TEXTILE WATER SECURITY MISSION RECYCLING ZLD -Girish Luthra

TEXTILE & WATER SECURITY MISSION RECYCLING/ZLD -Girish Luthra, Chairman Gujarat Eco Textile Park & Gujarat Enviro Protection & Infrastructure Ltd.

Rhyme of the Modern Processors Water, water, everywhere, And all the brains did shrink, Water, water, everywhere, Nor any drop to drink

About Indian Textile Industry Indian textile industry contribute to 4 % of GDP Indian textile industry contribute to 27 % of foreign exchange earning. Processing (Next Five Years) • Add. Proc. capacity built by 2017 -22 : 47 bill Mts. • Add. Capex (in 2017 -22) : € 6 Billlion. (Rs. 42000 Crs)

About Indian Textile Industry-Water • Approx. waste water volume of Indian textile industry = 3000 Million litre / Day. • Most centers are water scarce. • Water source of most center’s is ground water. • Waste water recycling is very low • Potential additional investment in water / waste water = Rs. 24000 crore (€ 3. 5 BILLION) • Potential Annual T. O in water / Waste water = Rs. 7000 crore (€ 1 BILLION) • Possible daily fresh water saving=2400 -2600 MLD

Challenges in Indian processing industry (In relation to water & wastewater) • Availability of water / High water consumption • Waste water treatment & Recycling • Discharge of treated effluent (Brine) • Disposal of solid waste generated during effluent treatment. • Compliance of environment laws and international protocols. • Inability to meet Pollution control norms & Zero Discharge. • Legal intervention of court. • Public Awareness

Major Textile Processing Cluster State, Area Effluent Load (in MLD) Haryana Gujarat Surat 600 Sonipet 50/75 A’bad 200 Jetpur 100 Faridabad 50 Rajasthan Jaipur 25/50 Bhilwara 50/75 Balotra-Jodhpur 75 Pali 75 Punjab Ludhiana 150 Tamilnadu Tirupur / Coimbatore 300 Telangana Hyderabad 200 Maharshtra Bhiwandi/ Icchalkarnji 400

Major Textile Processing Centers Amritsar Ludhiana Faridabad Panipat Sonipat Jaipur Jodhpur Pali Balotra A’bad Jetpur Kolkata Indore Surat Bhivandi Hyderabad Vishakhapatnam Tirupur Coimbatore Cuddalore Madurai

Water status

Water status

Eco Concept of Industry

Cleaner Production

Effluent Treatment /ZLD CETP (As per legal requirement) Recycling & ZLD Recycling (60 to 90 %) - Equalisation: Tertiary: Final cleaning collection tank for pre process for removal of mixing inorganic substances before - Primary : phisio chem recycle. treatment & Sludge -U F. -Ultra filtration for removal of setting - Secondary : Biological Treatment - Discharge : After Treatment effluent discharge to river micro particles -R. O. : With help Membranes removal of salt & other impurities from treated water. Reduce TDS -Other technologies ZLD (Options) - Solar Drying : Solar PONDS used for evaporate Treated effluent - Mechanical Drying : Evaporate Treated effluent with electro mech. eqip. Marine Outfall : Non useable Treated effluent discharge to Sea

CASE STUDIES Surat, Gujarat Balotra, Rajasthan

Surat, Gujarat (Synthetics Textile Processing Centre) Gujarat Surat

Surat, Gujarat (Synthetics Textile Processing Centre) Present Water Scenario • Total water consumption is approx. : 600 MLD • Water cost is ranging between : Rs 18/-Rs. 40 / KL ( € 0. 25 to € 0. 60) • Ground water and river water are major sources of water Cont….

Surat, Gujarat (Synthetics Textile Processing Centre) Sr. No Parameters Unit Effluent Inlet Surface Discharge Industrial recycling water quality - 6. 5 – 9. 0 5. 5 – 9. 0 6. 5 – 8. 5 1 p. H 2 BOD (3 day @27° C) MG/L 400 30 BDL 3 COD MG/L 1200 100 < 30 4 TDS MG/L 2000 -3500 2100 < 500 5 Suspended Solids (SS) MG/L 280 100 BDL 6 Oil & Grease MG/L 10 10 BDL

Case 1 – Present Status Effluent Inlet Coagulant, lime, polyelectrolyte dosing Equalization Tank Basic Treatment Clarifier with flash mixer Sludge Secondary Clarifier Chemical Sludge to SLF Sludge Filter Press Biological Sludge to composting Discharge to River / Sea through surface

