zero liquid discharge

0

March to Sustainability: Zero

Liquid Discharge

Market Opportunities and Outlook for India by 2020

MAY 2016

Report includes a deep dive

market assessment for:

• Textiles • Distillery • Pulp & Paper

Report Excerpt

Amidst the problem of water scarcity plaguing the entire nation, the Government has been providing the required

thrust to move industries towards sustainability to reduce their water footprint. Indian industries have been

operating well below the global best scenarios and have been a major reason for pollution of the country’s water

resources. Zero Liquid Discharge in this scenario is a welcome move for ensuring water security in the country.

This market assessment report is a primer for Zero Liquid Discharge in India, which describes the current scenario,

illustrates the outlook for 2020 and quantifies the market opportunity with a focus on three highly polluting and

water intensive industries, i.e. Textile (wet processing), Distillery (molasses based) and Pulp & Paper (large wood

based).

A mixed method approach was adopted to create a bottom-up model to estimate the market potential for ZLD

across the three sectors of focus, covering the following three dimensions:

Geographical lens (state-wise)

Time lens (present and future scenario)

Technology lens

Extensive research was conducted for assessing the current policy landscape, industrial growth, water usage,

effluent characteristics etc. In depth interviews were conducted with a number of stakeholders, including policy

makers, regulatory institutions, industry (including firms as well as industry associations) and technology solution

providers for arriving at the potential market size for ZLD solutions across the three sector of focus.

What to Expect in this Report Based on a detailed bottom up model built to estimate the potential opportunity, the report assesses the potential

market size for ZLD solutions in India by 2020 across textiles, distilleries and pulp and paper sectors. It also critically

analyses the implications of ZLD on the corporate bottom lines and impact on the end product pricing from a

consumer lens and presents the outlook for the sector by 2020.

Report Excerpt

Total market potential of ZLD estimated to be USD 3 billion by 2020

The report highlights that the textile (wet processing) sector accounts for the largest share in the cumulative

potential of USD 3 billion (INR 210 billion) for the three focus sectors by 2020. Though ZLD has a significant impact

on the cost of production in the wet processing segment, the impact on final product (garment in this case) is not

very substantial.

Molasses based distilleries sector follows second in terms of market share of ZLD. This is in line with the fact that

both textiles and distilleries already have regional mandates for ZLD and have a national mandate in the pipeline.

The distilleries sector have a relatively strong business case for ZLD due to the additional revenue from by-

products generated as a result of adoption of bio-compositing as a route for achieving ZLD in the sector.

The Pulp & Paper sector at present does not have any ZLD mandate, however the Charter for Water Recycling &

Pollution Prevention in Pulp & Paper Industry aims at making the industry efficient and sustainable in terms of

water use. The industry is currently operating well below the global standards and is highly inefficient in terms of

water use and also a major contributor to the pollution of India’s water resources. Of the three sub-segments

(based on raw material used), the large wood based pulp & paper mill are highly polluting and much worse than

the global best with regards to water consumption of ~29 m3/Mt of product produced. Thus, there is a high

probability that the large wood based pulp & paper mill will be targeted first to lead the Pulp & Paper industry

towards Zero liquid Discharge. Once the industry achieves the global best level of water consumption, it is likely

that the market opportunities for ZLD solutions would open for the sector and the investment would pick up by

2020.

Geographies of High Potential

The actual market penetration of ZLD would primarily be governed by how the policy landscape shapes up in the

next few years. In the near term, the potential market would be focused on the Ganga basin states but with the

onset of the national mandate, other states are expected to climb the ladder to become the hotspots for market

potential in this domain. The report analyzes and estimates the potential market for ZLD solution across different

states of India for each of the focus sectors.

Market Sizing for ZLD Solution Components

The report provides an in-depth assessment of the technology options for achieving ZLD in the three industries.

Reverse Osmosis (RO) and Multiple Effect Evaporator (MEE) are the key components of ZLD solution in these three

sectors of focus. The market size for each of these components has also been estimated in this report.

Action Agenda and Outlook for ZLD in India

There is high market opportunity for ZLD solutions in these sectors, however, there are a few roadblocks for the

industries to achieve ZLD like low price of water leading to weak business case, high cost of implementation

leading to reduced cost competitiveness in the national and global markets, lack of financing sources, disposal of

solid by-product in certain sectors, escalated carbon footprint of the industry, technology limitations.

Achieving ZLD by the industry is the need of the hour, although is difficult. The actual market penetration would

primarily be governed by the policy landscape in 2020. In order to smoothen out the implementation pressures

and drive the action agenda, focus should be on models of operation and capacity building of operators within

industrial units which have been dealt in detail in the report.

