Water Conservation - June 19-2017

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© 2017 Confederation of Indian Industry
All rights reserved.
No part of this publication may be reproduced, stored in retrieval system, or transmitted in

any form or by any means electronic, mechanical, photocopying, recording or otherwise,
without the prior written permission from CII – Sohrabji Godrej Green Business Centre.
While every care has been taken in compiling GreenCo Education Material - Water
Conservation, CII – Sohrabji Godrej Green Business Centre and supporting organizations
accept no claim for compensation with respect to any wrong, abbreviated, omitted or
incorrectly inserted content in the book. The book is only an attempt to create awareness
and share best practices on Water Conservation.
Published By
CII – Sohrabji Godrej Green Business Centre
Survey No 64, Kothaguda Post
Near Hitec City
Hyderabad - 500 084
India
Tel: +91 40 44185111, 101
Fax: +91 40 44185189
Acknowledgement
GreenCo education material has been made possible through the efforts of core committee members
and staff. We extend our deepest gratitude to :
1 Mr. Hussain Shariyarr, Manufacturing Head and Senior VP, Godrej Appliances Division, Godrej &
Boyce Mfg. Co. Ltd.
2 Mr K N Rao, Director - Energy and Environment, ACC Ltd.
3 Mr Narayan P. S., General Manager & Head - Corporate Sustainability, Wipro Technologies
4 Dr L Ramakrishnan, Distinguished Professor & Head, Indsearch Centre of Sustainability
Management, Pune
5 Mr. Abhay Pathak, Sustainability Lead, Tata Motors Ltd.
6 Mr. Venkataraman, VP – Marketing, ITC PSPD Ltd.
7 Mr. P N Sridhar, RM (South), ITC PSPD Ltd.
8. Mr. Ramani Iyer, Forbes Marshall
We also thank other industry stake holders for their contribution in developing GreenCo guidelines.
GreenCo - Water Conservation | 5

Contents
11 | 1. Introduction
11 | 1.1 Global Scenario
12 | 1.2 Current Status in India
12 | 1.2.1 Water Demand
12 | 1.2.2. Water Resources
13 | 1.2.3 Water Scarcity
14 | 1.3 National Initiatives
14 | 1.3.1 National Water Policy
14 | 1.3.2 National Water Mission
15 | 1.4 Industrial Water Usage
15 | 1.4.1 Fresh Water Contamination and Treatment
16 | 1.4.2 Water Intensive Sectors
18 | 2. Water Metering and Monitoring
18 | 2.1 Benefits of Better Water Measurement
18 | 2.2 Flow Water and Flow controllers

Contents
20 | 3. Water management in industries & best practices
20 | 3.1 Approach to water management within & beyond the fence
24 3.2 Approach to process water management
40 | 4. WATER HARVESTING
41 4.1 Rainwater Harvesting Techniques in Urban Area
43 | 4.2 Rainwater Harvesting Techniques in Rural Areas
46 | 4.3 Designing Rainwater Harvesting System
47 | 5. Case Studies
56 | 6. Resources
57 | Annexure A: GreenCo Introduction and Background

Executive Summary At the GreenCo Summit 2014, GreenCo
Education Committee was launched with
The growth of countries across the world is
a mission to enhance the knowledge &
leading to increased consumption of natural
build capacity of the nation to global green
resources. There is an urgent need to establish
standards. One of the key deliverables
environmental sustainability in every activity
of the education committee is to publish
we do. In a modern economy, environmental
GreenCo education material on all aspects
sustainability will play a critical role in the
of environment sustainability like renewable
growth strategy of an organization.
energy, greenhouse gas emissions mitigation,
India declared its new action plan to combat water conservation, waste management, green
climate change known as Intended Nationally supply chain, product stewardship and life
Determined Contribution (INDC) with a goal to cycle assessment. GreenCo education material
reduce the emissions intensity of its GDP by 33 to will serve as a reference document for GreenCo
35 percent by 2030 from 2005 level. According Accredited Professional Exam.
to the India GHG report 2015, Industrial
The competition for scarce amounts of water
processes and product use contributed to
will become more and more prominent for
8% of India’s total GHG emissions. The Indian
industries in years to come and they will need
industry will need to take several initiatives to
to develop and rely on aggressive water-saving
reducing its GHG intensity and help the nation
technologies to remain competitive. Freshwater
in achieving its INDC goals.
resources are limited and need to be managed
In 2011, CII- Sohrabji Godrej Green Business wisely in order to avoid the current crisis from
Centre through an extensive stakeholder worsening. Industries need to prioritize water
consultation and interaction with experts management as part of business management
has developed Greenco, Green Company and at the same time work towards the
Rating System to help the Indian Industry in community as their water interests are
evaluating and improving their environmental interlinked. GreenCo education material on
performance. GreenCo acts as a milestone for water conservation provides the reader with
companies pursuing green to assess where they information on the global scenario of water
stand and help in defining the path forward. availability and demand, water metering and
GreenCo has evoked great interest by the monitoring, water management in Industries,
Indian industry and as of June 2017, more than rainwater harvesting, best practices across
250 companies have embarked on this journey sectors and other resources.
and 116 companies have been certified.