Case 2 - Recycling water factory Water recovery + Discharge of rejects in to Sea (Proposed) Effluent Inlet Equalization Tank Chemical dosing Clarifier with flash mixer Secondary Clarifier Coagulant, lime, polyelectrolyte dosing Chemicals for UF cleaning Tertiary Reactor Clarifier Ultra Filtration Air Blowers Sludge Sand & Carbon Filter Multistep RO Unit Chemicals for RO cleaning Chemical Sludge to SLF Sludge Filter Press RO treated water Sump RO Rejected water Sump Recycled water to Industry Biological Sludge to composting Brine – Marine Outfall/ MEE

RO & Marine outfall RO Plant Marine Out fall Discharge line Marine Outfall

R O Reject Handling Drying / Salt recovery by multi effect evaporator

Case study of Balotra- Cotton Textile Processing Centre (Local Locked Area) Rajasthan Balotra

Balotra, Rajasthan (Cotton Textile Processing Centre) Present Water Scenario • Balotra is a land locked area in Rajasthan Desert. • 350 Process houses, mainly small process house, engaged in cotton dyeing, Printing and processing they are spread in 5 areas. • Total water consumption is approx. : 50 -60 MLD • Water cost is ranging between : Rs. 35 to 70/ KL (€ 0. 50 to 1. 0) • Source of water is ground water. Cont….

Balotra, Rajasthan (Cotton Textile Processing Centre) Present Waste Water effluent Scenario • No discharge of treated effluent to river, restriction by Court. • No possibility of discharge into sea, as this is land locked area. So the left over has to be air dried / mechanically dried to evaporate water and salt has to be reused/ disposed. • This area has high temperature and strong sun throughout the year. This is low rainfall area. Good for solar evaporation.

Balotra, Rajasthan (Cotton Textile Processing Centre) Sr. No Parameters Unit Effluent Inlet Surface Discharge Industrial recycling water quality - 6. 5 – 9. 0 5. 5 – 9. 0 6. 5 – 8. 5 1 p. H 2 BOD (3 day @27° C) MG/L 700 30 BDL 3 COD MG/L 2400 100 < 30 4 TDS MG/L 20000 2100 < 500 5 Suspended Solids MG/L 800 100 BDL 6 Oil & Grease MG/L 100 10 BDL

Recycling Water Factory + ZLD Effluent Inlet Balotra Flow chart with Recycling & ZLD Equalization Tank Chemical dosing Clarifier with flash mixer Secondary Clarifier Coagulant, lime, polyelectrolyte dosing Tertiary Reactor Clarifier Sand & Carbon Filter Ultra Filtration Multistep RO Unit Chemicals for UF cleaning Air Blowers Sludge Chemicals for RO cleaning Chemical Sludge to SLF Sludge Filter Press RO treated water Sump RO Rejected water Sump Recycled water to Industry Solar Evaporation pond Biological Sludge to composting Salt Reuse Salt to MLF

R O Reject Handling Solar evaporation pond with mechanical sprinkling R O Plant Solar evaporation pond with mechanical sprinkling Salt for reuse/MLF

R O Reject Handling Solar evaporation pond with mechanical sprinkling • Rajasthan : High evaporation area High solar Radiation Low Rainfall • Cheapest / Cost effective mode of Drying • Sprinklers to enhance evaporation • Salt recovery/usage possibilities • Salt manufacturing plant as an option

Municipal waste water potential

Municipal waste recycling industrial water / Plantation green belt water Top 150 cities of India : Population 300 Million Per capita waste water generation (Conservative) 30000 MLD (Mill. Lts / Day) (100 Lits / Day person ) Capex Requirement € 18 Billion +pipelines Visit us : www. getp. in , www. gepil. in

Business Opportunities • Cost effective water / waste water treatment / recycling technologies; Water frugal Technologies • Disposal technologies of leftover concentered effluent. Marine outfall or drying or any other option for zero discharge. • Quality control technology for water / waste water technologies. • Reduction of specific water consumption per kg of textile processed (reduction at source). • Cleaner Production technologies / Techniques • Cluster based approach. • Energy Efficiency.

About GEPIL / GETP (Major Works) Type of facility Some Location Eco Towns/ICHWTSDF Surat, Alang, Silvasa, Haryana, Panoli, Dahej, Tamilnadu Integrated MSW Management Surat, Vadodara, Durgapur, Nagpur, Rajkot, Salem, Sewage/ Common Effluent Treatment Plants Balotra, Palsana, Pali, Kosamba, Surat Integrated eco sustainable Industrial Parks Palsana, Vadadla, Kosamba. Waste Recycling Park Dahej Waste Mix Processing Facility Surat, Panoli, Silvasa, Haryana , Ranipet, Telangana

ﺷﻜﺮﺍ ﻟﻚ THANK YOU When you refuse to reuse, it's our earth to abuse Visit us : www. getp. in , www. gepil. in