Report Excerpt

Contents of the report 1 Sustainable Water Management in Industry: Topic du jour? ......................................................................... 1

1.1 Objective of the Report ............................................................................................................................... 2

1.2 Methodology ............................................................................................................................................... 2

2 India’s Water Woes ......................................................................................................................................... 4

2.1 Inconspicuous Water Reserves, Conspicuous Crisis ................................................................................... 4

3 Addressing the Problem: Zero Liquid Discharge for Industries....................................................................... 8

3.1 Evolution of Zero Liquid Discharge in India: Policy Landscape ................................................................... 8

3.2 Outlook for the Policy Agenda .................................................................................................................. 12

4 Towards the Solution: Technological Landscape of ZLD ............................................................................... 13

5 The Rising Tide of ZLD in India: Key Accelerators for the Market ................................................................. 19

5.1 Policy is the Strongest Driver .................................................................................................................... 19

5.2 Water Scarcity, Increasing Competition for Access .................................................................................. 19

5.3 Increasing Industrial Water Productivity .................................................................................................. 20

5.4 Recovery of Water and Other Valuable Resources .................................................................................. 21

6 Challenges for Adoption of ZLD in Industry .................................................................................................. 22

6.1 Low Price of Water ................................................................................................................................... 22

6.2 Reducing Cost Competitiveness in the National and Global Market ........................................................ 22

6.3 Lack of Financing Sources ......................................................................................................................... 23

6.4 Disposal of Solid By-product ..................................................................................................................... 23

6.5 Escalated Carbon Footprint of the Industry ............................................................................................. 23

6.6 Technology Limitations ............................................................................................................................. 24

6.7 Limited Available Space ............................................................................................................................ 26

7 Action Agenda and Outlook for ZLD in India ................................................................................................. 27

7.1 Exploring New Models of Operation & Implementation .......................................................................... 27

7.2 Capacity Building for Technology ............................................................................................................. 30

8 ZLD: INR 210 billion (USD 3,182 Million) Market Potential in Textile, Distilleries and Pulp &

Paper by 2020 ........................................................................................................................................................ 31

9 Textile (Wet Processing) Industry: INR 90 billion (USD 1,364 Million) ZLD Potential Market by

2020……………………………………………………………………………………………………………………………………………… 33

9.1 Gujarat, Punjab and Maharashtra to Lead the ZLD Market; Not Ganga Basin States .............................. 35

9.2 ZLD Technology for Textile Industry (Wet Processing) ............................................................................. 37

9.3 Understanding the Cost Structures of ZLD for Textile Industry (Wet Processing) ................................... 38

9.4 Business Case for ZLD in Textile (Wet Processing) Industry ..................................................................... 42

10 Distillery Industry: Opportunity Exists even though Inroads have been made into the Market ................. 44

Report Excerpt

10.1 ZSD Market Demand to Reach INR 76 billion (USD 1,152 Million) for Molasses Based Distillery ............ 45

10.2 Bio-composting – Most Widely Used ZLD Pathway for Molasses Based Distilleries ................................ 47

10.3 Understanding the Cost Structure for ZLD in Distillery ............................................................................ 50

10.4 Additional Revenue from By-product (Compost) of ZSD Leads to Partial Recovery of Expenses ............ 53

11 Pulp & Paper Industry: INR 46 billion (USD 697 Million) ZLD Market Contingent on Policy Push ………………54

11.1 ZLD Economically Unviable at Current Levels of Water Consumption ..................................................... 55

11.2 Global Best Water Consumption + Indian Policy = INR 46 billion (USD 700 Million) ZLD Market in Pulp &

Paper ................................................................................................................................................................. 55

11.3 ZLD Technology for Pulp & Paper (Large Wood Based) ............................................................................ 58

11.4 Current Effluent Disposal Norms not the Most Suited ............................................................................. 60

11.5 ZLD Difficult, not Impossible in Pulp & Paper Sector ................................................................................ 62

11.6 Business Case for ZLD in Large Wood Based Pulp & Paper Sector ........................................................... 63

Annexures

Annexure 1: Methodology Adopted for Sizing the Market Potential of Zero liquid Discharge across 3

Sectors of Focus ..................................................................................................................................................... 66

Annexure 2: Business Models for Implementation of ZLD .................................................................................... 67

Annexure 3: Key Policies and Schemes Promoting Industrial Water Conservation .............................................. 70

Annexure 4: Effluent Disposal Standards for Industries in Focus .......................................................................... 73

Annexure 5: Effluent Characteristics of Sectors in Focus ...................................................................................... 74

Annexure 6: State-wise Installed Capacity of Molasses Based Distilleries in Million Liters (2012-2013) .............. 76

Annexure 7: List of Technology Suppliers/Vendors for ZLD .................................................................................. 77

Annexure 8: List of Organizations in Ganga Basin which Received Notice from NGT ........................................... 82

Annexure 9: List of Industries Issued Closure Notice by CPCB Regarding Failure of Installation of

Online Monitoring Systems ................................................................................................................................. 102

Annexure 10: Industrial Sectors Already Practicing Zero Liquid Discharge ......................................................... 105

Report Excerpt

List of Figures

Figure 1: Aggregated Global Water Gap ........................................................................................................................ 1

Figure 2: Stage of Groundwater Development .............................................................................................................. 4

Figure 3: Baseline Water Stress ..................................................................................................................................... 5

Figure 4: Current Industrial Water Usage and Predictions for 2050 ............................................................................. 5

Figure 5: State Wise Industrial Water Consumption and Wastewater Generation in the Ganga Basin ........................ 7

