1. Azher Uddin Khan Managing Director NEC Consultants Private Limited
Water, Wastewater, and Industry
Azher Uddin Khan Managing Director NEC Consultants Private Limited

2. Sources
The World Bank, “Evaluation of Industrial Environmental Management-Pakistan”, 2010
Cleaner Production Institute, “Program for Industrial Sustainable Development”
Cleaner Production Institute, “Environmental Improvement in Pakistan: The Way Forward”, 2013
WWF-UK and Cleaner Production Institute, “City-wide Partnership for Sustainable Water Use and Water Stewardship in SMEs in Lahore, Pakistan (WSP)”, Switch Asia,
Urban Unit, “Energy Audit of 1,600 tube wells and disposal pumps of Five Major Cities of Punjab”, The World Bank, 2016.
Combined Effluent Treatment Plants for S-III Project-Karachi, Kornagi Tanneries-Karachi, Sundar Industrial Estate, Faisalabad Industrial Estate, Qauid-e-Azam Industrial Estate, National Industrial Parks, and more than 200 industrial units.
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3. Industry and Wastewater Profile of Pakistan
Small industrial base and bound to grow;
About 20 large and 80 small industrial estates are operating without any wastewater treatment facilities;
About 20% of industrial units are highly polluting with respect to wastewater pollution loading;
The major industries are: oil refineries, textile, pharmaceutical, chemicals (organic and inorganic), food industries, ceramics, steel, sugar mills, paper mills, oil mills and leather tanning etc.;
Largest concentrations of industries are in Karachi and central Punjab;
Estimated shares of municipal and industrial wastewaters discharges are 70% and 30%, respectively;
Estimated shares of municipal and industrial pollution loading are 50% each.
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4. Industry and Wastewater Profile of Pakistan
Estimated wastewater discharges in the sea is 2-3 MCM per day, and share of industrial wastewater discharges is about MCM per day;
Estimated inland wastewater discharges are 6-9 MCM per day, and industrial wastewater discharges are 2-3 MCM per day;
Punjab represents about 65% of inland industrial wastewater discharges i.e MCM per day;
Potential of polluting 20 times fresh surface water resources of its volume;
Already polluted fresh water groundwater resources in cities.
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5. Estimated Pollution Loads by Biological Parameters and Treatment Cost (Margin of Error +/-20%)
2017
(Ton Per Day)
2025
Inland
In sea
Total
Total BOD5
8,300
1,350
9,650
11,350
1,800
13,150
Total COD
18,550
3,000
21,550
25,500
4,000
29,500
Total TSS
90,000
2,900
92,900
124,000
3,800
127,800
Wastewater discharges (MCM Per Day)
7.5
2.5
10.0
11.0
4.0
15.0
Estimated Treatment Cost (Rs. Billion)
250
375
50% of this cost is for Industrial Wastewater Treatment
125
188
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6. Concentrations at Discharge Point and Drain Confluence for Common Parameters of Wastewater
Expected concentrations of effluent (mg/liter)
Concentration of drain effluent prior to discharge of effluent (mg/liter)
Standards (mg/liter)
BOD 80
COD
150
TSS
07-14
200
Source: Cleaner Production Institute Database
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7. Length of Major Rivers Where Water Quality is Affected by Human Activity
Source: Ministry of Water and Power, “Pakistan Water Sector Strategy: National Water Sector Profile”, Volume 5, October 2002
Notes: a-Length of the river reaches adjoining to cities and villages
b-12% length of the river reported to have depleted DO
c-Length of the river reach between Lahore and Balloki
d-24% of length of the river reported to have no DO during low flow period, which is prevalent except for the monsoon season
e-Lengths of the river reaches between Peshawar and Nowshehra
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8. Rivers Water Quality Monitoring of Dissolved Oxygen (DO) Data 2010-12
NO of
DO Concentration (mg/l)
Percentage within
Samples
Min
Median
Max
Criteria Value (4 mg/l)
KABUL 24
5.7
8.1
8.8
100
HARO 12
6.2
9.2
SOAN
0.2
2.0
6.4 17
JHELUM
6.1
9.4
CHENAB 48
2.3
7.3
9.3 98
RAVI
Vicinity of Lahore 36
0.1
6.8
9.0 78
Downstream of Lahore
0.3
8.7 86
SUTLEJ 41
4.6
6.7
10.5
INDUS 93
5.1
7.8
10.0
Overall
326
7.4
10.50
Source: Environmental Improvement in Pakistan: The Way Forward”, 2013 research study – Conducted by Cleaner Production Institute
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9. A Qualitative Comparison of Alternate Biological Treatment Processes
Parameter
Activated Sludge
Trickling Filters
UASB Reactors
OP & CW
Typical BOD Removal Efficiencies
> 90 %
70 – 80 %
60 – 75 %
Plant Area Requirement
Minimum: of the Same Order
Very High
Operation and Maintenance Cost
High
Moderate
Low
Minimum
Process Energy Requirement
Nil
Operational Supervision & Control
Construction Cost
High: of the Same Order
Capital Cost
High [1]
Process Mechanical Equipment
Yes No
Quantities of Sludge Produced
OP: Oxidation Ponds
CW: Constructed Wetlands
[1] Largely depends upon the cost of land
Source: Environmental Improvement in Pakistan: The Way Forward”, 2013 research study – Conducted by Cleaner Production Institute
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10. Major Questions What to treat: Heavy Metals BOD, COD, TSS
Where to treat:
At industry discharge point
At industrial estate discharge point
At drains discharge point to the river
How to treat
Heavy metal recovery plants
Individual treatment plants
Combined effluent treatment plants
What to conserve
Water, chemicals, and energy

11. General Framework of Cleaner Production
Cleaner Production is a series of environmental solutions, implemented in a logical sequence of small steps that leads to much smaller and cost effective end-of-pipe solutions.
