REPORT WITH BEST PRACTICES AND CONCLUSIONS · SSI Small Scale Industries ... ZLD Zero Liquid...

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REPORT WITH BEST PRACTICES AND CONCLUSIONS

Containing:

EU – India Strategic Priorities for Water Related Research & Innovation

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Case study on Water & Industry in the framework of the India – EU Water Partnership

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Part 1: EU – India Strategic Priorities for Water Related Research & Innovation indigo Policy

OUTPUT SUMMARYProject Information

Project Title: Support for the advancement of policy cooperation between India and Europe in Research and Innovation

Project Acronym: Indigo Policy

Call Identifier: FP7 – INCO-2013-2

Contract Number: 609535

Starting Date: 01/11/2013

End Date: 30/04/2017

Web-Site Address: https://indigoprojects.eu/about/indigo-policy

Coordinator: Teresa de Oliveira

E-Mail: [email protected]

Telephone Number: +431495044230

Deliverable Title: Report with best practices and conclusions

Work Package: WP 4.2

WP Leader Netherlands Enterprise Agency

Nature: Governmental Agency

Dissemination: https://indigoprojects.eu

Editor (s): Bart Jeroen Bierens / Teresa de Oliveira

E-Mail(s): [email protected] / [email protected]

Telephone Number: +31 88 6245145

Date of Delivery March 31th, 2017

List of Participants

Participant number Acronym Participant Organisation Name Country

2 RVO.nl Netherlands Enterprise Agency NL

6 DLR Deutches Zentrum für Luft- und Raumfahrt DE

10 CSIR Council of Scientific and Indsutrial Research India

mailto:[email protected]

mailto:[email protected]

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Table of Contents

OUTPUT SUMMARY............................3

List of Participants............................3

Contents............................5

List of abbreviations............................6

Executive summary............................7

Part 1: EU – India Strategic Priorities for Water Related Research & Innovation............................91. Introduction Strategic R&I Agenda............................91.1 Short term priority areas on water............................9

Technologies for drinking water purification including removal of emerging toxic pollutants and Online/remote water quality monitoring techniques ............................10Technologies for wastewater treatment for reuse and recycle and reject management in urban and agricultural sectors............................10Urban Water Management............................11Technology Incubation and Demonstration Park(s) ............................11

1.2 Long term priority areas............................121.3 Topics for short term collaboration (joint call) ............................121.4 The way forward between EU – India S&T collaboration on water............................14

Part 2: Water and Industry: The case of Hindon River and River Kali............................15

2 Introduction Water & Industry............................152.1 Workshop September 5, Delhi............................15

CETPs............................16Zero Liquid Discharge (ZLD)............................18Water Polluting Industries ............................18Definition of ZLD............................18

2.2 Case Study............................19

Introduction and objective of case study............................19Background and current situation of the Indian P&P industry............................20Development targets for the Indian P&P industry............................21Project location: the Hindon River case............................21Pollution by the P&P industry and abatement technologies............................23Available P&P and Wastewater Treatment Technologies............................25Innovation and way forward in Industrial Wastewater Management............................26Innovation in process section ............................27Innovation in energy recovery............................28

2.3 Conclusions, Recommendations and Proposal for Actions............................34Short term proposed actions............................34Mid to long-term proposed actions............................35

ANNEX............................37

1) Background ZLD Policy............................37ZLD Policy............................37

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List of abbreviationsBREF - Best Available Techniques Reference Document: European reference document under the IPPC Directive and the IED, http://eippcb.jrc.ec.europa.eu/reference/

BOD Biological Oxygen Demand

CETP Common Effluent Treatment Plant

CPCB Central Pollution Control Board

DST Department for Science & Technology

EIP European Innovation Partnership

ETP Effluent Treatment Plant

Fit for Use (also known as “Fit for Purpose”): water or wastewater is treated for reuse ac-cording to the specific quality requirement and application. The US EPA (2012) explains: “…that water treatment technologies (combined with disinfection) offer a ladder of in-creasing water quality, and choosing the right level of treatment should be dictated by the end application of the reclaimed water for achieving economic efficiency and envi-ronmental sustainability. There are numerous case studies that demonstrate the balance of treatment costs along with the intended use of the reclaimed water.”

GSO Group of Senior Officials

IEWP India EU Water Partnership

PCC Pollution Control Committee

R&I Research & Innovation

SPCB State Pollution Control Board

SSI Small Scale Industries

WFD Water Framework Directive

WSP Water Safety Plan

WssTP Water Supply and Sanitation Technology Platform

ZLD Zero Liquid Discharge

P&P Pulp & Paper

JPI Joint Programming Initiative

http://eippcb.jrc.ec.europa.eu/reference/

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Executive summaryThis report is the result of the joint activities between EU and India in the field of water between 2014 and 2017 in the framework of the Indigo Policy project. This reports con-tains 2 main parts;

Part 1: The first part describes the joint EU – India water agenda in the field of Science, Technology and Innovation. It forms the basis for further collaboration and a joint effort between water experts from academia, research institutes and industry from India and EU. The joint expert meeting took place in April 2014 and was organized by Indigo Policy project in close cooperation with the EC.

The themes explored were Drinking Water Quality, Waste Water Treatment and Urban Water Management.

Part 2: The second part describes the best practices in the field of Water & Industry. Indigo Policy project organized two joint workshops in the field of Water & Industry in September 2016.

Paragraph 2.1 gives a general overview of challenges, constraints and approaches for in-dustrial waste water treatment identified through a workshop organised jointly by CSIR and Netherlands Enterprise Agency.

Paragraph 2.2 of the report focuses on a concrete case related to the Paper & Pulp- and sugar industry in Muzaffarnagar, Uttar Pradesh, India. A joint workshop was organized together with the Muzaffarnagar paper cluster, Water Resources Group 2030, industry association FICCI and the EC. The report gives an overview of short- and long term mea-sures for the paper- and pulp cluster in Muzaffarnagar. It gives excellent insights on how an industrial cluster wants to improve the water situation and the challenges they need to bridge.

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Part 1: EU – India Strategic Priorities for Water Related Research & Innovationindigo Policy

Part 1:

EU – India Strategic Priorities for Water Related Research & Innovation

1. Introduction Strategic R&I Agenda

There is a long history of collaboration between the European Commission (EC) and the Indian Department of Science & Technology (DST). The India-European Union Joint Dec-laration on Research and Innovation cooperation signed during 10th India-EU Summit and India-EU S&T Ministerial Meeting in May 2012 have set the stage for Jointly defining the scope and develop a Strategic Research & Innovation Agenda (SRIA).

Further, both sides agreed to establish a Group of Senior Officials (GSO) composed of officials from India, the Member States and the European Commission with a view to streamline the governance of Indo-European cooperation by designing effective mecha-nisms that can provide solutions to major societal challenges of common interest in the area of Health, Water, Energy etc.

India-EU GSO Thematic Groups have been mandated to build SRIA and outline a program for the thematic areas covered by EU/MS-India Stakeholders Conference of May 2012. Thematic Groups contain experts from EU and India and chaired by 2 co-chairs on a thematic area.

The Thematic Group on Water developed a roadmap and SRIA called ‘‘Water for Life‘‘ (2013). This document describes the common challenges on water including a road map.

The members of the Thematic Group on Water drafted topics for the short- and longer term and these are described in the next paragraph.