1. INTRODUCTION
1.1 Global Scenario
Excerpts from Reports –
(a) ‘Facts & Trends version 2’ by World Business
Council for Sustainable Development
(b) ‘Business in the world of water’ by World
Business Council for Sustainable Development
Everyone understands that water is essential

to life. But many are only just now beginning
to grasp how essential it is to everything in life
– food, energy, transportation, nature, leisure, Figure 1: Distribution of the 0.5% of freshwater
identity, culture, social norms, and virtually Source of Figure 1: ‘Facts & Trends version 2’
all the products used on a daily basis. With by WBCSD
population growth and economic development
driving accelerating demand for everything,
the full value of water is becoming increasingly
apparent to all.
Businesses cannot afford to ignore this trend.
For some it means new economic opportunities
in making water available to meet demand or in
finding solutions to improve water quality and
water use efficiency. For others, it means closer
scrutiny of how they, their supply chains, and
their markets access and use water, and of how
new business risks emerge as they compete Figure 2: Areas of physical and economic water
with other users. In any case, it is time for scarcity
businesses of all sectors and sizes to add water Source of Figure 2: Earthscan and International
to their strategic thinking. Water Management Institute, “Water for Food,
Water for Life: A Comprehensive Assessment
Where is freshwater found?
of Water Management in Agriculture”, 2007,
Less than 3% of the world’s water is fresh – the
London: Earthscan, and Colombo: International
rest is seawater and undrinkable. Of this 3%
Water Management Institute.
over 2.5% is frozen, locked up in Antarctica, the
Areas of physical and economic scarcity have
Arctic and glaciers, and not available to man.
been highlighted in Figure 2 and explained
Thus, humanity must rely on this 0.5% for all of
below:
man’s and ecosystem’s fresh water needs.
In the near future – as a result of changes in • Little or no water scarcity: Abundant water
both human and natural systems that affect resources relative to use, with less than 25%
water availability, access, affordability, and of water from rivers withdrawn for human
quality – the water management challenges purposes.
facing humanity will become more complex. • Physical water scarcity: Water resources
The prospect of water shortages, scarcities, development is approaching or has
and stresses will increase.

exceeded sustainable limits. More than 75% and demand from 2025-2050: Business as usual
of river flows are withdrawn for agriculture, scenario & issues’, the total water demand is
industry and domestic purposes (accounting projected to increase by 22 % by 2025, and
for recycling of return flows). by 32 % by 2050 as shown in the table. A
• Approaching physical water scarcity: More major part of the additional water demand is
than 60% of river flows are withdrawn. for the domestic and industrial sectors. The
These basins will experience physical water water demands of the domestic and industrial
scarcity in the near future. sectors will account for 8 % and 11 % of the
total water demand by 2025. And these shares
• Economic water scarcity: Human, will increase to 11 % and 18 %, respectively, by
institutional and financial capital limit 2050. Moreover, the domestic and industrial
access to water even though water in nature sectors will account for 54 % of the additional
is locally available to meet human demands. water demand by 2025, and more than 85 %
Water resources are abundant relative to by 2050.
water use, with less than 25% of water from
rivers withdrawn for human purposes, but 1.2.2. Water Resources
malnutrition exists. According to the National Environment Policy
It is to be noted that all of India is shown in (NEP) 2006:
either approaching physical water scarcity, “India’s freshwater resources comprise
physical water scarcity or economic water the single most important class of natural
scarcity. There isn’t a region of India shown endowments enabling its economy and its
under little or no water scarcity. human settlement patterns. The freshwater
resources comprise the river systems,
1.2 Current Status in India groundwater, and wetlands. Each of these has a
Excerpts from Reports – unique role and characteristic linkages to other
environmental entities. (MoEF, 2006: 28)”
(a) ‘India’s Water Supply and Demand from
2025-2050: Business- as- Usual Scenario and 1.2.2.1 Rainwater
Issues’ by Upali A. Amarasinghe, Tushaar The long-term average rainfall for the country
Shah, and B.K.Anand, International Water is 1,160 mm, which is the highest in the world
Management Institute for a country of comparable size. Owing to
physiographic factors, rainfall in India is highly
(b) ‘Water in India: Situation & Prospects’ by
variable. More than 80 percent of the annual
UNICEF, FAO, SaciWATERs, 2013
run-off of the rivers occurs in the monsoon
(c) ‘Water Scarcity and Security in India’ by Dr. months of June to September, often causing
Narayan Hegde floods. However, acute water shortage is faced
1.2.1 Water Demand in many parts of India during the rest of the
year. Even in areas such as Cherrapunjee in
SECTOR BCM) 2000 2025 2050
Meghalaya, where there is surplus rainfall, the
Irrigation 605 675 637 soil may not be able to retain the water for long
Domestic 34 66 101 thereby causing water scarcity.
Industrial 42 92 161 1.2.2.2 Rivers
Total 680 833 900 According to the report, ‘Water in India:
Situation & Prospects’, the average water
According to the report, ‘India’s water supply
resources potential of river basins in India is
12 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

