taken in order to establish data for the water use for the rinsing process. The industry team reduced flow rates in rinsing water tanks for steel parts in steps while checking for quality on rinsed parts. The team came to the conclusion that good results could be achieved with a flow rate of 120 litres/hr. In the rinsing tanks for aluminum parts, the valve was simply shut off for 4 hours per day during which these parts were not being treated. The implementation of these purely operational measures led to considerable water savings as specified in the table below.

Problems identified

Solutions

Cost 

Results

Inefficient water use in the pre-treatment section of the powder coating plant

Reduction of water flow according to requirements

No cost

Water savings of a total of 480m3 per year:

  • 360m3 per year on rinsing tanks for steel parts
  • 120m3 per year on rinsing tanks for aluminium parts

Wastewater generated and to be treated reduced by 480m3 per year

Total investments: 0 INR 

Total savings: Savings through reduction of wastewater generation                           (yet to be quantified)

Estimated payback period: 0 months

Environmental Benefits

Water savings of 480m3 per year

Reduction of wastewater generation of 480m3 per year

Reduction of cost for waste-water treatment (yet to be quantified)

The Success!..The benefits!!

In total, the implemented measure led to water savings of 480m3 per year, a valuable resource saved. This, in turn, led to a reduction of wastewater generation of 480m3 per year. Before the intervention, there was a general lack of knowledge and awareness regarding saving potentials through efficient production processes. Measurement and detection devices, lack of knowledge of techniques to conduct tests for water consumption and losses were not available at the plant. 

The fact that cleaner production is not merely a good deed for the environment, but also helps to increase operational efficiency, leading to cost-savings and increased competitiveness is being vividly demonstrated by the implementation of these simple, but effective changes. They further contribute to a change in perception regarding environmental friendly production, paving the way for further, large-scale, interventions. The reduced consumption of water, as well as wastewater generation, is resulting in cost savings since less wastewater has to be treated now.

Testimonials

Mr. Mukul Chandra, Plant Head, M/s Vansal Narayan Engineering Works

“As a company, we are keen to learn new and improved ways of working. The RECP project has helped us in this through a structured approach analysing the use of natural resources in our plant. We have started the journey of resource efficiency with our initial focus on water use reduction. In parallel, we are working to save energy as well. This project is very beneficial for industries like ours as the consultants focus on areas that we normally ignore, and the suggested measures are easy to implement and do not cost much.”

Mr. Sandeep Kumar, Quality Engineer, M/s Vansal Narayan Engineering Works

“This project has helped us technically to identify the tools and techniques to carry out assessments of our processes. We have learnt how to do a leak test on a compressor and how to reduce leaks, thus saving energy. Regarding water use, we learnt how to measure conductivity in rinsing processes which has helped to reduce water use at no cost. We look forward to further engagements with the GIZ’s project team.”

 

 
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