Figure 6: Unfolding of ZLD in India ................................................................................................................................ 9

Figure 7: Snapshot of Mandates for Reducing Industrial Water Footprint ................................................................. 10

Figure 8: Pictorial Representation of ZLD Value Chain ................................................................................................ 13

Figure 9: Components of ZLD System .......................................................................................................................... 15

Figure 10: Depth of Water Level in India ..................................................................................................................... 19

Figure 11: Projected Water Demand ........................................................................................................................... 20

Figure 12: Industrial Water Productivity (IWP) of Water ............................................................................................ 21

Figure 13: Effect of Recovery on Overall Operating Cost (in INR) ............................................................................... 21

Figure 14: Total Cost of Water around the World ....................................................................................................... 22

Figure 15: Specific Carbon Dioxide Emissions for Different Fuels (in kg CO2/kWh) .................................................... 24

Figure 16: Amount of Risk Associated for Service Provider in relation to their Involvement ..................................... 28

Figure 17: Potential Market Opportunity for ZLD by 2020 (in INR Million) ................................................................. 31

Figure 18: Potential Cumulative Operating Expenditure for ZLD by 2020 (in INR Million/Annum) ............................ 31

Figure 19: Impact of ZLD on Production Cost .............................................................................................................. 32

Figure 20: Estimated CAPEX for ZLD in Textile (Wet Processing) Industry .................................................................. 34

Figure 21: Estimated OPEX for ZLD in Textile (Wet Processing) Industry .................................................................... 34

Figure 22: Market Potential as per Technology for Textile (Wet Processing) Industry by 2020 ................................. 34

Figure 23: Total Market Size for ZLD in Textile (Wet Processing) Industry in Ganga Basin and Non Ganga Basin

States by 2020 ............................................................................................................................................................. 35

Figure 24: State-wise Market Size for ZLD in Textile (Wet Processing) Industry by 2020 ........................................... 37

Figure 25: Technology Options Available for ZLD in Textile (Wet Processing) ............................................................ 38

Figure 26: Percentage Break-up (CAPEX and OPEX) for Different Components for ZLD in Textile (Wet Processing) . 39

Figure 27: Amount of Water Recovered across Different Components of ZLD in Textile Industry ............................. 40

Figure 28: Comparison of Impact of ZLD on the End Product Price ............................................................................ 42

Figure 29: Specific Water Consumption with Various Dyestuff ................................................................................... 43

Figure 30: Estimated CAPEX for ZSD in Distilleries (molasses based) .......................................................................... 45

Figure 31: Estimated OPEX for ZSD in Distilleries (molasses based) ............................................................................ 45

Figure 32: Total Market Size in Molasses Based Distillery for ZLD in Ganga Basin and Non Ganga Basin States by

2020 ............................................................................................................................................................................. 46

Report Excerpt

Figure 33: State-wise Market Size for ZLD in Molasses Based Distillery by 2020 ........................................................ 46

Figure 34: Most Prevalent Technological Pathways to Achieve ZLD for Molasses Based Distilleries.......................... 49

Figure 35: Market Potential as per Technology for Molasses Based Distillery by 2020 .............................................. 50

Figure 36: CAPEX and OPEX Break-up for Bio-composting (Option 1) of the Concentrate ......................................... 51

Figure 37: CAPEX and OPEX Break-up for Incineration (Option 2) of the Concentrate ............................................... 51

Figure 38: Production Share of Different Types of Pulp & Paper Mills in India (Based on Raw Materials Used) ........ 55

Figure 39: CAPEX and OPEX Projections for Large Wood Based Pulp & Paper Industry by 2020 ................................ 56

Figure 40: ZLD Market Projections for Large Wood Based Pulp & Paper Industry for Ganga Basin and Non Ganga

Basin States by 2020 .................................................................................................................................................... 57

Figure 41: Market Potential for ZLD in Large Wood Based Pulp & Paper Industry across Different States by 2020 .. 58

Figure 42: Technological Option for ZLD in Large Wood Based Pulp & Paper Industry .............................................. 59

Figure 43: Market Potential as per Technology for Large Wood Based Pulp & Paper Industry by 2020 .................... 60

Figure 44: Major Findings from the Pilot Project in Pulp & Paper Industry by TWIC .................................................. 63

Figure 45: Average Water Consumption in Pulp & Paper Industry ............................................................................. 63

Figure 46: ZLD Cost Compared to Overall Production Cost in the Present Scenario and as Projected for 2020......... 64

List of Tables

Table 1: Places on the Ganga Basin which do not Meet the CPCB Criteria ................................................................... 6

Table 2: Sector Wise Water Consumption and Wastewater Generation in the Ganga Basin ....................................... 7

Table 3: Groundwater Withdrawal Limit as per Groundwater Category .................................................................... 12

Table 4: Typical Operating Conditions of a MEE .......................................................................................................... 15

Table 5: Different ZLD Technologies Currently Prevalent ............................................................................................ 17

Table 6: Comparison of Different Evaporation and Membrane Technologies ............................................................ 25

Table 7: CAPEX-OPEX Scenario for Different Configurations ....................................................................................... 41

Table 8: CAPEX-OPEX Scenario for Different Configurations ....................................................................................... 52

Table 9: Freshwater Consumption Target for Pulp &Paper Industry in Ganga Basin States ....................................... 60

Table 10: Effluent Generation Norms for Pulp & Paper Industry in Ganga Basin States ............................................. 61

Report Excerpt

Executive Summary In the backdrop of severe water crisis foreseen for the country, the Government is

mulling to bring in policies to push industries towards sustainability. Stimulated by the

policies, the industries are increasingly adopting water conservation and wastewater

management strategies as a step towards Zero Liquid Discharge (ZLD).