projected to be 1,869 BCM. It is estimated that
owing to topographic, hydrological and other
constraints, the utilizable water is 1,123 BCM
which comprises of 690 BCM of surface water
and 433 BCM of replenishable ground water
resources.
The entire country is divided into 20 river
basins/group of river basins comprising twelve
major basins: 1.Indus; 2.Ganga-Brahmaputra-
Meghna, 3.Godavari, 4. Krishna, 5.Cauvery,
6.Mahanadi, 7.Pennar, 8.Brahmani-Baitarani,
9.Sabarmati, 10.Mahi, 11.Narmada and 12.Tapi.
Each of these basins combining suitably
together all the other remaining medium
and small river basins are: 1.Subernarekha
– combining Subernarekha and other small
rivers between Subernarekha and Baitarni,
2. East flowing rivers between Mahanadi and
Pennar, 3. East flowing rivers between Pennar Fig 3: State-wise Status of Groundwater
and Kanyakumari, 4.Area of inland drainage Resources (2004)
in Rajasthan Desert, 5.West flowing rivers of According to the report, ‘India’s groundwater
Kutch and Saurastra including Luni, 6.West challenge and the way forward’ by PS Vijay
flowing rivers from Tapi to Tadri, 7.West flowing Shankar, Himanshu Kulkarni, Krishnan, the
rivers from Tadri to Kanyakumari and 8.Minor rate of withdrawal of groundwater has
rivers draining into Myanmar(Burma) and reached “unsafe” levels in 31% of the districts,
Bangladesh. covering 33% of the land area and 35% of the
1.2.2.3 Groundwater population. The situation has dramatically
According to the report, ‘Water in India: worsened within a short span of nine years,
Situation & Prospects’, India is the largest between the assessments done in 1995 and
consumer of groundwater in the world with 2004. There is enough evidence of increased
an estimated usage of 230 km3 per year. pressure on aquifers and the resulting
Approximately 60 per cent of the demand from hydrological imbalance. The amount of water
agriculture and irrigation, and about 80 per available matters but so does its quality. Out of
cent of the domestic water demand, is met 593 surveyed districts of India, more than 35%
through groundwater. As per the Department districts have problems like high F, As, Ni, Fe,
of Drinking Water and Sanitation nearly 90 etc.
per cent of the rural water supply is from 1.2.3 Water Scarcity
groundwater sources. According to the report ‘Water Scarcity and
The notion of groundwater as a private Security in India’ by Dr. Narayan Hegde, the
resource, the rights of which are associated demand for water in India is steeply increasing
with land rights, has led to an exploitative because of the following reasons:
extraction regime.
• India’s population which is 1.32 billion in
2016 is expected to rise to 1.66 billion in
2050.