1.1 Short term priority areas on water

a. Technologies for drinking water purification including removal of emerging toxic pollutants and Online/remote water quality mon-itoring techniques

b. Technologies for wastewater treatment for reuse and recycle and reject management in urban and agricultural sectors

c. Technology Incubation and Demonstration Park(s)

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Technologies for drinking water purification including removal of emerging toxic pollutants and Online/remote water quality monitoring techniques

Most of the drinking water sources in rural India are isolated independent sources, be it surface or sub-surface. The surface water quality results from a variety of sources in-cluding the contributions of geological formations located in the drainage basin, climate, possible anthropogenic interventions etc.. However, the ground water quality mostly de-pends on the hydrogeology of the region and the characteristics and the location of the recharge areas, groundwater fluctuations and the possible contaminations from anthro-pogenic activities including the impact of agriculture, industry and even extreme events.

Though significant efforts have gone into water treatment and purification technology development, the exponential increase in water quality problems as well as treatment options is making their application more region and water input quality sensitive. This makes it more important to put in more efforts in this direction. Considering the number of water purification technologies already developed in India and EU countries, the pro-posed work in this direction can focus on:

• Development of water quality kits, with multi-sensors including molecular tools capable of real-time data collection and wireless transmission for water quality monitoring and analysis.

• Improvement in treatment processes mainly with respect to- development of multi pollutant treatment process, effective regeneration of materials with minimization of waste; handling / safe disposal / treatment of the sludge / used materials / other process generated solid and liquid waste.

• New scientific approaches for development of improved treatment options• Solutions for pesticide removal and new and emerging pollutants like selenium,

uranium etc.

Technologies for wastewater treatment for reuse and recycle and reject management in urban and agricultural sectors

In India, around 30 % sewage generated in urban regions is subjected to treatment. Out of this only 30% of the treated waste meets the prescribed treatment efficiency. On many occasions untreated water finds its way either to farm lands for irrigation or the natural ecosystems polluting the rivers and groundwater regime. Countries like India cannot easily afford the conventional wastewater treatment processes because of the high initial followed by O & M costs along with the requirement of skilled personnel for routine operation and maintenance. Some of the common problems of most STPs that turns most of the STPs deal with local conditions, poor maintenance, frequent power breakdowns, fouling, improper management of sludge and biogas emanating in the pro-cesses. Further, none of the models provide any scope for the involvement of stakehold-ers nor any incentive to the operating agency. If the multilateral research and innovation strategies can rigorously address some of these pertinent issues with a focus on eco-nomic returns, the systems in place will not face functional and sustenance problems. Treated water can be put to very efficient use for multiple purposes inconsonance with the social and psychology of the beneficiary community. The following aspects need to

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be considered.

• Regulatory requirements governing production and use of recycled water • Water recycling criteria should aim to protect public health and ensure safety in

recycling and reuse practices• Easy O&M by unskilled locals• Minimum energy dependence• Built in economic returns• Efficient sludge management and effective use of byproducts’ like bio-gas• Social psychology of local communities• To create potential recycled water markets such as urban and agricultural irrigation,

industrial use, environmental enhancement and water exchange etc. in the framework of economic efficiency

Urban Water Management

Urban water issue has been acquiring immense importance in recent times due to com-plexities of water supply and associated quality issues. Water quality objectives are normally lost when confronted with water availability issues. While there is a push to increase access to drinking water in urban areas of India, often water quality supplied to the end users via urban distribution systems remains poor due to occurrence of contam-ination during transmission of the purified water. Management of urban water systems is fragmented, which aims at primarily quantity of water supplied and does not integrate the issues of water quality for all periods of supply. The risk of contamination needs understanding of contaminating sources or chances of such occurrences due to various reasons. Water Safety Plan (WSP) framework plays a key role in an attempt to get better control over the whole water supply chain and enables relevant stakeholders to become more confident in the water quality issues. This subsequently leads to economic and health improvements in a region. WSP is holistic by nature and considers the safety of water from catchment to consumer i.e. at the point-of-use WSP is carried out to assess all the potential hazards and risks in the water supply system with focus on quantity as well as quality aspects and cost effectiveness. In brief, WSP is designed to ensure long term sustainability for continuous and safe water supply to the consumers. It is proposed to develop and demonstrate a city specific Water Safety Plan for its further replication by related agencies. Occurrence of floods has been on the increase not only due to changing climate but also due human interventions like change in land use- land cover patterns, hydrological interventions etc. Marginal increase in intensity of rainfall many a times results in devastating floods. Proper model studies will provide scientific solutions to mitigate these events.

Technology Incubation and Demonstration Park(s)

To design, develop, test and demonstrate any technology and to sustain the same against the contemporary developments, a paradigm shift in R&D approach from “knowledge generation” to “knowledge utilization” is inevitable. A technology incubation and demonstration park established in India with complimentary support from India and EU can lead to the development of world-class technology in water treatment at affordable cost. India being the best field laboratory with a variety of complex water problems

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twined with political societal issues can be the best testing ground to test the S&T effi-cacy and the communal adoptability of any technology. This will also ensure continued partnership between the two entities. For logistic and operational convenience these Technology Park(s) may be attached to well-established R&D institutions working in this area in India. The primary objectives of these Park(s) will be:

• To demonstrate potential water treatment technologies developed in India and EU partner countries

• To mainstream business opportunities of safe water supply and sustainable water treatment projects as this will encourage public private participation and provide opportunities to replicate water treatment plants

• To develop frugal technologies in water treatment and management to support the needy population.

• To undertake training and capacity building of Stakeholders in provision of safe water.• This is conceived to get better visibility for the participating States as well as to extend

a helping hand at affordable cost to the needy nations.

1.2 Long term priority areas

• Climate change (data collection/availability/quality, modeling, prediction and impact assessment, climate services), building on, e.g., the High Noon project, with focus on moving up the reliability curve and creating a direct interface between climate solution providers and decision makers. This has the potential to be an iconic project. Similarly, strong collaboration on reliable assessment of groundwater dynamics. Flood routing and forecasting can be from climate change perspective supplemented by human intervention of the natural hydrological systems can be one of the major components of this theme.

• Water purification and reuse (integrated urban water management, inexpensive yet robust decentralized systems with option of remote monitoring, cost effective innovative solutions for alternative energy/energy efficiency, management of residues in inland areas, sensors for monitoring critical constituents, etc.)

• Water in agriculture (enhancement of efficiency, e.g., through improved (seasonal) weather forecasts; substitution of freshwater with alternative agriculture with sea water and agriculture in the sea: extremely relevant considering the long coastline of India)

1.3 Topics for short term collaboration (joint call)

In the framework of the “Water for Life“ document an Expert Conference was organized in Delhi in April 2014 to further develop the EU – India Research & Innovation agenda for short-term areas and to make the first steps towards a joint call. It was organized by Indigo Policy under the responsibility of the European Commission. About twenty Euro-pean experts and 50 Indian experts were present to jointly draft a Strategic Research & Innovation agenda in three separate workshops and plenary sessions.

The themes explored were Drinking Water Quality, Waste Water Treatment and Urban Water Management.

During the conference three workshops were organized in which participants worked towards elaboration of the subjects defined in the GSO Water for Life document.