This market assessment report is a primer for Zero Liquid Discharge in India, which

describes the current scenario, illustrates the outlook for 2020 and quantifies the market

opportunity with a focus on three highly polluting and water intensive industries, i.e.

Textile (wet processing), Distillery (molasses based) and Pulp & Paper (large wood

based). A mixed method approach was adopted to create a bottom up model to

estimate the market potential for ZLD across the three sectors of focus, covering the

following three dimensions:

Geographical lens (state-wise)

Time lens (present and future scenario)

Technology lens

1.1 The Rising Tide of ZLD in India: Key Accelerators for the Market

Traditional thinking is that industrial units should be located in areas with sufficient

water. This assumption will not hold true in future. The actual market for ZLD across

industrial sectors would depend on a variety of drivers, such as the policy scenario,

water status of the region, increasing the industrial water productivity and recovery of

valuable resources such as water, salts and other by-products.

1.1.1 Policy is the Biggest Driver for ZLD

ZLD is not a completely new concept in India and was first introduced in the country in

2006, with Madras High Court and Tamil Nadu Pollution Control Board (TNPCB) directing

the textile dyeing and bleaching units in Tirupur to achieve ZLD. Central Pollution Control

Board (CPCB) having identified 17 highly polluting industries for achieving ZLD in 9 Ganga

basin states, has mandated textiles, distilleries, tanneries, chemicals, fertilizers,

pesticides, dyes and pharmaceuticals in the first phase of the Ganga Action Plan in 2015.

Moreover, with the draft national mandate for ZLD in Textile (wet processing) and

fermentation already released, it is expected that ZLD would be extended across other

sectors and geographies in the near future, hence causing a surge in demand for ZLD.

1.1.2 Key Challenges Plaguing Implementation

Despite the strong policy push and case due to acute water scarcity in certain regions,

ZLD implementation has a few challenges. These include:

Low Price of water leading to weak business case

High cost of implementation leading to reduced cost competitiveness in the

national and global markets

Lack of financing sources

Disposal of solid by-product in certain sectors

Escalated carbon footprint of the industry

Technology limitations

Report Excerpt

In order to smoothen out the implementation pressures and drive the action agenda,

focus can be on models of operation and capacity building of operators within

industrial units.

1.1.3 Exploring New Models of Operation & Implementation

Use Solar Heat for Preheating Boiler Steam for Improving the Economic Viability of ZLD

One way to bring down the treatment cost of ZLD is to use solar water heaters to

preheat boiler water and save fuel in the boiler. The resulting low cost steam can be

used to carry out both the manufacturing process as well as run the Multi Effect

evaporator

Combining Treatment of Sewage with Industrial Effluent

In areas where even access to make up water is a challenge, industrial units can explore

the model of treating sewage water with industrial effluent water, thereby not only

fulfilling their requirements of water but also earn revenue from municipal authorities as

fee for treatment of sewage.

CETP for Multi Effect Evaporator

For small and medium scale units it is highly cumbersome to operate a plant which is

almost as big as their manufacturing facility. Also at the end of the day any industry will

minimize time and effort spent for treating water and complexity associated with it.

One way to counter issues of cost and complexity is to have a common effluent

treatment plant (CETP) only for Multi Effect Evaporator and units can treat the water in

their Effluent treatment plant till Reverse Osmosis which will enable them to recover a

significant proportion (say around 80 percent) of effluent and the remaining 20 percent

high TDS effluent can be sent to the CETP where it will be treated with the help of MEE

and the treated water and salts will be sold back to the member units.

1.1.4 Capacity Building for Technology

One of the key concerns of industries is the lack of skilled manpower to efficiently

operate and maintain ZLD systems. Imparting training to improve the skills of manpower

will help reduce implementation pressures and help accelerate the adoption of ZLD by

the industry.

1.2 INR 210 billion (USD 3.2 billion) Market Potential for ZLD Solutions in Textile,

Distilleries and Pulp & Paper Industry by 2020

The cumulative market potential across the three sectors of focus in 2020 would be

nearly INR 210 billion (USD 3,182 million), with investment in ZLD for Textile (wet

processing) constituting the largest chunk of market at approximately INR (x) billion

(USD (y) million). The market size for key components of ZLD system, i.e. Reverse

Osmosis (RO) is INR (x) billion (USD (y) million) and that for Multi Effect Evaporator

(MEE) is INR (x) billion (USD (y) million) by 2020.