• There is also going to be a major impact on • Establishment of National and State level
development in the form of urbanization. data banks to monitor the demand and
In 2007, 28.2% of the Indian population supply;
was living in urban areas and the urban • Facilitation for transformation of available
population is expected to increase to 55.2% water resources into utilizable water;
by 2050.
• Non-conventional methods for efficient
• As the per capita income of Indians will water use;
increase from $468 in 2007 to $6735
in 2050, the purchasing power will also • Supply of water from water surplus areas to
increase. This will have a direct impact on water shortage areas;
the calorie intake putting greater pressure • Judicious allocation of water for different
on existing water resources. uses and pricing of water to ensure
• Increased industrialization will demand sustainable development;
more water as its contribution to GDP • Regulation on ground water exploitation
will increase from 29.1% in 2000 to 40% and close monitoring of water table using
by 2050. Thus, the demand for water will modern scientific techniques;
increase from 30 billion m3 in 2000 to 161 • Sustainability of existing water bodies,
billion m3 in 2050. involving all the stakeholders and local
• The agriculture development will be more communities;
on water intensive cash crops and there will • PPP for water resource development and
be 80% increase in the demand for water by distribution;
2050.
• Master plan for flood control, by linking
different rivers and promoting soil
conservation measures;
• Development of drought prone areas
through watershed development,
afforestation and sustainable farming
Fig 3: Water Availability per Capita practices;
Source: Water in India: Situation & Prospects
by Unicef • Interstate water sharing policy and timely
A per capita availability of less than 1,700 addressing of disputes.
cubic metres (m3) is termed as a water- 1.3.2 National Water Mission
stressed condition while per capita availability The main objective of the National Water Mission
below 1,000m3 is termed as a water scarcity is “conservation of water, minimizing wastage
condition. and ensuring its more equitable distribution
both across and within States through
1.3 National Initiatives
integrated water resources development and
Excerpts from GoI- Ministry of Water Resources,
management”. The five identified goals of the
River Development & Ganga Rejuvenation
Mission are: (a) comprehensive water data
website
base in public domain and assessment of
1.3.1 National Water Policy impact of climate change on water resource; (b)
The salient features of India’s National Water promotion of citizen and state action for water
Policy, 2002 are: conservation, augmentation and preservation;

(c) focused attention to vulnerable areas • Transportation and segregation of solids
including over-exploited areas; (d) increasing • Washing of process lines, process
water use efficiency by 20%, and (e) promotion equipment, etc.
of basin level integrated water resources
management. • Firefighting applications
For achieving the objectives of the National • Indoor domestic use (bathing, drinking,
Water Mission, long-term sustained efforts both kitchens, and laundries)
in terms of time bound completion of identified • Landscape irrigation
activities and ensuring the implementation of
1.4.1 Fresh Water Contamination &Treatment
identified policies and enactment of necessary
legislation through persuasion at different S Contamina-
levels with the State Governments have been Treatment method
No tion
envisaged. Some of the important activities
Suspended
which are planned to be completed in a time
matter that Gravity settling in settling
bound manner on priority are- 1
could be tanks
• Comprehensive water data base in public settled
domain and assessment of the impact of Suspended Coagulation and floccula-
climate change on water resources 2 colloidal tion in a clarifier followed
• Promotion of citizen and state actions for particle by filtration
water conservation, augmentation and Coagulation and
preservation flocculation along with
• Focused attention to vulnerable areas oxidising biocide in clari-
Organic
including over-exploited areas 3 fier followed by filtration
matter
• Increasing water use efficiency by 20% and if required filtration
through activated carbon
• Promotion of basin level integrated water Filters
resources management
Colour and Aeration, clarification,
4
1.4 Industrial Water Usage odour activated carbon filtration
Excerpts from CII Water Manual, 2007 Aeration, degasification
Dissolved
Water is an essential resource for the industries. 5 and activated carbon
gases
Industry depends on water, much like filters
agriculture and domestic households depend Softening through ion
on water. In industry, water is generally used 6 Hardness exchange resin in sodium
for the following applications- form, soda lime softening
• Cooling of steam in condenser, use in heat Ion Exchange demineral-
Dissolved
exchangers for the cooling of liquid, gas and 7 isation, Reverse osmosis,
salts
solids, in humidifiers and chilling units Multi stage evaporators
• Scrubbing of gases and for dust suppression
• Steam generation in boilers
• As an ingredient of the product
• For washing of product in different stages of
the process

1.4.2 Water Intensive Sectors Assembly Plants
The following industries are considered water • cooling of welder tips
intensive- • rinsing operation while applying
Textile Industry: corrosion protection metal phosphate
• boilers layer
• dyeing and rinsing of yarn • electrostatic dip unit (DM water)
• humidification of the yarn • for cooling of the paint solution, water

is used in the chillers or in the open
• air washers for maintaining humidity circulating cooling tower
Soft water and demineralized water is used for • car wash operation
bleaching and dyeing of fibers. Demineralized
water is used for conditioning the air in the • air conditioner unit as well as in the
spinning and weaving shop. operation compressors.
Pulp and Paper Industry: Chemical Industry:
• steam production • cooling applications
• pulp preparation • boilers for steam generation where

