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

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

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

4. About Indian Textile Industry-Water
Approx. waste water volume of Indian textile industry = 3000 Million litre / Day.
Most centers are water scarce.
Water source of most center’s is ground water.
Waste water recycling is very low
Potential additional investment in water / waste water = Rs crore (€ 3.5 BILLION)
Potential Annual T.O in water / Waste water
= Rs crore (€ 1 BILLION)
Possible daily fresh water saving= MLD

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

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

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

8. Water status

9. Water status

10. Eco Concept of Industry

11. Cleaner Production

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

13. Case studies
Surat, Gujarat
Balotra, Rajasthan

14. Surat, Gujarat (Synthetics Textile Processing Centre)

15. Surat, Gujarat (Synthetics Textile Processing Centre)
Present Water Scenario
Total water consumption is approx. : MLD
Water cost is ranging between : Rs 18/-Rs. 40 / KL ( € 0.25 to € 0.60)
Ground water and river water are major sources of water
Cont….

16. Surat, Gujarat (Synthetics Textile Processing Centre)
Sr. No
Parameters
Unit
Effluent
Inlet
Surface Discharge
Industrial recycling water quality 1 pH -
6.5 – 9.0
5.5 – 9.0
6.5 – 8.5 2
BOD (3 C)
MG/L
400 30
BDL 3
COD
1200
100
< 30 4
TDS
2100
< 500 5
Suspended Solids (SS)
280 6
Oil & Grease 10

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

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

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

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

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

22. Balotra, Rajasthan (Cotton Textile Processing Centre)
Present Water Scenario
Balotra is a land locked area in Rajasthan Desert.
350 Process houses, mainly small process house, engaged in cotton dyeing, Printing and processing they are spread in 5 areas.
Total water consumption is approx. : MLD
Water cost is ranging between : Rs. 35 to 70/ KL (€ 0.50 to 1.0)
Source of water is ground water.
Cont….

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

24. Balotra, Rajasthan (Cotton Textile Processing Centre)
Sr. No
Parameters
Unit
Effluent
Inlet
Surface Discharge
Industrial recycling water quality 1 pH -
6.5 – 9.0
5.5 – 9.0
6.5 – 8.5 2
BOD (3 C)
MG/L
700 30
BDL 3
COD
2400
100
< 30 4
TDS
20000
2100
< 500 5
Suspended Solids
800 6
Oil & Grease 10

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

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

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

28. Municipal waste water potential

29. Municipal waste recycling industrial water / Plantation green belt water
Top 150 cities of India : Population
300 Million
Per capita waste water generation (Conservative)
30000 MLD (Mill. Lts / Day)
(100 Lits / Day per person )
Capex Requirement
€ 18 Billion +pipelines
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30. Business Opportunities
Cost effective water / waste water treatment / recycling technologies; Water frugal Technologies
Disposal technologies of leftover concentered effluent. Marine outfall or drying or any other option for zero discharge.
Quality control technology for water / waste water technologies.
Reduction of specific water consumption per kg of textile processed (reduction at source).
Cleaner Production technologies / Techniques
Cluster based approach.
Energy Efficiency.

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

32. Thank You شكرا لك When you refuse to reuse, it's our earth to abuse
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