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CHALLENGES ACTION Topics

Drinking water Cheap and robust technologies for treatment

Sustainable and safe water sources

Cheap and reliable monitoring and sensoring including implementation

Treatment technologiesApplied research for energy neutral technology (removal of pesticides, arsenic, uranium, a.o)Multiscale developmentModification, validation and demonstration of European products

TreatmentCost effective technologiesReject managementDemonstration/ development/ adaptation of EU technologies in Indian scenario at mid-scale community level using renewable sources of energyRobust water testing technologiesLeak management technologies

1.2.2 Management aquifer rechargeAssessing the options of treated waste water for recharge/reuse for non-drinking purposesMass replication for artificial recharge (look for more efficient technologies)Remote monitoring on real time basis (quality and quantity)

Demand managementEfficient metering systemEfficient irrigation technologies (studying the hindrances for improvisation ex clogging of drips)Leak management technologies

Joint product development and testing procedures (incl. certification)Development of sensors/bottle system or testing sticksDemonstration of systems in the field

Waste water Sustainable waste water treatment

Decentralized Approach for Municipal SectorSeparate collection of Grey and Black Water and apply treatment options Recovery of Biogas/Energy, Nutrients etc. Recycling and Reuse of Treated Water (agriculture, ponds, groundwater recharge, psi-culture, toilet flushing etc.)Industry specific approach

Industry specific approachWaste Heat Recovery – Separation, Heat, PowerOrganic – Energy and Chemicals RecoveryInorganic – Recovery of Minerals, Nutrients

Post Treatment to meet the specific industrial standardsStart with Chemical Industry (multinational, solutions for India and EU)

Monitoring SensorsImprove WWTP efficiency, river quality, Maintenance, non contact possible), Cost effective, robust, low power consumptionSensors need improvement/applicability for IndiaSensors needing breakthrough (NH4 / odors, etc)

On site testingDevelop dipstick tests-chemical and equipmentDevelop ecological testing and compare output with classical parameters

Resource recovery Program for Industrial water loop closure on joint R&D, pilot testing, Joint patenting, upscaling, dsissimination of technology and commercialization on:Membrane distillationCDI – Capacitive de-ionizationMFC´s – Microbial fuel cellsSpecial Membranes: - high pressure, high recovery, low energy, low maintenanceMED Membrane Electro Dialysis

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Urban water management

Technology and management Build a model plant/smart (water) city)Database of technologiesTechnology matchmakingFunding for technology acquisition, adaptationJoint R&D project with corsortia appraoch with industry, government and civil cosiety

Focus on development and application ofSensor technology, Data analysis, decision support systems, IT/communication technology, leakage detection technology, cross contamination detection,

Pilot study model/WDN and allocation

Supply and demand(long/short term)

Community of best practicesIdentify existing methods in India and EURe-examine recharge zonesDemonstration of technology solutions

MonitoringIdentify contaminants of different water flows for rechargeIdentify available sensors /develop new cost effective sensorsDSS for management of flows (incl. data

Study on statistics for extremes urban areas

Comprehensive study on alternative water storage (reduce floods, mitigate droughts)

1.4 The way forward between EU – India S&T collaboration on water

In general the topics defined in this EU – India Research & Innovation Agenda also cover the Strategic Research Agenda of the Water JPI. As India is facing severe water problems the collaboration will have an emphasis on applied research and innovation but also on demonstration and implementation. Contacts between Department of Science & Tech-nology and the Water JPI are established and are investigating joint opportunities in the calls of the ERA-NET COFUND Water Works for both the short – as well for the longer term.

For 2017 the EC announced a joint call on water in Horizon 2020 between EU and India where the EC funds the European parties and DST the Indian parties. By launching this joint call a firm step is taken in the collaboration.

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Part 2: Water and Industry: The case of Hindon River and River Kaliindigo Policy

Part 2:

Water and Industry: The case of Hindon River and River Kali

2 Introduction Water & Industry

The second activity within Indigo Policy was organized in the framework of the India – EU Water Partnership (IEWP). The IEWP is a joint partnership between the EU and India with the aim to strengthen technological, scientific and management capabilities of India and the EU in the field of water management on the basis of equality, reciprocity and mutual benefit. The launch of the initiative was signed vi a Memorandum of Under-standing on October 7, 2016.

In close cooperation with the EU delegation in Delhi it was decided that Indigo Policy can contribute in the field of technology and innovation in the relation with “water & industry”.

Therefor a two-days workshop was organized on September 5 and 6, 2016 on Water & Industry in Delhi and Muzaffarnagar. Indigo Policy teamed up with the EU delegation in Delhi to introduce European technology platforms to the India EU Water Partnership (IEWP) initiative and share best practices on Water & Industry. The second day was a workshop together with the paper- and sugar industry in Muzaffarnagar to discuss how these industries can reach a Zero Liquid Discharge status by March 2017.

2.1 Workshop September 5, Delhi

On September 5 a workshop was organized jointly with the Council for Scientific and Industrial Research (CSIR) in Delhi to introduce the Water Supply and Sanitation Tech-nology Platform (WssTP) and the European Innovation Partnership on water (EIP). Differ-ent challenges, policy measures and technology developments were discussed from an EU and Indian perspective. The meeting was chaired by the EU delegation in Delhi and showed different technologies, approaches and results of previous studies on water & industry.

Numerous technologies have been developed over the last decades at institutes to im-prove the water situation in industry. It is evident that new technologies could be the key for water re-use and energy recovery. A good background report on technologies are the “Best Available Techniques Reference Document (BREF) by the European IPPC Bureau. It describes different technologies for different industries.

The successful uptake from industry for a new technology and a sustainable use of it depends on many issues. Besides price there are a number of critical factors that are

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Part 2: Water and Industry: The case of Hindon River and River Kali indigo Policy

relevant for successful technology uptake:

a. Poor Operations and Maintenance: corrosion, no monitoring.

b. Insufficient technical skills and lack of trained staff.

c. Financial constraints (more investments in modernization pro-duction process).

d. Limited space for ETP.

e. On a public level a lack of legislation and law enforcement (moni-toring) causes less focus on treatment of waste water by indus-try.

These issues causes that no water is recycled with increasing pressure on water shortage in some areas and further pressure of (an)organic loads on surface- and ground water.

For a general overview of an ETP see figure 1.

Figure 1 (C. Kazner)

As said before the pollution from small and medium sized industries is a major problem in India. The Water Act of 1974 and its subsequent amendment in 1988 compel these industries to treat their wastewater to meet the stringent effluent discharge norms set by Central Pollution Control Board (CPCB) and State Pollution Control Boards (SPCBs)1. Since then many industries have implemented ETPs at their premises.

CETPs

An alternative model for industry is to introduce the Common Effluent Treatment Plant (CETP) where waste water from different industries is treated at a central place.

In 1984 the ministry of Environment and Forests first mooted the idea of the concept _________

1 Study on CETPs by Saumyen Guha and C.S. Harendranath, IIT Bombay

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of CETPs for cluster of small scale industries. Since then, public authorities such as CPCB and SPCBs are actively promoting this idea for the small scale industries to join hands and treat their effluent jointly.

CETP can be owned and managed fully by government or in a public private partnership model. The industries are charged based on their effluent discharge. The CETP for small and medium industries as a concept is similar to town or municipality sewage from in-dividual households.

Figure 2: Advantages of a CETP

In 2014 the number of installed CETPs in India is 171. In particular Tamil Nadu (47), Maharashtra (27), Gujarat (27), Rajasthan (13), Delhi (13) are front runners with the development of CETPs.

Different CETPs in India have been evaluated on their affectivity. Figure 3 explains the barriers and issues of the CETP model.

Figure 3: Barriers and issues with CETPs 2

_________

2 C. Kazner

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Zero Liquid Discharge (ZLD)

It has been estimated that 501 MLD of industrial effluent is being discharged by water polluting industries (see below) through drains of tributaries into River Ganga. Water polluting industries (GPI), are mainly of industries discharging effluents having BOD load of 500kg/day or having toxic / hazardous chemicals. There are 2535 industries identified in Ganga basin which includes the states of Uttarakhand, Uttar Pradesh, Bihar, Jhark-hand and West Bengal, Delhi, Madhya Pradesh, Chhattisgarh. The industries have been persuaded to set-up effluent treatment plants & CETPs and operate them to meet with prescribed standards3.