heating is required
• transport of fibers and for making of
paper • hydraulic conveying, hydraulic
classification, washing and equipment
Automobile Industry: cleanup
Foundry Operation • firefighting
• scrubbing of gas • Water used in the process may
• direct cooling of cupola / furnace sometime become a part of the product
• granulation of slag tapped from the Food Processing Industry:
furnace • In food industry the quality of water
Machining Operation is very important, especially the water
which goes along with the product.
• clarified water and sometimes soft
water in case of hard water for making • Mainly three types of water are used
coolants in food processing industry viz. process
water, cooling water and boiler feed
• cleaning of parts
water.
• boilers for steam generation and for the
• Process water is used for washing of
cooling in heat exchangers
raw materials and process equipment,
• paint spray booths conveying product from one area to
• cleaning of the parts after stamping another process area, dissolving or
extracting, and addition to the finished
Metal Plating products.
• Both clarified as well as demineralised • Cooling water is used to condense steam
water are used in the process from evaporators or turbines, in the

operation of refrigeration equipment, by making the metal into fine powder
to cool process equipment like cookers, slurry.
compressors, jacket cooling, etc. Aluminum Industry:
• Boiler feed water is used for the steam • used as a solvent in the process.
generation for heating application or
for power generation and to use the • steam produced in the process is used
extraction steam in the process. for heating in various stages and the
condensate is used in the boilers.
Sugar Industry:
• used as a media to transport the solids
Sugar industry is one of the largest water users from one unit to another unit.
in the food processing sector. Water is used to
wash sugar cane, for steam production as well • used as a medium for wet grinding of
for cooling application. the ore.
Beverage Industry: • contact cooling of vapors and barometric
condensers
• steam generation
Steel Industry:
• cooling of compressors and refrigeration
equipment, • indirect cooling by heat exchangers
- closed cycle cooling systems are
• washing of bottles and containers, normally used
equipment, etc.
• direct cooling- water is in direct contact
• Some portion of the water may go along with the material in granulation of the
with the product products, de-scaling, scrubbing of gases
Mining: the effluent become dirty and needs
• removal of unwanted minerals from the continuous treatment.
surrounding of the ore • indirect condensation of gases, wet
• processing of the ore collected dust removal, cooling of furnace
components, quenching of slag, cooling
• media for transporting the finely of different parts of converters, cooling
crushed ore for cleaning and for further of furnace and ladlers, cooling of ingot
processing and electrodes, in hot rolling mills and
• water spray is used to control the dust in cold rolling mills
suppression as well as for hydraulic Copper Industry:
mining
Copper is produced through dry and wet
• In coal processing, coal is washed in a process depending on the nature of the ore.
slurry bath to remove the clay and dust Copper wire bars are rolled to make sections,
or ash content and to increase the heat cables and wires. During this process, the de-
value. scaling of the metal surface is done with water.
• In metal mineral, large quantity of Petroleum Industry:
water is used for separating the
In petroleum industry 80 % water is used for
metal containing ore fraction from
cooling applications. Other applications include
the contamination by means of froth
boiler feed water and domestic consumption.
flotation or by magnetic separation

Power sector: conservation programme
• condensing the steam in turbines and • Accounting for individual water use
for the cooling of equipment combined with pricing policies that
• boilers for the production of steam penalize excessive use.
• In coal based thermal power plants, • At least 2% of the water saving can be
water is required for the evacuation easily achieved by just measuring and
of solid waste, fly ash from the Electro monitoring in the plant.
Static Precipitator and bottom ash 2.2 Flowmeters and flow controllers
from the boiler. Water from cooling
tower blow down can be used for this Excerpts : www.krohne.com
application. Electromagnetic flowmeters
2. Water Metering and Monitoring Mass flowmeters

Ultrasonic flowmeters
Monitoring and measurement are two most
important things in effective industrial water Variable area
management. It is applicable in case of both Flowmeters
water and electricity; if you cannot measure it Vortex flowmeters
you cannot conserve it.
Flow controllers
2.1 Benefits of Better Water
Electromagnetic flowmeters
Measurement
The measurement principle of electromagnetic
Besides proper billing for water usage, many
flowmeters (EMF) is based on Faraday’s law of
benefits can be derived by upgrading water
induction. EMF can measure the volume flow
measurement programs and systems. Although
of any electrically conductive liquid medium,
some of the benefits are intangible, they
even those with low conductivities.
should be considered during system design or
when planning water measurement upgrade. Typical applications include:
Good water management requires accurate • Water industry: revenue metering, district
water measurement. Some benefits of water metering, water abstraction, leakage
measurement are: detection
• Accurate accounting and good records • Wastewater industry: transport networks,
help allocate equitable shares of water sewage treatment plants, sludges
between competitive uses both on and • Food & beverage industry: mixing, dosing
off the plant. and filling of drinks under hygienic
• Good water measurement practices conditions, filling systems applications
facilitate accurate and equitable • Chemical industry: acids, alkalis, dosing
distribution of water within district or applications, abrasive or corrosive mediums
farm, resulting in fewer problems and
easier operation. • Pulp & paper industry: pulp, pastes, sludges
and other caustic mediums, liquor, additives,
• Proper recording and monitoring leads bleaches, colourants
to develop a clear Water balance of any
• Metal & mining industry: mediums with a
plant which is the primary key to water
high solid content, like ore or excavator mud