Report Excerpt

Figure 1: Potential Market Opportunity for ZLD by 2020 (INR Million)

Source: Sustainability Outlook Analysis

1.3 Textile (Wet Processing): INR (x) billion (USD (y) million) Market Opportunity

Imminent with National Mandate

Textile wet processing industry currently holds the maximum potential for Zero Liquid

Discharge accounting for more than (X)% of the estimated market size for 2020 (for 3

sectors of focus). The opportunity in the textile is likely to increase from ~INR (X) billion

(USD (Y) milllion) in 2016 to ~INR (x) billion (USD (y) million) in 2020, with Gujarat and

Punjab accounting for 38% of the total opportunity by 2020. Tamil Nadu currently

accounting for 56% of the market due to the high market penetration of ZLD in the state,

is likely to constitute only 27% of the entire market in 2020, as the national mandate

kicks in. It is interesting to note that the 9 Ganga basin states for which currently there is

a mandate, are likely to account for only 13% share of the market opportunity by 2020.

The market potential for RO is expected to be INR (x) billion (USD (y) million), while MEE

shall hold the lion’s share of 66% at INR (x) billion (USD (y)million) by 2020 for the textile

(wet processing) industry.

Figure 2: Estimated Capital requirement for ZLD in Textile (Wet Processing) by 2020

Figure 3: Operational Expenditure for ZLD in Textile (Wet Processing) by 2020


Textile (wetprocessing)

Distilleries (molassesbased)

Paper & PulpIn

INR

Mill

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2016 2017 2018 2019 2020

in I

NR

Mill

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2016 2017 2018 2019 2020

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Mill

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/Ye

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Report Excerpt

This sector is likely to see a spending to the tune of millions in operating expenses from

2016 to 2020 with the annual OPEX increasing from INR (x) billion (USD (y) million) to

INR (x) billion (USD (y) million) in the same period.

1.3.1 ZLD Increases Cost of Textile Wet Processing by 8-10% but that of Final Product

by Less Than 1%

Implementation of ZLD is likely to increase the cost of dyeing fabrics by INR 15-20/kg and

therefore has a does have a considerable impact (8-10%) on cost of product in the wet

processing segment of the textile value chain. The industry can recover water and salts,

which may help improve the economics depending on the price of water in different

states. However, the textile sector as a whole has a considerably good business case for

ZLD as the impact on the end product for the sector is not very significant. In the textile

supply chain, increase in water cost majorly affects the wet-processing but does not

have a substantial impact on overall end product (garment in this case) pricing. The

impact of ZLD on a shirt would be less than 1% impact on the end product pricing for a

shirt that costs INR 6.5/250 g.

Figure 4: Comparison of Impact of ZLD on the End Product Price in textiles


1.4 Distillery Industry: Opportunity Exists even though Inroads have been made

into the Market

The potential market for Zero Spentwash Discharge (ZSD) in molasses based distilleries is

likely to be nearly INR (x) billion (USD (y) million) by 2020. A considerable portion of the

ZSD market in distillery sector has already been tapped due to the policy mandate.

However, with the sector expected to grow at a CAGR of 8.8%, the market potential is

likely to be stable at around INR (x) billion/year (USD (y) million/year) - (x) billion/year

(USD (y) million/year) between 2017 and 2020 after a relatively large near term (2016)

market opportunity of INR (x) billion (USD (x) million). The total operating expenses likely

to be incurred by molasses based distilleries from 2016 to 2020 is nearly INR (x) billion

(USD (y) million). As expected, the sugar producing states of Uttar Pradesh and

Maharashtra lead the pack in terms of likely market for ZLD, with the two states

accounting for almost 46% of the total market share by 2020 and a cumulative market

potential of INR (x) billion (USD (y) million) and INR (x) billion (USD (y) million)

With Zero Liquid

Discharge

Overheads – INR 24.05

Freight – INR66.95

Manufacturing & Finishing

- INR 245.63

Without Zero Liquid

Discharge

Overheads – INR 24.05

Freight – INR 66.95

Manufacturing &

Finishing – INR 239.14

Increase in cost due to

ZLD ~ INR 6.5/250g

Report Excerpt

respectively. The market demand in the Ganga basin states accounts for almost 38% of

the total market demand for ZSD in the molasses based distillery sector in the country. Source: Sustainability Outlook Analysis

The market potential for MEE alone would account for (x)% of the market in 2020, while

the investment for RO and Incinerator would be comparable at INR (x) billion (USD (x)

million) and INR (x) billion (USD (x) million) respectively. The smaller share of incinerator

in the market is a consequence of the high investment requirement and operational

difficulties like choking, clinker formation, etc., which has resulted in only 10% of the

sector taking it up as an option to achieve ZLD.