Water Polluting Industries

The industries identified as water polluting industries are: Sugar, Distilleries, Pulp and Paper, Tanneries, Chemicals, Dyeing and Textiles, Refineries, Food, Dairy and Beverages, Electroplating and others. The water polluting industries discharge their effluent having high organic contents measured in-terms of bio-chemical oxygen demand (BOD), and other toxic constituents like metals, organic and in-organic compounds4.

Definition of ZLD

Zero Liquid Discharge refers to installation of facilities and system which will enable industrial effluent for absolute recycling of permeate and converting solute (dissolved organic and in-organic compounds/salts) into residue in the solid form by adopting me-thod of concentration and thermal evaporation. In the ZLD concept the treated water from the CETP/ ETP is recycled back for reuse in the industry. No effluent is permitted for discharge within or outside the CETP premises.

ZLD will be recognized and certified based on two broad parameters that is; water consumption versus wastewater re-used or recycled (permeate) and corresponding so-lids recovered (percent total dissolved / suspended solids in effluents).

Pre-requisite for ZLD accomplishment would need physical and chemical treatment and followed by biological treatment to remove organic load. The treated effluents can be then subjected for concentration and evaporation. The concentration process as applicable can be adopted at appropriate stage. The concentration method quite often involves the adop-tion of Reverse Osmosis (RO) and Nano Filtration (NF) methods. The evaporation methods involve incineration/ drying / evaporation of effluent in multi effect evaporators (MEE)5.

Industries are forced to meet the standards of ZLD and in practice the larger industries have the financial resources to make this happen. However for many Small Scale Indus-tries (SSI) ZLD is not economically feasible in terms of CAPEX and OPEX. There are more than 300.000 SSIs spread over India and they contribute to over 40% of the total output. About 1/6 of these SSIs are connected to a CETP6. Shutting down these facilities would mean an enormous economic loss which of course causes social and political instability in many regions in India.

_______

3 Report Central Pollution Control Board India 19-01-2015. Guidelines on Techno-Economic Feasibility of ZLD for Water Polluting Industries. 4 Report Central Pollution Control Board India 19-01-2015. Guidelines on Techno-Economic Feasibility of ZLD for Water Polluting Industries. 5 Report Central Pollution Control Board India 19-01-2015. Guidelines on Techno-Economic Feasibility of ZLD for Water Polluting Industries. 6 Source: IGEP 2014

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As shown in the case of the Muzaffarnagar paper- and sugar mills (part 2B) there is a lot of un-clarity on the application of ZLD. As we learn from Europe ZLD is quite rare. Instead of using ZLD waste water is treated to certain standards of the Water Framework Directi-ve (WFD) and the effluent discharged or re-used for other purposes. Also the operations of ZLD installations can be complex which needs training of staff.

One of the outcomes is that first a common vision and objective needs to be formula-ted. Furthermore, an advice was given to build related knowledge and capacities on all levels (government, administration, research institutes, consultants, industries, far-mers, technology providers, etc.). The Muzaffarnagar paper- and sugar mills are willing to take next steps in a public private cooperation.

For more back ground information on ZLD see Annex 1

2.2 Case Study

Insights from an EU – India expert mission to Muzaffarnagar, UP on paper- and sugar industry (Christian Kazner (FHNW) and experts from CSIR)

Pictures of Muzaffarnagar paper mill. Picture on right bottom: Kali River which flows through

Muzaffarnagar and merges with Hindon River.

Introduction and objective of case study

The Government of India has prioritized the rejuvenation of the River Ganga and its trib-

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utaries (known as Namami Gange Programme, National Mission for Clean Ganga) due to the high importance for the population living in the river basin, the spiritual significance, the severe environmental pollution and the ever increasing water scarcity calling for sub-stantial improvement of the current water management practices in all involved sectors.

Although industry contributes to the total water consumption in India only with 2 to 5% (UNICEF 2013) industries could play a particular role in achieving rapid improvement of the state of water resources. Industries produce a variety of wastewaters depending on the different wastewater sources and type of industrial activity. One of the main pol-luters is the pulp and paper industry with paper mills producing effluents of different qualities and quantities depending on the type of production. Qualities and quantities may vary significantly from slightly polluted waters such as cooling tower blowndown to stormwater and sewage with municipal characteristics to finally industrial effluents with poorly biodegradable constituents often in high strength, sometimes toxic or otherwise harmful to the environment or humans. Improper management of these wastewaters, effluents and stormwater poses serious pollution threats to groundwater and surface water bodies in particular.

The 2030 Water Resources Group – hosted within the World Bank Group by the Interna-tional Finance Corporation is working, in close cooperation with the Uttar Pradesh gov-ernment, on rejuvenating the Hindon River atributiary of the the Yamuna River and part of the Ganga Basin. The larger industries have already implemented different measures but there is still a long way to go concerning the many SMEs.

One of the actions foreseen is the development of a Center of Excellence in Uttar Pradesh in which EU, India and possibly other actors share best practices on technologies, water management and governance.

The Indigo Policy workshop on Water & Industry shared best practices from Europe and India and focused on the Hindon challenges related to SMEs and large industry and to find technical and non-technical solutions.

A group of European and Indian experts from academia and research including CSIR, UNESCO-IHE Delft, VITO from Belgium, the European Innovation Partnership (EIP Water) on Water Reuse and Recycling, the Water Supply and Sanitation Technology Platform and the University of Applied Sciences and Arts North-western Switzerland (FHNW), In-stitute of Ecopreneurship has participated in the workshop and visited selected sites in Muzaffarnagar district during 5-7 September 2016. The observations of this mission are summarised in the following paragraph.

Background and current situation of the Indian P&P industry

The Indian paper industry accounts for ca. 3% of the world’s production of paper em-ploying about 0.5 million people directly and 1.5 million indirectly (IPMA 2016). The per capita paper consumption is about 13 kg/cap•a against a global average of 57 kg/cap•a.

The Indian paper industry is highly fragmented and produces mainly for the domestic market (Jaako Pöyry, 2002). In 2013/14 the estimated production of paper, paperboard and newsprint in India amounted to 14.49 million t/a against a capacity of 18.40 million

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t/a. While 0.56 million t/a were exported 2.58 million t/a were imported. The total do-mestic consumption was estimated to 16.51 million t/a (CPPRI 2014). A total of 750 to 800 paper mills in India create a turnover of about 8 billion USD. The average turnover of an Indian paper mill can thus be estimated at around 1 million USD. In reality the size of the paper mills vary significantly.

About two thirds of the raw material come from waste paper and recycled fibre (65%). Agro residues such as bagasse and wheat straw (11%) and wood and bamboo (24%) are the other sources of raw material (CPPRI 2014). The Indian paper machines are mostly small units. In an international comparison, even the largest machines are medium-size (Jaako Pöyry, 2002). According to IPMA (2016) the Indian paper mills operate on a very diverse range of technological level from the oldest to very modern. The average capaci-ty of an Indian paper mill is ca. 10,500 t/a compared to 85,000 t/a on average in Asia and 300,000 t/a in Europe and North America (Deloitte, 2011).

Opportunities arise from the fact that India has the fastest growing paper market of the world. However, development challenges arise from fragmentation, old production facilities, lack of quality standards and environmental standards, and poor global com-petitiveness. Also shortage of high quality raw material such as wood is raising concern (IPMA 2016).