Mass flowmeters addition in reactor control metering,
The function of mass flowmeters is based on demineralised water
the Coriolis principle. They allow for a direct • Petrochemical refineries: feedstock, cooker
measurement of mass flow, density and feed flow, cracking, desulphurisation,
temperature of liquids and gases as well as residues, blending of crude oil and refined
calculation of volume flow and mass or volume product
concentration with a single device. • Petrochemical plants: feedstocks (e.g.
Typical applications include: naphtha and natural gas), (intermediate)
products such as ethylene, propylene,
• Chemical: measurement of concentration
solvents
or density, bulk loading, batching to
reactors, hydrocarbon cracking, aggressive, • Oil & gas industry: measurement of crude oil
abrasive or viscous mediums or mediums of and refined product, natural gas, liquefied
unknown composition natural gas (LNG) and biogas; standard and
custody transfer applications in production,
• Food & beverage: filling machine
pipeline transfer and leak detection, loading
applications, measurement of degrees
and off-loading, storage and distribution
Brix, flow, density, specific gravity, additive
components dosing • Water/utilities: demineralized water, water
purification, effluent, compressed air
• Pharmaceutical: batching, dosing and
filling, solvent extraction ultra-pure water • HVAC: metering of chilled water and
measurement hot water for (custody transfer) energy
measurement
• Water & wastewater: flocculent dosing,
sludge flow and density measurement Variable area flowmeters
• Pulp & paper: paper stock, pulp, additives, Variable area flowmeters are suitable for
bleaches, colourants measuring pure liquids and gases. They have
• Oil & gas: metering skids, bypass density an upright conical tube made of metal, glass
measurement, CNG/LPG dispensers, leak or plastic, in which a float moves freely up and
detection, custody transfer applications down. The flow through the tube causes the
such as tanker loading, bunkering and float to rise until the forces are in equilibrium.
pipeline transfer Typical applications include:
Ultrasonic flowmeters • Measurement and dosing of additives such
Using the transit time method, ultrasonic as catalysts, surfactants, foam and corrosion
flowmeters measure liquid and gaseous inhibitors, caustic soda, chlorine or sulphur
mediums. substances, etc.
• Inerting of tanks or containers
Typical applications include:
• Measurement and dispensing of rinsing
• Power plants: cooling water and
mediums (purge meters)
demineralised water, steam, thermal oil
(HTF), molten salt • Sample feed measurement for analyser
systems
• Chemical industry: metering of liquid
hydrocarbons and low-conductivity liquids, • Dosing and monitoring of lubricants and
including feedstock, solvents, chemical coolants for bearings and seals for process

pumps and rotating machinery electromagnetic flow controllers monitor
• Hygienic applications in the food and or measure the flow speed of electrically
pharmaceutical industries conductive liquids.
• Measurement of gases and chemicals in Typical applications include:
laboratoriesand test facilities • Largely homogenous liquids, pastes.
• Gas/oil burner consumption measurement suspensions and sludges, even with solid
content
Vortex flowmeters
Vortex flowmeters are based on the principle 3. Water management in industries
of the Kármán vortex street and are used in & best practices
main as well as auxiliary and supply processes. Industries have adapted a two pronged
Capable of compensating for different approach for water management:
temperature and pressure conditions, they • Within the fence and
measure the volume flow of both conducting
• Beyond the fence
and non-conducting liquids, industrial gases
and steam. 3.1. Approach to water management
within the fence & beyond the fence:
Applications include measurement of:
• Saturated steam and superheated steam The Industrial sector compared to the
agriculture and municipal sectors offers
• Hot steam, also for CIP and SIP processes excellent opportunities for water conservation
• Liquefied gas, wet gas and flue gas and management. The industry water
• Demineralised water and boiler feed water consumption within the fence assumes
enormous significance due to the fact that
• Solvents and heat transfer oil
results of various efforts on water conservation
• Steam boiler monitoring are truly rewarding. The rewards may be either
• Compressor output monetary benefits due to the water and saving
due to the implementation of several projects
• Consumption in compressed air systems
or reduction of fresh water withdrawal. The
• Burner consumption approach to water management within the
Mechanical flow controllers fence in Indian industry may address the
following aspects leading to higher water use
Mechanical flow controllers work via a spring-
efficiency:
mounted baffle that changes its position as
flow increases. Adjustable switches generate • Reduce, reuse & recycle in industries/
alarms once switching points are reached. buildings
Typical applications include: • Reuse of treated municipal waste water in
industries
• Local indication of flow without power
supply – cooling systems, pump protection, • Augmentation of water resources
lubrication control or cavitation alarm, for
instance
Electromagnetic flow controllers
Based on Faraday’s law of induction,