Figure 7: Market Potential as per Technology for Molasses Based Distillery till 2020


MEE RO Incinerator

in I

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Figure 5: Estimated Capital Market for Zero Spent Wash Discharge in Distillery (Molasses Based) by 2020

Figure 6: Operational Expenditure on Zero Spent Wash Discharge in Distillery (Molasses Based) by 2020

2016 2017 2018 2019 2020

in I

NR

Mill

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2016 2017 2018 2019 2020

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Mill

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/Ye

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Report Excerpt

1.4.1 Additional Revenue from By-product (Compost) of ZSD Leads to Partial

Recovery of Expenses

Zero Spentwash Discharge in the distillery industry has a business case. Although, a huge

initial investment is required and operating expenditure for treating the spentwash is

significant (17% - 20%) to the tune of INR 4-5/L of alcohol produced (excluding land cost)

in case of bio-methanation and INR 6-8/L of alcohol produced in case of incineration, but

there is recovery of atleast operating expenses due to additional revenue generated

from by product or savings on fuel. Bio-compostingleads to the production of bio-

enriched compost which can be sold in the market to generate additional revenues. The

distillery units adopting the incineration route are able to generate savings on fuel cost

by using the steam and power generated from the slop fired boiler.

1.5 Pulp & Paper: INR (x) billion (~USD (x) million) ZLD Market Contingent on Policy

Push

The pulp & paper sector in India, is one of the most polluting industry and third largest

consumer1 of fresh water. ZLD has not been achieved for the sector in any part of the

world and is currently economically unviable in the country due to the large effluent

volume generated by the industry. At the present scenario the OPEX incurred for

achieving ZLD is nearly INR 6,000/MT of product, which is too huge a sum for the

industry to sustain.

However the wood based pulp & paper industry is currently operating at much lower

efficiency in terms of water consumption with respect to the global best of 29m3/MT.

The Charter for Water Recycling & Pollution Prevention in Pulp & Paper Industry, aims at

making the industry water efficient and it can be expected that with stringent policies

stimulating the industry, the large wood based pulp & paper mills will most likely be able

to achieve the global best in terms of specific water consumption by 2020.

Driven by policy and with reduced specific water consumption, the sector will open a

new market for ZLD. Assuming, that the large wood based pulp & paper industry in India

will achieve the global best level of water consumption of approximately 29 m3/MT of

product and Indian regulations mandate the adoption of ZLD for this sector, the total

market potential for ZLD would be nearly INR (x) billion (~USD (y) million) by 2020.

However, the actual market penetration would primarily be governed by the policy

landscape in 2020.

Tamil Nadu shall lead the market for the sector, accounting for almost 15% of the total

market at INR (x) billion (USD (y) million). Andhra Pradesh, Maharashtra and Odisha

would account for almost 10% each of the total market share.

1 http://psa.gov.in/sites/default/files/Pulp___Paper_-Final.pdf

http://psa.gov.in/sites/default/files/Pulp___Paper_-Final.pdf

Report Excerpt

Figure 8: Market Potential for ZLD in Large Wood Based Pulp & Paper Industry across Different

States in 2020


The gross operational cost being around INR 160/kl of effluent generated has an impact

of about INR 6,400/MT of product produced for a 100 TPD plant. However, with the

sector achieving the global best and hence reducing the total effluent generated, the

OPEX is expected to reduce to around INR 3,700/MT of product. Moreover, considering

95% water recovery and 70-80% salt recovery, the operational cost is expected to

substantially reduce further.

Sustainability Outlook will continue to track progress of this space. To stay updated and

engage with us, please visit www.sustainabilityoutlook.in or contact us at

[email protected]

Figure 9: ZLD Cost Compared to Overall Production Cost in the Present Scenario and as Projected for 2020


15 21 15 18.7

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5

10

15

20

25

Production Costwithout ZLD

Production Costwith ZLD

Production Costwithout ZLD

Production Costwith ZLD

In IN

R/k

g

In 2020 Present Scenario

http://www.sustainabilityoutlook.in/

mailto:[email protected]

Report Excerpt

Annexure 7: List of Technology Suppliers/Vendors for ZLD S.No. Name Service City, Country Postal Address Website Phone

1 A.T.E. Envirotech Pvt. Ltd.

ZLD Equipment Supplier

Mumbai, India (Headquarter)

49A & 47A first floor, Virwani Industrial Estate Western Express Highway, Goregaon (East) Mumbai - 400063 India

www.ateenviro.com

Tel : (+91)-22-29271818 /1717

2 Aastropure Systems Pvt. Ltd.


Ahmedabad, India (Headquarter)

Plot No:404,GIDC Estate, Phase IV , Naroda Ahmedabad - 382 330, Gujarat - India

http://www.aastropure.com/

Tel: +(91) - (79) - 22817904, +(91) - (79) - 40081141

3 ABS Envirotech India Pvt Ltd


Chennai, India (Headquarter)

Old No: 324 / New No:468, MKN Road, F1, 1st Floor, Alandur, Chennai - 600 016,

http://www.absenvirotech.com/

Tel: +91- 44 - 4541 0820, 9444302337

4 Acmefil Engineering Systems Pvt. Ltd.



Plot No. 535, Phase II G.I.D.C, Vatva Ahmedabad - 382 445 Gujarat - India

http://www.acmefil.com/

Telefax: +91 79 2589 0722 / 2589 7872

5 Aeon India Corporation Pvt. Ltd.


Pune, India (Headquarter)