Development targets for the Indian P&P industry

A working group on Pulp and Paper sector of the Government of India’s Planning Com-mission has defined the path for the development of the paper industry in the years from 2012 to 2017 as follows (GOI WG on P&P, 2011):

• Expected growth of 7.85 per year achieving a production of 22 million tonnes in 2025. • Main requirements are improved raw material availability, technological upgradation,

capacity building, improved environmental compliance, skill development, and R&D support

For environmental compliance a high demand of capital investment was identified, par-ticularly for improved fibre recovery systems and filtration systems as well as tertiary treatment systems such as membrane filtration (ultrafiltration and reverse osmosis), activated carbon treatment, sand filtration, and up gradation/modification of existing effluent treatment plants with the main objective to close water loops up to a zero liquid discharge level.

The working group (GOI WG on P&P, 2011) concluded that “there is an urgent need for the adoption of cutting edge technologies and innovative R&D to address the following environmental issues being faced by the Indian Pulp & Paper Industry: high effluent load, colour removal, black liquor management (agro based Kraft mills), solid waste manage-ment, and air pollution control”.

Project location: the Hindon River case

Flowing between the Yamuna River and the Ganges River, the Hindon River is a major source of water to the highly populated and predominantly rural population of Western

20


Uttar Pradesh province. The total catchment area is 7083 km2 covering Muzaffarnagar District, Meerut, Baghpat, Ghaziabad, Noida & Greater Noida. It originates in the lower Himalayas In Saharanpur, UP and merges after 260 km with the Yamuna River down-stream of Delhi. Industrial activity is a very severe source of pollution along the Hindon River and its two main tributaries, the Kali (West) and the Krishni Rivers, with 60 in-dustrial manufacturing units operating. They both abstract large volumes of water from the river for their manufacturing processes, and also discharge their industrial effluents, often with nominal or no treatment, directly to the river.

The expert mission focused on the Muzaffarnagar District, which is dominated by agri-culture (mainly production of sugar cane and jaggery) and linked sugar mills as well as paper mills besides other industries such as steel. It has a total population of 2.8 million and a population density of 950 inhabitants/km2. The literacy rate in the district is about 70% against 74% in India on average. The urban agglomeration of Muzaffarnagar has a population of about 500,000 (census 2011) with about half of their wastewater currently being treated in a sewage treatment plant while the rest reaches the nalas (open chan-nels) untreated. The nalas convey the wastewater and stormwater finally to the river. Water supply of 125 L/cap•d is from groundwater using tubewells.

The 29 paper mills in the paper cluster of the Muzaffarnagar District are producing from waste paper/recycled paper (16 mills) or from a mix of agro waste and waste paper/recycled paper (12 mills). One paper mill is only agro based. They manufacture main-ly Kraft paper (about two thirds) besides duplex board and writing/printing paper. The total installed capacity is about 0.5 to 0.6 million t/a. A large number of these mills was set up in the 1980’s and 1990’s and are now characterized by out-dated technologies with inefficient energy and water management systems (Deloitte, 2011). 15 paper mills have a rather small capacity of 1750 – 10,500 t/a. The three biggest units have capacities ranging from 50,000 to 90,000 t/a. The average capacity is about 19,000 t/a almost twice as high as the Indian average. The majority of the small units (12 of 15) produce from waste paper (Deloitte, 2011).

The Hindon River and Kali River - having little to no natural perennial base flow - dis-charge currently mainly untreated domestic sewage and industrial effluents of different qualities. The rivers must thus be regarded as open sewer channels. In the light of the multiple sources of pollution and the difficult socio-economic boundary conditions il-lustrated above, a rapid rejuvenation of these surface water bodies appears to be very challenging

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Figure 4 Mass stream overview for a pulp and paper mill (Lacorte et al., 2003)

Pollution by the P&P industry and abatement technologies

Paper mills use a variety of raw materials and additives as shown in figure 4. Additives are used in chemical pulping (e.g. caustic soda and sodium sulphide in the Kraft process), in bleaching (chlorine and hypochlorite in chlorine bleaching, chlorine dioxide or sodi-um chlorate in ECF elemental chlorine-free bleaching, and in TCF totally chlorine-free bleaching oxygen and hydrogen peroxide), and in sizing and strengthening (e.g. cationic starch and polyacrylamide). Further binders such as styrene butadiene latex, styrene acrylic, dextrin, and oxidized starch as well as fillers like China clay, calcium carbonate, titanium dioxide, and talc are used in paper production. Furthermore chemicals such as pigments, dyes and optical brighteners are used in coatings. About 90% of all chemical additives used in pulp and paper production belong to the group of functional additives while the remaining 10% are process chemicals.

Water is the lifeblood of the pulp and paper industry used as process water and as cool-ing water. The composition of the wastewater pollutants depends on the production process of the pulp such as the Kraft process or sulphite process as well as the bleaching method to destroy the lignin or to remove colour in recycled pulp.

Wastewater from the P&P industry is often characterized by a high concentration of organics measured as chemical oxygen demand (COD), high suspended solids (TSS) con-centration arising from fibres, and high adsorbable organic halides (AOX) concentration when chlorine or chlorine dioxide is used for bleaching.

These chlorinated compounds measured as AOX as sum parameter are formed in chem-ical reactions between residual lignin and chlorine/chlorine compounds used for bleach-ing. Being xenobiotic many of these compounds are poorly biodegradable. Some of them show a tendency to bio accumulate while some are proven carcinogens and muta-gens. Most critical compound classes include dioxins and furans. Hence, it is necessary to remove or degrade these compounds from wastewater. A typical wastewater treatment

22


in a paper mill (Fig. 5) consists of primary treatment to remove particulates such as fi-bres and subsequent biological treatment such as conventional aerobic activated sludge treatment to biodegrade organic compounds. Further treatment in a tertiary stage de-pends on the discharge requirements or recycling purpose and can involve (membrane) filtration or activated carbon.

Figure 5 Generalized schematic diagram of paper mill effluent treatment plant

Table 4 presents the wastewater characteristics from P&P industries at different pro-cesses. COD concentrations may reach up to 10,000 mg/L in pulp production often re-quiring anaerobic treatment (e.g. UASB) for economic treatment and energy efficiency.

Table 4

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Table 5 shows the results of a study investigating the effluents from several recycled paper mills in Utthar Pradesh (Maheswari et al. 2012). In most cases and for parameters the effluents do not meet the discharge requirements of the Indian Standard particularly regarding COD, TSS and salinity (measured as total dissolved solids TDS). The authors conclude that the present effluent treatment plants are incapable to effectively remove many pollutants and that the treated effluents are neither fit for discharge nor for agri-cultural irrigation.

The high residual BOD (biochemical oxygen demand) in the range of 120 to 190 mg/L against a discharge standard of 30 mg/L indicates that the biological treatment is often incomplete, probably due to insufficient treatment or aeration capacity and poor oper-ation and maintenance.

Table 5 Physicochemical characteristics of effluents from recycled paper mills collected from ETPs of recycled paper mills of Northern districts of UP (Saharanpur, Muzaffarnagar & Meerut); all data except pH in mg/L (Maheswari et al. 2012)

Available P&P and Wastewater Treatment Technologies

The approach to mitigate pollution problems in the basin should start with Reduce→ Reuse→ Recycle. In the Indian context, implementing CPCB Charter for Water Recycling and Pollution Prevention in Pulp & Paper Industries (CPCB, 2015)8 1

Prior to implementation of the lessons learnt from India - EU ventures would immedi-ately help the industry in understanding the issues with respect to local regulations and move ahead to grasp the concept of Indigo Policy.