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12. Relevant Industrial Sectors
Leather
Pulp and Paper
Edible Oils and Ghee
Sugar
Fertilizer
Textile Cotton Processing
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13. Relevant Industrial Sectors
Petro Chemicals
Industrial Chemicals
Pesticides and Insecticides
Dyes and Pigments
Cement
Dairy
Steel
Automobile
Textile Polyester Processing
Pharmaceuticals
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14. Approaches for Cleaner Production
United Nations Industrial Development Organization promotes eight approaches for minimizing waste at source.
Good House Keeping
Better Process Controls
Equipment Modification
On-site Recovery/Reuse
Production of Useful By-Products
Input Substitution
Technology Change
Product Modification
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15. Better Process Controls Equipment Modification On-site Recovery/Reuse
Out of eight UNIDO CP approaches, practical implementation experience exists for five approaches: List of Cleaner Production Option.pdf
Good House Keeping
Better Process Controls
Equipment Modification
On-site Recovery/Reuse
Production of Useful By-Products
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16. Good House Keeping
Good house keeping includes resource conservation and better working practices.
Relevant Industrial Sectors: Paper, Leather, Textile, Sugar, Pharmaceutical, Edible Oil, Dairies, Industrial Chemical, Pesticides & Insecticides, and Dyes and Pigments.
Water Conservation Measures:
Adoption of batch washing instead of continuous
washing
Controlled water utilization for floor washing
Recycling the water of vacuum presses
Installation of flow measurement valves
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17. Good House Keeping Optimisation of recycling of water
Installation of high pressures nozzles for high speed
filtration
Improving the efficiency of vacuum pumps for
recycling
Proper coordination between in-charges of different
processes for optimising water conservation
Implementation of these measures has reduced the water consumption in the range of 30-50%.
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18. Good House Keeping – Other Cleaner Production Options
Training on environmental Auditing, monitoring,
environmental management system, ISO 14000
frameworks, and good working practices.
Improvement in raw material storage and handling
Spillage control of molasses, fibres, trimmings,
fleshing in the drains
Proper management of hazardous chemicals and
wastes
Reduction in Hydraulic Load: %
Pollution Load Reduction: %
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19. Better Process Control
Better process control includes the modification of working procedures, machine instructions, and process record keeping.
Relevant Industrial Sectors: Sugar, Leather, Textile, Paper, Edible Oil, Fertilizer, Petrochemical, Cement, Steel, and Automobile.
Improvement of gear boxes, bearings, and other equipment
Installation of oil skimmers
Establishment of in-house environmental laboratories
Improvement in the efficiency of evaporators
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20. Better Process Control
Fly ash removal from scrubbing water
Salts minimization in wastewater
Application of biodegradable and less hazardous
chemicals
Better fixation of chemicals and optimised recipes
formulations
Reduction of hazardous wastes
Pre-cleaning of the raw material with dry and wet
processes
Counter current washings
Reduction in pollution load: 8-15%
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21. Equipment Modification
Equipment modifications are mostly opted for increasing the efficiency of the manufacturing process and reducing the pollution load.
Relevant Industrial Sector: Textile, Paper, Sugar, Pesticides & Insecticide, Cement, and Pharmaceutical.