Aeon India Corporation Private Limited 64, Alankar Society, Karve Nagar, Pune-411 052. India.

http://www.aeonindia.com/

Tel: +91 20 6400 1111, 6500 3924

6 Aksh Engineering Systems Pvt. Ltd.



407, Radhekishan Arista, Opposite Hirabhai Towers, Uttamnagar, Maninagar Ahmedabad - 380008, Gujarat, India

http://www.akshengineering.com/

Tel: 09643337884

7 Aqua Designs ZLD Equipment Supplier


Off 200 Feet Road, Kolathur, Chennai - 600 099, Tamilnadu, India.

http://www.aquadesigns.in/

Tel: +91 44 37171717

8 Aquatech International Corporation

EPC Pennsylvania , USA (Headquarter) Pune, India (India office)

One Four Coins Drive Canonsburg, PA 15317 USA Telephone: +1 724 746 5300

http://www.aquatech.com/

Tel: +1 724 746 5300, Tel (India): +(91) 20 6654 7000

9 Arvind Envisol Pvt. Ltd.



Arvind Mill Premises, Naroda Road, Ahmedabad - 380 025, India

http://www.envisol.co.in/

Tel: +91-79-30138000

10 Balaji Thin Film Technlogies



31, Karm Industrial estate Near zaveri estate, Kathwada, Dist - Ahmedabad, Gujarat,India.

http://www.balajithinfilm.com/

Tel: 09712942756

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Report Excerpt

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47 Zion Enviro Systems Pvt. Ltd.



MEHTA VILLA, NO.72, BALAJI NAGAR, PADIKUPPAM ROAD, ANNA NAGAR, CHENNAI - 600 040.

http://www.zionenviro.com/

Tel: 044 - 4330 8333, +91 99400 32914, +91 99400 32910



Report Excerpt

Annexure 8: List of Organizations in Ganga Basin which Received Notice from

NGT S.No.

Name and Address of the Unit District State Type of Industry

Water Consumption (industrial) (m3/day)

Waste Water Generation (m3/day)