The charter has timeline for conducting studies and implementing the bare minimum technologies required for wastewater management systems in place to meet the new proposed water footprint guidelines as presented here under in Table 6.

8 http://www.inpaper.com/Annexure-II.pdf

http://www.inpaper.com/Annexure-II.pdf

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Table 6: Proposed Water Consumption / Wastewater Discharge Standards

The major reasons are that the industry would listen to what the regulatory agencies say in the long run for running the industry. This can be integrated with the state of the art technologies available with international manufacturers. Major companies which oper-ate in India include Voith, GLV, and Andritz supplying state-of-the-art technologies and production methods. Best practices in P&P production have been collected by Confeder-ation of Indian Industries (CII) and published online (2008 and 2009). Also best practices in energy efficient production have been studied and published online (Deloitte 2011).

Furthermore state-of-the-art water and wastewater treatment technologies are avail-able in India from several big international companies and technology providers such as Veolia, Suez Degremont, GE Water, Evoqua (former Siemens Water Technologies), Xylem, Pentair, and Wabag.

The Indian Paper Mill Association (impa.co.in) plays an active role in disseminating knowledge regarding improved state-of-the-art production as well as water and waste-water management technologies. It also organizes the annual conference “PaperTech” which provides a forum to present recent developments and available equipment along-side discussion and networking.

Innovation and way forward in Industrial Wastewater Management

In the pulp and paper industry, innovations in abatement technology are interrelat-ed to process and product changes. Pressure on abatement tends to come from the environmental authorities; pressures on process changes come from competitors and customers; whereas pressures on products come from consumers and pressure groups.

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Abatement of pollutant generation has mainly been triggered by environmental policies that have required waste water treatment. Process changes have predominantly been triggered by the competitive need to economise on resources (e.g., higher energy effi-ciency in pulping, and a more productive use of heat and the unusable wood fraction of the process (black liquor)). Innovations are targeted on the following themes in the pulp and paper industry:

• Energy• Water• Renewable fibre• Salts recovery.• Chemical/ water optimization using software (e.g. Balas).

Innovation in process section

• Integration of new technologies to reduce contamination load in process section to achieve the water quality for recycle or reuse. Introduction of advanced effluent treatment process necessary to improve treated effluent quality. Key area in papermaking currently shows the greatest potential for increasing effective resource management.

• Increasing the dry content of paper by improved pressing technics will reduce the heat consumption for drying of paper.

• New production technology for pulp production (”explosion pulping”) would reduce the electric energy consumption by 25%.

• An increased use of recycled fibres will reduce the electric energy consumption. Increasing recycled paper for paper production could result in saving of raw materials, coal, and water.

• The technology for closing of bleaching process has not been developed to allow for full scale production along with totally effluent free technology. The discharges from the bleachers are taken care of either by destruction or by evaporation and recovery of chemicals.

• Radiofrequency (RF) is used for the drying process in many production activities and some tests are just being carried out in the paper sector. The technology enables the heating of a body mass directly from inside by transforming the energy of an electromagnetic field that can penetrate and be transformed into thermal energy based on the chemical and physical structure of the material meets some given requirements.

Innovation in wastewater treatment

Various wastewater technologies have been utilised for paper mill effluent treatment. However, minute adaptations / improvements have been developed in recent years.

• Water and wastewater reduction (closed loop/zero emission systems). Reduction or total elimination of effluent from the manufacturing process.

• Introduction of zero liquid discharge in pulp and paper industry which involves a range of advanced wastewater treatment technologies to recycle recovery and re-use of the treated wastewater and thereby ensure there is no discharge of wastewater to the environment.

• Recent developments in aeration technology have been achieved in increasing the air transfer rate to the wastewater through innovations such as aerotube, flex disc, fine bubble membrane diffuser. A new technology Floor Mounted Aerotube and Floating Aerotube™ based on porous tube diffuser has been developed to increase oxygen transfer and mixing for wastewater treatment. The tubing can either be mounted on the floor of the basin or suspended from a floating carriage. In another development,

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a flex disc fine bubble membrane diffuser has been developed. The highly efficient flex disc reduces half the electric utility costs with higher oxygen transfer efficiencies. The unique sealing action when the airflow is stopped eliminates plugging that is prevalent in conventional coarse bubble diffusers and the diffuser pipe thread makes retrofitting easy.

• Improve the anaerobic digestion faster and potentially increase biogas yield.• Chemical, physical and biological treatment of effluents from paper industry

produces sludges. As the cost and difficulty of sludge disposal increases the paper mills are gradually adopting thickening installations to reduce the volume of sludges. The technologies implemented are: band filters, rotating drum filters under vacuum and press filters placed after the decanters.

• Wet oxidation (Wetox) - removes suspended solids from wastewater using heat and oxygen under high pressure. The Wetox (wet oxidation) technology converts organic sludge generated from wastewater treatment process (4-15%) back into reusable elements such as water, steam, fertilizer (nitrogen and phosphorus). The sludge volume is reduced. The byproducts could be used on site to help offset the cost, or sold off site. Wetox is part of a green chemistry trend that seeks non-toxic, sustainable alternatives to petroleum and other toxic chemicals. Much effort has been devoted to the development of the technology for gasification of black liquor and using the purified gas in a gas turbine for production of electric energy. The potential for additional electric power production is considerable. According to estimates that have been made, about 5 - 7 TWh/year could theoretically be produced by the year 2010.

• Ultrasound systems can be used for industrial wastewater treatment. It can be used in sludge treatment, control of sludge bulking, foaming and improved nitrogen elimination by providing internal carbon carriers.

• Another method to reduce coagulants for wastewater treatment using magnetic seeds in combination with ultra sonication. A combination of hydrodynamic cavitation and heterogeneous advanced Fenton Process (AFP) based on the use of zero valent iron as the catalyst has been investigated for the treatment of industrial wastewater. A new approach of latent remediation has also been investigated where hydrodynamic cavitation is used as a pre-treatment with an aim of reducing the overall pollutant cost of degradation.

Innovation in energy recovery

• Vaporization of cellulose fraction for bioethanol production, paper manufacturing or fibre obtaining. Conversion of lignin into fuel hydrocarbon such as bio-ethanol and bio-butanol from cellulosic biomass use as fuel, solvent or chemicals.

• Hydrogen production is one of today’s hottest researched topics globally. The basic methods for hydrogen production, though, have remained the same at their core, and everything is now innovated around the same old principles.

• Identification of integration of an industrial complex consisting of industries utilizing common resources, products, by-products and waste products. Eg. Sugar-distillery, pulp and paper, waste management unit and textile.

• Concept of water minimization techniques such as pinch technology, water-free systems and re-circulating systems.

• Mechanical steam recompression is used for the treatment of wastewaters in various industrial sectors, including the paper. It consists in increasing the pressure of saturated steam by means of a mechanical compressor. The major advantage of this technology consists in the outstanding energy saving (electrical power 1 kWh electrical energy vis-à-vis 15 - 20 thermal kWh) and in the reduction of the amount of steam produced

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Current Research Focus on Pollution Reduction in Paper Mills

Activity Section Technology intervention BenefitsProcess Paper machine Micro-filteration/ Ultrafiltra-

tionWater reuse and fiber recov-ery.

Process Pulping

(Biopluping)

Fungi O. piliferum Reduced chemicals.

Process Bleaching (Biobleaching) Enzymes

Xylase

Laccase

Lipase

Cellulase

Catalase

Reduced Bleaching agents.

Process Deinking Enzymes

Cellulase

Reduced Bleaching agents.

Effluent Evaporators Condensate recovery/ Nanofil-tration.

Reduced fresh water con-sumption.