in toilet flushing
This further enhances the reduction of the
waste water discharge and in turn increases the
percentage recycling of treated effluent back
in to suitable high and low end applications.
The increase in percentage of recycling of
treated effluent leads all our activities towards
approaching zero water discharge.
Reuse of treated municipal waste water in
Reduce dependence on fresh water by Reduce, industry:
Reuse & Recycle in industries and buildings The objective is to promote the reuse and
This approach enables industry to achieve recycle of treated municipal waste water in
a minimum of 30% reduction in the water industry. This offers enormous scope for the
consumption. This can be achieved with the reduction in the withdrawal of fresh water
use of metering and monitoring on a regular consumption for industrial applications. The
basis and the use of suitable innovative cost quality of secondary treated water from
effective technologies by using the 3R principles municipalities would be suitable for non-potable
of reduce, reuse and recycle. The potential consumption in the industry with appropriate
water conservation opportunities exist in the treatment. The industries may consider this as
following common applications in any industry- an additional water resource for consumption
thereby reducing the dependence on fresh
Utilities water resources.
• Cooling towers Augmentation of water resources:
• Filter backwash The cost effective method for augmentation of
• Reuse of boiler and cooling tower blow available water resources is through artificial
down recharging. This brings in multiple benefits to
• Recovery of condensate of air handling the industry within the fence such as the water
units (AHUs) is free; the only cost is for collection and use.
Process The end use of harvested water is located close

to the source, eliminating the need for complex
• Cascading of processes- Re-use of rinse and costly distribution systems.
water from various stages based on
quality Rainwater provides a water source when
groundwater is unacceptable or unavailable, or
• Reuse of condensate water it can augment limited groundwater supplies.
Domestic The zero hardness of rainwater helps prevent
• Installation of water saving faucets and scale on appliances extending their use;
fixtures for toilet flushing rainwater eliminates the need for a water
softener and the salts added during the
• Use of centralized RO for drinking water
softening process.
supply
Potential availability meets atleast 3 months
• Use of treated water from STP and ETP
of industrial water requirements during non-

monsoon months for potable and non-potable Additional costs might include -
applications. • Energy cost for heating, pumping,
Rainwater harvesting is practical only when the treating water
volume and frequency of rainfall and size of • Treatment costs
the catchment surface can generate sufficient
water for the intended purpose. From a financial • Maintenance costs
perspective, the installation and maintenance
costs of rainwater harvesting system for potable
water cannot compete with water supplied by Indian companies are now expected to discharge
a central utility, but is often cost-competitive their stakeholder responsibilities and societal
with installation of a well in rural settings. obligations, along with their shareholder-
With a very large catchment surface, such as wealth maximization goal. Nearly all leading
that of big commercial building, the volume corporates in India are involved in corporate
of rainwater, when captured and stored, can social responsibility (CSR) programmes in
cost-effectively serve several end uses, such as areas like providing access to drinking water,
landscape irrigation and toilet flushing. education, health, livelihood creation, skill
development, and empowerment of weaker
Find out the true cost of water sections of the society.
It is also very important for organizations to Though industry is consuming only 8% of the
measure the true cost of water. This involves available fresh water resources it carries the
looking at – responsibility of a corporate to safeguard the
interest of all stakeholders competing for the
available water resources. Availability of water
has a direct impact on the business. Highly
water intensive industries can get affected
by external changes that can result in steep
increase in water costs, leading to production
delays, limits on production and strong
community opposition to its activities.
Industries need to approach this situation
by identification of partnerships with local
communities, water authorities, NGOs and
other organizations. Water related projects that
• water bills from the last 2-3 yrs – note could support local communities by improving
annual consumption and cost water quality for drinking and sanitation, for
• Identify any trends of patterns such use in agriculture are some of the ways of
as seasonal variations or unexplained mitigating the possible risks to business due to
increases sharing of water resources. Business needs to
adapt to competition with other water users.
• Consider associated costs such as
energy requirements The strategies may be directed towards
innovating to significantly increase value chain
• Read water meter regularly and product eco-efficiency, investing in the
restoration of ecological systems that affect