Installation of economizer and condenser to reduce the natural resource consumption and air emissions.
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22. Equipment Modification
Shift from co-current mode to regeneration of resin
to counter current to reduce boiler blow down, salt &
chemical consumption, and water and gas
consumption.
Installation of reverse osmosis plant to reduce
wastewater generation and gas consumption
Pulp-dewatering
Insulation of digesters
High pressure nozzles
Reduction in Pollution Load = 10-20%
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23. On-site Recovery/reuse
On-site recovery and reuse options are implemented with the objectives of recycling of waste materials, reduction in pollution load, and generating extra revenue for the companies.
Relevant Industrial Sectors: Leather, Sugar, Paper, Textile, Petrochemical, and Cement.
Chrome recovery and re-use plant in tanneries
Recycling of sulphide liquor after removal of
hairs in tanneries.
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24. On-site Recovery/reuse
Recovery of oil through oil skimmer in sugar mill
Fibre recovery and re-use of caustic after processes of
mercerising and scouring in textile mills.
Optimising the operations of heat exchangers for
energy efficiency in textile mills.
Efficiency: 70-98% recovery of reusable material, pay back period 6 months to one year.
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25. Production of Useful By-products
This option is applies to transform the generated waste into material that can be reused for other applications outside the company.
For Example:
In tanneries fleshing and trimmings of wet-blue
leather can be used for chicken feed, leather board,
and glue manufacturing.
In paper mills the recovered fibre can be used for
manufacturing of paperboard.
Manufacturing of compost by mixing the mud cakes
with the distillery wastewater.
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26. Business Case for Water Conservation
Scenario
Textile
Tannery
Paper
Sugar I S P 01 6 5 7 02 18 19 23 25 03 15 20
I=Investment (Rs. Million), S=Savings (Rs. Million), and P=Payback Period
Source: City-wide Partnership for Sustainable Water Use and Water Stewardship in SMEs in Lahore, Pakistan
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27. Financial Viability of Environmental Investments in Dyeing Mills(Rupees in Million)
Investments/Savings
Year-1
Year-2
Year-3
Year-4
Year-5
Total
Large Dyeing Mills
Capital Investment
3.36
8.03
10.04
3.03
34.50
Saving (CP + Charge)
6.10
6.58
7.54
8.26
8.98
37.47
Net Savings
2.74
-1.45
-2.50
-1.78
5.95
2.97
Cumulative Saving -
1.29
-1.20
-2.99
Medium Dyeing Mills
2.48
2.03
5.04
1.53
16.12
Saving (CP + Change)
3.11
3.35
3.84
4.20
4.57
19.07
0.63
1.32
-0.83
2.95
1.95
0.75
-0.08
Small Dyeing Mills
1.88
3.04
0.73
9.42
1.70
1.84
2.12
2.32
2.59
10.51
-0.18
-0.92
1.59
1.79
1.09
-1.38
-2.30
-0.71
Note: Totals do not tally due to rounding error.
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28. Recommendations
Cleaner Production can be best implemented under a solution development framework under which all pollution prevention options at source and resource conservation options at the process level are investigated and implemented which have direct impact on the size and cost of the end-of-pipe treatment systems’.
CP options offer about 30% reduction in the size of environmental investments. These are easy to implement and are sustainable with good financial paybacks.
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29. Recommendations
CP options can be best implemented with the involvement of industry technicians and management. Process technologist develops the most effective solutions after the identification of environmental problem by the environmental engineers.
Best tools for identifying the areas of CP options implementation are material balances and water balances.
CP options are not replacement to end-of-pipe treatment systems in all cases. These have the potential to reduce the size of end-of-pipe treatment and resource conservation.
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30. Recommendations
Provide legal cover to cleaner production Options under PEPA’s.
Adopt a realistic and practicable holistic approach, originating from the natural waters and ending at the required wastewater treatment.
Establish the ambient water quality requirements or standards, for the natural water bodies.
Provide and operate combined public wastewater treatment systems, for achieving the established ambient water quality standards in the receiving surface waters.
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31. Recommendations
Public organizations, responsible for the execution and OM of the combined wastewater treatment facilities, to be separated from the respective environmental regulatory bodies, in their structure and functioning. OM of the combined wastewater treatment facilities may be outsourced to private water companies, to off-load the governments.
The federal and provincial governments shall, within their areas of jurisdiction, levy and collect appropriate Environmental Charges, on account of the provision of combined treatment facilities, from different categories of the polluters, connected to these facilities.
Treatment for Specific pollutants at source, to comply with the specified Emission Standards, and not at the combined treatment facilities
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