Effluent Post bio-oxidation Ozonation. Color and residual organic fraction reduction.

Effluent Clarifiers Sludge conversion to

Fertiliser

Biogas.

Less hazardous waste gen-eration and energy genera-tion.

Effluent All sections - Instrumentation in effluent management viz., supervisory and data control and optimisa-tion software.

Optimum use of material

Energy

Chemicals

Water.

Approach for improved water management

General remarks

Industry today is no longer an island for itself and must be seen as one of the key stake-holders in sustainable management of the global resources. The linkages and interac-tions in industrial water reuse with the other stakeholders such as agriculture and urban areas are depicted in figure 5.

Besides material flow, water and energy are two main aspects of a circular economy, which is the new paradigm to safeguard sustainable wealth and a healthy environment (World Economic Forum, 2015; Ellen MacArthur Foundation, 2016). All interventions and improvements of the current environmental dilemma should thus involve no-regret solutions in staged approaches with a long-term perspective. Related roadmaps and ac-tion plans require consideration of the site-specific socio-economic and environmental

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conditions considering the economic capacities and safeguarding optimum and sustain-able investments in pollution abatement technologies.

Key factors in successful implementation are adequate environmental laws and law en-forcement requiring skilled and committed administration, monitoring and often sup-port from governmental subsidies for initial investments. Integrated water resources management as laid down in the European Water Framework Directive further relies on a participatory approach involving all stakeholders. These principles also apply for any improvement in the highly complex situation of the Ganga basin with its tributaries.

Figure 6 Industrial water reuse as part of integrated water management (Jansen, 2014)

The Namami Gange Programme has an allocated budget of 20,000 crore Indian Rupees equivalent to 3 billion USD for the next 5 years (The Hindu 2015). With a population of 500 million living in the Ganga basin the average potential investment amounts to 6 USD/cap or 1.2 USD/cap•a. This relatively low investment capacity compared to the of-ten very poor state of the public and industrial infrastructure might illustrate the massive challenge in achieving the intended rapid improvement of the surface water quality and stopping further environmental degradation.

To address the multiple sources of pollution, the Government of India foresees a combi-nation of measures at all points of the human impacted water cycle including bio-reme-diation, appropriate in-situ treatment, use of innovative technologies, sewage treatment plants (STPs), effluent treatment plant (ETPs) as well as rehabilitation and augmentation of existing STPs (The Hindu 2015). Learning from previous experiences, the GOI plans to support O&M of the assets and adopt Public Private Partnership approaches (The Hindu 2015). To immediately stop industrial point source pollution of rivers and other surface water bodies the principle of zero liquid discharge - applied in some industrial clusters in Southern India - is often regarded as best solution.

It is obvious that the Clean Ganga Fund installed for the rejuvenation of the Ganga catch-

29


ment needs more sources. According to the Indian Express (2016) the fund has received donations of over 132 crore INR (20 million USD) by the end of June 2016. Further tech-nical and financial support can be expected from international development coopera-tion such as GIZ and funding agencies like The World Bank which supports the National Ganga River Basin Authority with an 1 billion USD credit and loan over a period of 8 years (The World Bank, 2015).

Integrated water resources management with prioritiza-tion of water reuse

Against the backdrop of public and private financial capabilities any investment should only be made after sound evaluation of alternative treatment and reuse concepts to identify the least-cost options for achieving environmental compliance and set the right priorities within the development plan.

European water management relies on river basin management plans as laid down in the Water Framework Directive (2000) involving the key public and private stakeholders. Within this planning framework it is foreseen to identify shortcomings and develop ac-tion plans to achieve the environmental quality standards in the intended time frame. Water scarce regions in Europe have started to prioritize water reuse as a key element for sustainable water resources management. As shown in figure 7 treatment require-ments for the respective reuse categories vary significantly and are typically increasing with the potential of exposure to humans. The lowest requirements are to be met for agricultural irrigation and environmental purposes such as river flow augmentation. A comprehensive overview of the treatment options, technologies and international case examples including project experiences from India (Delhi, Bangalore and Nagpur) is giv-en in the US EPA Water Reuse Guidelines (2012).

Figure 7 Water reuse categories vs. water quality requirements (Asano et al. 2007)

In the human impacted water cycle as presented in figure 8 contaminants and organic trace pollutants such as industrial chemicals may reach drinking water sources and fi-nally end up in the supplied drinking water. Therefore technological barriers to retain

30


pollution are introduced in integrated water management to avoid negative health and environmental impacts when water sources are intensely used.

Industry Hospital Household Agriculture

Sewer drains

Sewage treatment plant

Surface water Groundwater

Waterworks

Drinking water

RunoffDischarge Irrigation(Soil passage, infiltration)

Strom wateroverflow

Leakages

Bank filtration

Process water AnimalsConsumersPatients

Industry Hospital Household Agriculture

Sewer drains

Sewage treatment plant

Surface water Groundwater

Waterworks

Drinking water

RunoffDischarge Irrigation(Soil passage, infiltration)

Strom wateroverflow

Leakages

Bank filtration

Process water AnimalsConsumersPatients

Figure 8 Water cycle with potential pollution pathways leading to unintended pota-ble water reuse. Industrial discharge to surface water include prior treatment at the industry (Ternes and Joss 2006)

The state-of-the-art concept of particularly industrial reuse relies on the “fit-for-purpose” principle where the recycled water is treated according to the specific quality demand.

Fig. 6 and 10. The large industry-related EU FP7 Research Project “AquaFit4Use” has studied this principle and demonstrated its applicability in several cases including paper industry. Information and results of this project is available online (http://www.aquafi-t4use.eu/).

As presented in Fig. 9 combinations of biological treatment involving anaerobic and aer-obic treatment alongside advanced treatment such as membrane technology, chemical oxidation such as ozone and thermal evaporation (as used also in Zero Liquid Discharge prior to brine concentration). In this context Zero Liquid Discharge must be regarded as the most demanding and most expensive solution to achieve water reuse and contain environmental pollution (cf. table 3). Examples of the big river European river basins such as the rivers Rhine, Danube and Elbe demonstrate that intense industrial activi-ty including high usage of surface water and groundwater and subsequent discharge of sufficiently treated effluents can be enabled without rigid application of expensive “last-exit” technology.

Figure 9 Treatment technologies are available to achieve any desired level of water

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quality (US EPA 2012)

MBR

Anaerobic Process

Membrane (UF/NF/RO)

Ozone

concentrate

Evapo-ration

1

5

6

3FM

3

Water quality for reuse

low

medium

high

high

Aerobic

Softening

4

7

2

3

Figure 10 AquaFit4Use: Case study of improved water management in paper industry at the factory of Hamburger Rieger, Germany (WssTP 2013)

GWI (2010) points out that economic benefits can outweigh the costs of advanced treat-ment and water reuse if all externalities and opportunity costs are taken into full consid-eration (Figure 11).

The table below summarizes typical price ranges for costs in water reclamation and re-use. Agricultural reuse of domestic wastewater thus provides the cheapest option with costs below 0.10 USD/m3 while industrial reuse of domestic sewage ranges between 0.15 and 0.60 USD/m3. Industrial water recycling within the plant including a ZLD system has estimated cost of 0.80 to 1.50 USD/m3 of reused water.