1 Indian Oil Corporation Limited, Oil Refinery

Begusarai Bihar Chemical 12000 7200

2 United spirits Ltd. Patna Bihar Distillery 640 66

3 Budhiya Textile Bhagalpur Bihar Textile & Dyeing

3 1.5

4 JJ Exporters Bhagalpur Bihar Textile & Dyeing

10 5

5 Tassat Dyeing Bhagalpur Bihar Textile & Dyeing

10 5

6 Hindustan coca cola beverages Pvt. Ltd.

Patna Bihar Food & Beverage

150 85

7 Patna Dairy Patna Bihar Food & Beverage

600 300

8 ITC ltd( India tobacco division) Munger Bihar Other 411.9 250

9 N.T.P.C. Ltd. Bhagalpur Bihar Other 70348 3407

10 Barauni Thrmal Power Station Begusarai Bihar Other 4350 5051

11 United Paper boards Private Patna Bihar Pulp & Paper 1091 475

12 Bata India Ltd. Patna Bihar Tannery 1200 400

13 Bata India Ltd. Patna Bihar Tannery 100 66

14 Jubilant Industries Limited (Polymer Unit)

JP Nagar Uttar Pradesh Chemical 206 104.2

15 Jubilant Life Sciences Limited (Chemical Unit I)

JP Nagar Uttar Pradesh Chemical 3599 1365

16 Jubilant Life Sciences Limited (Chemical Unit II)


17 Merino Industries Ltd. Ghaziabad Uttar Pradesh Chemical 1500 200

18 Synthetic Silica Prod. Kanpur Uttar Pradesh Chemical 10 12

19 Peacock Pigment Pvt. Ltd. (New Name Axis Nirman and industries Ltd.)

Kanpur Uttar Pradesh Chemical 24 26

20 Daurala Sugar Works (Chemical Unit)

Meerut Uttar Pradesh Chemical 3625 3600

21 Daurala Organics (A unit of D.C.M. Sri Ram Ind. Ltd.)

Meerut Uttar Pradesh Chemical 2400 1600

22 IFFCO Uttar Pradesh Chemical 33000 14200

23 Kribhco Shyam Fertilizer Ltd. Uttar Pradesh Chemical 24000 110

24 IFFCO Ltd. Uttar Pradesh Chemical 34200 4712

25 Jubilant Industries Limited (Fertilizer Unit)


26 Duncan Fertilizers Uttar Pradesh Chemical 7590 3460

27 Government Opium and Alkaloid Works

Varanasi Uttar Pradesh Chemical 200 170

28 Swedeshi Insecticides Pvt. Ltd. Kanpur Uttar Pradesh Chemical - -

29 Swedeshi Pesticides Pvt.Ltd., Kanpur Uttar Pradesh Chemical - -

30 Deys Medical Stores Manu.(U.P) Ltd.

Allahabad Uttar Pradesh Chemical 50 40

31 . Teva API India Ltd. Bijnor Uttar Pradesh Chemical 1200 265

32 Agjonoble India Ltd.(Ici), Kanpur Uttar Pradesh Chemical 1.5 6.5

33 Bee Chem Ind., Kanpur Uttar Pradesh Chemical 15 2.5

34 Nibi steels Ltd.(Chemical division Mau Uttar Pradesh Distillery 80 56

35 The Kisan Sahkari Chini Mills Ltd.(Distillery Unit)

Mau Uttar Pradesh Distillery 1950 450

36 Keser Enterprises (Distillery Unit) Bareilly Uttar Pradesh Distillery 10240 5120

37 Majhola Distillery & Chemical Works

Bareilly Uttar Pradesh Distillery 2896 1448

38 United Spirits Ltd. Unit Shajhanpur Uttar Pradesh Distillery 1458 729

39 Superior Industries Ltd.(Distillery Division)

Bareilly Uttar Pradesh Distillery 600 300

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738 Kashipur Sugar Mills Ltd. Kashipur Uttarakhand Sugar 2000 1500

739 Aroma Craft & Tissues Private Haridwar Uttarakhand Pulp & Paper 3875 2712.5

740 Sagar Paper Mills Pvt Ltd. Haridwar Uttarakhand Pulp & Paper 3.4 2.38

741 Uttranchal Pulp & Paper Mills (P) Haridwar Uttarakhand Pulp & Paper 450 150

742 PMC Rubber Chemicals Hooghly West Bengal Chemical 2599 1440

743 United phosphorus Ltd. Purba medinipur

West Bengal Chemical 325 150

744 Hindustan Unilever Ltd. Kolkata West Bengal Chemical 350 175

745 Indian oil corporation Purba mednapur

West Bengal Chemical 16133 10005

746 Haldia Petrochemicals Ltd. Medinipur West Bengal Chemical 32731.2 11470

747 MCC PTA Corp .Pvt. Ltd. Haldia West Bengal Chemical 33780 37780

748 I FB Agro Industries Ltd. Burdwan West Bengal Distillery 2357 935

749 United Brewaries Ltd. Nadia West Bengal Distillery 975 810

750 Aditya Birla Nuvo Ltd. Hooghly West Bengal Textile & Dyeing

2599 2400

751 Dhunseri Petrochem & Tea Ltd. Purba Medinipur

West Bengal Food & Beverage

1104 552

752 Mother Dairy Calcutta Hooghly West Bengal Food & Beverage

935 700

753 Britannia Industries Ltd. Kolkata West Bengal Food & Beverage

238 206

754 Diamond Beverages Pvt. Ltd. Kolkata West Bengal Food & Beverage

760 380

755 Bengal Beverages Pvt. Ltd. Hooghly West Bengal Food & Beverage

1150 450

756 Dankuni Coal Complex Coal India Ltd.

Hooghly West Bengal Other 1750 1000

757 Eveready Industries India Ltd. Unit

Kolkata West Bengal Other 45 22.5

758 Hindustan Motors Ltd. Kolkata West Bengal Other 680 800

759 Emami paper Mills Ltd. Kolkata West bengal Pulp & Paper 1120 900

760 ITC Limited Paper Boards & Speciality

Hooghly West Bengal Pulp & Paper 12990 15140

761 Supreme Paper Mills Ltd. Nadia West Bengal Pulp & Paper 1760 1232

762 Shree Renuka sugars Purba medinipur

West Bengal sugar 720 520

763 Khaitan (India) Ltd. Nadia West Bengal Sugar 395 90

Report Excerpt

Annexure 9: List of Industries Issued Closure Notice by CPCB Regarding

Failure of Installation of Online Monitoring Systems Textile Industry

S.No. Name District State Date of Notice

1 A.R. Polymers (P.) Ltd. Fatehpur Uttar Pradesh 18-Jan-16

2 Elgin Mill Co. Ltd. (Unit- 1, 2)

Kanpur Uttar Pradesh 18-Jan-16

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Malwan) Fathpur Uttar Pradesh 18-Jan-16

26 Reliance Industries Ltd. (Unit-1, 2) Allahabad Uttar Pradesh 18-Jan-16

Distillery Industry

S.No. Name District State Date of Notice

1 Lokmangal Agro Industries Ltd. Solapur Mahrashtra 29-Apr-16

2 Bannari Amman Sugars Ltd. Mysore Karnataka 29-Apr-16

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78 Majhola Distillery & Chemical Works Bareilly Uttar Pradesh 18-Jan-16

Pulp & Paper Industry

S. No. Name City/District State Date of Notice

1 Victory Paper & Boards Ltd. Palakkad Kerala 29-Apr-16

2 Mahadev Pulp Products Pvt Ltd. Kanpur Uttar Pradesh 26-Apr-16

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35 Shree Shaym Pulp & Board Mills Ltd (Unit 1)

Kashipur Uttarakhand 29-Dec-15

36 Shree Shaym Pulp & Board Mills Ltd (Unit 2)

Kashipur Uttarakhand 29-Dec-15

Report Excerpt

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h-sustainability-zero-liquid-discharge-756544

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http://sustainabilityoutlook.in/content/market/march-sustainability-zero-liquid-discharge-756544

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