Table 7 Typical cost of reclaimed water (GWI, 2010)

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Figure 11 Financial analysis versus economic analysis (GWI 2010)

2.3 Conclusions, Recommendations and Proposal for Actions

The Hindon and Kali Rivers rejuvenation concept requires a coordinated and stepped approach involving all stakeholders. While some elements involve major investments and new physical measures, other measures are targeting at capacity building, improved operations and sustainable management practices. The objective of a universal appli-cation of the Zero Liquid Discharge principle appears to be overambitious even without detailed knowledge of the site-specific boundary conditions in Muzaffarnagar and com-parable locations. Instead of that a sound evaluation of cost-effective treatment trains and supporting management concepts should be developed and consider in particular the socio-economic boundary conditions.

Recommendations can be divided into short-term actions to be realized within one to two years and mid to long-term actions to be realized within two to five years.

Short term proposed actions

• The following short-term actions are recommended:• Assess implementation status of CPCB charter for water recycling and pollution

prevention in pulp & paper industries in the river basin.• Formulate common vision and objectives• Build related knowledge and capacities on all levels (government, administration,

research institutes, consultants, industries, farmers, technology providers, etc.)• Establish basin related water associations and cooperation of stakeholders • Characterize and improve monitoring all waters and wastewaters• Study water demands in agriculture and urban contexts • Foster small scale local natural treatment systems, e.g. constructed wetlands in nalas• Optimise operations in existing ETPs• Identify potential, treatment requirements and location for agricultural reuse and

managed aquifer recharge (MAR)• Improve management of solid waste from industries and discontinue unsustainable

disposal practices such as waste dump sites near water bodies• Adopt rules for water reuse according to international standards (e.g. WHO & US EPA)• Develop realistic achievable action plans and roadmaps, and safeguard law

enforcement

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Mid to long-term proposed actions

The recommended mid to long-term actions encompass:

• Upgrade Effluent Treatment Plants (ETPs) in all industries for environmental compliance

• Maximise water recycling and water reuse within the industries • Upgrade ETPs with tertiary and advanced treatment applying the “Fit4Use” principles• Build Sewage Treatment Plants (STPs) where the sewage is still untreated• Install MAR for local groundwater recharge and implement agricultural reuse • Safeguard reuse water quality through monitoring (e.g. online monitors)• Apply the concept of water sensitive urban design in the residential and industrial

area• Transform the local industries to cleaner production with Resource Efficient and

Cleaner Production (RECP) methods and trainings

References

Deloitte (2011) Manual on Energy Conservation Measures in Paper Cluster, Muzaffar-nagar, prepared by Deloitte Touche Tohmatsu India Pvt. Ltd on behalf of the Bureau of Energy Efficiency (BEE), Ministry of Power, Government of India, available online: http://sameeeksha.org/pdf/dpr/Muzaffarnagar_Paper.pdf

CII - Confederation of Indian Industries (2008) National Best Practices Manual Pulp & Paper Industry - ‘Making Indian Pulp & Paper Industry World Class’, Vol. 1, June 2008, CII, Hyderabad

CII - Confederation of Indian Industries (2009) National Best Practices Manual Pulp & Paper Industry - ‘Making Indian Pulp & Paper Industry World Class’, Vol. 2, July 2009, CII, Hyderabad

Maheshwari R. et al, (2012) J Adv Scient Res, 2012, 3(1): 82-85

Jaako Pöyry Consulting (2002)

JRC - European Commission: Joint Research Centre (2015) “Best Available Techniques Reference Document for the Production of Pulp, Paper and Board” JRC Science and Pol-icy Reports, Authors: M. Suhr, G. Klein, I. Kourti, M. Rodrigo Gonzalo, G. Giner S.,Serge Roudier, L. Delgado Sancho, Luxembourg: Publications Office of the European Union, doi:10.2791/370629, available online: http://eippcb.jrc.ec.europa.eu/reference/BREF/PP_revised_BREF_2015.pdf

JRC - European Commission: Joint Research Centre (2016) Reference documents under the IPPC Directive and the IED, available online: http://eippcb.jrc.ec.europa.eu/refer-ence/

Lacorte S., Latorre A., Barcelo D., Rigol A., Malmqvist A., Welander T. (2003) Organic compounds in paper-mill process waters and effluents, Trends in Analytical Chemistry 22 (10), p. 725-737 doi:10.1016/S0165-9936(03)01009-4

The Hindu (2015) “Centre okays Rs. 20,000-crore budget for Namami Gange scheme”, article on 13 May 2015, http://www.thehindu.com/news/national/rs-20000crore-bud-

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get-for-namami-gange-scheme/article7201467.ece

UNICEF (2013) Water in India: Situation and Prospects, UNICEF India and FAO, http://www.unicef.org/india/Final_Report.pdf

US EPA (2012) Guidelines for Water Reuse, Environmental Protection Agency, http://nepis.epa.gov/ ,

The World Bank (2015) The National Ganga River Basin Project, article on 23 March 2015, http://www.worldbank.org/en/news/feature/2015/03/23/india-the-national-ganga-riv-er-basin-project

WssTP – EU Water supply and sanitation Technology Platform (2013) “Water Reuse”, scientific report, WssTP Publications, The European Technology Platform for Water, Brus-sels, Belgium, http://wsstp.eu/publications/

http://wsstp.eu/publications/

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INDIGO POLICY

ANNEX

1) Background ZLD Policy

It has been estimated that 501 MLD of industrial effluent is being discharged by water polluting industries (see below) through drains of tributaries into River Ganga. Water polluting industries (GPI), are mainly of industries discharging effluents having BOD load of 500kg/day or having toxic / hazardous chemicals. There are 2535 industries identified in Ganga basin which includes the states of Uttarakhand, Uttar Pradesh, Bihar, Jharkhand and West Bengal, Delhi, Madhya Pradesh, Chhattisgarh. The industries have been per-suaded to set-up effluent treatment plants & CETPs and operate them to meet with prescribed standards.1

ZLD Policy

Environmental Discharge Standards (Table 1 & 2) for compliance have been notified under the Environment Protection Act, 1986. The notified standards permit industries to discharge the effluents only after compliance. However, CPCB and SPCBs / PCCs are now insisting industries to reduce water consumption and also take measures not-to-discharge effluents. However, it has been observed that industries are not able to meet all time compliance standards and as a result, rivers like Ganga and its tributaries are carrying high pollution load; it is the dilution available in river water that helps in mini-mizing pollution load. 1

Nevertheless, dilution is not an acceptable approach to pollution as stream flows are getting reduced across the country. The effluent discharge standards implemented so far are based on the premise that the background river water quality is very good and at least 10 times dilution is available. These conditions are not met in most of the Indian rivers as partially treated or untreated industrial and domestic effluents are discharged. Hence, enhancement in the treatment level is pertinent which brings into focus the Zero Liquid Discharge (ZLD).

Table 1. Industry Specific Standards Notified under E(P) Rules, 1986Pollutant param-eters

L-PP S-PP

pH 7.5-8.5 5.5-9.0

TSS 100 100BOD 30 30COD 350 -COLOUR - -TDS, PCU - -

ANNEX

36

indigo Policy

AOX - -SAR - -

L-PP – Large pulp & paper mills capacity above 24k, MTPA

S-PP – Small pulp & paper mills capacity upto 24k, MTPA

Table. 2: Total wastewater discharge standards for pulp & paper millLarge pulp and paper mills

200 m3/t of paper

100 m3/t for mills after the year 1992Large pulp and paper mills – Rayon grade

150 m3/t of paper

Agro based small pulp and paper mills

200 m3/t of paper

150 m3/t for mills after the year 1992Waste paper based pulp and paper mills

75 m3/t of paper

50 m3/t for mills after the year 1992

The Concept of ZLD92

Issues and challenges in ZLD103

9 C. Kazner

10 C. Kazner

ANNEX

37

INDIGO POLICY ANNEX

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