water flow and engaging in collaborative pumps used,
strategies for maintaining water resources over • water-saving irrigation methods and
time.
• overall regulation and prioritization of
The concepts of public private partnership water use.
projects and public private community
partnership projects have been in vogue. 3.2 Approach to process water
Industry plays a pivotal role in engaging management
all stakeholders in such projects towards 3.2.1 Automobile
realizing the twin objectives of corporate social
responsibility and reaching out the benefits Major water uses in the automotive sector
to other stakeholders sharing the fresh water include:
resources. 1. Surface treatment and coating
2. Paint spray booths
These projects can bring in mutual benefits to all 3. Washing/rinsing/hosing
stakeholders, opportunity to create livelihood, 4. Cooling
expertise of private sector in leveraging projects, 5. Air conditioning systems and
involvement of Government within budgetary 6. Boilers
provision to implement more projects and
facilitate attainment of water positive status The following is a list of water conservation
for Industry. projects implemented by various automobile
manufacturers that has resulted in the
Science of hydrogeology plays a crucial role reduction of SWC for their respective units:
in sustainable groundwater management.
The first step in sustainable management
of groundwater is to carefully construct a
disaggregated picture by mapping aquifers and
delineating aquifer typologies. Disaggregated
aquifer maps and database management system
will make it possible to determine sustainable
yield for each aquifer. This gives the amount of
groundwater available that is to be divided and
allocated between competing uses and users.
There is a need to bring this information to the
communities residing outside the facility to
enable them to take informed decisions about
their water resources.
Thus, sustainable management of groundwater
involves:
• enhancing recharge through protection
of the recharge area,
• controlling the depth and spacing of
wells,
• regulating capacity and efficiency of

Typical water
S. Typical water
Brief description of the project saving poten-
No. conservation projects
tial (m3)
Cascading system in Reuse of good quality water from the farthest
01 36,500
paint shop end of the paint shop for initial rinsing
Wasted paint stripping Rerouting of the paint stripping water to a over-
02 water in the paint shop head tank in which the bypassed water would en- 15,600
ter after a mist spray to have effective cooling
Level sensors and sole- Installation of level sensors & solenoid valves at
03 15,000
noid valves different locations in the paint shop.
Oil chiller unit instead of Machine cooling tower replaced with chiller unit
04 cooling tower to prolonged coil life and reduce water consump- 11,700
tion
Sensor equipped spray Auto sensing of car to start spray instead of con-
05 zones tinuous spray in all spray zones of pretreatment 9,000
plant in paint shop
RO reject as scrubber Reuse of RO reject water as scrubber wash water
06 5,000
wash water in paint desludge pit
Mechanical evaporator Recycling of condensate from mechanical evapo-
07 condensate reuse rator through the RO plant for cooling towers and 4,500
washing machines
Industrial water pres- Reduction of production hours pressure from
08 sure reduction. 3.5kg to 2.5kg for 22days & non production hours 5,500
pressure from 2.5kg to 1.5kg for 22days
Rinse tank overflow to In Pretreatment tank area, Rinsing tank overflow
09 degassing tank water is recycled to top up the water at degreas- 3,000
ing tank. Use of cyclic timer for water top up.
Elimination of chassis Reduction of dust accumulation on chassis by im-
10 washing before painting proving storage facility and bypassing the need to 5,069
wash
3.2.2 Beverages
Major water uses in the beverage industry include:
1. Steam generation
2. Cooling of compressors
3. Refrigeration equipment
4. Washing of bottles and containers
5. Washing of equipments
The following is a list of water conservation projects implemented by various beverage manufacturers
that has resulted in the reduction of SWC for their respective units

S. Typical
Typical water
Brief description of the project water saving
No. conservation projects potential (m3)
1 Steam Condensate Steam Condensate recovery
recovery in CIP Final 2600
Rinse
2 Backwash Water Backwash water is treated with coagulation system
Recovery (Coagulation tank- Intermediate tank- Sand filter-
12500
Carbon filter- 5u - UV) and then used for the final
product
3 Bottle washer water Wash water is subjected to online disinfection and
recovery then passed through a sand filter to reduce turbudity.
102400
The recoverd water is used for soft water purpose to
minimise beverage quality risk
4 Bottle wash water Bottle washer nozzle size reduction to optimize
optimization consumption, Control unit maintaining constant
pressure along with interlock for cutting water supply 21900
incase of machine stopage, Rotary jet system to
eliminate wastage when there is no bottle
5 PET Rinse recovery Test rinse water for contamination with beverage
trace, color, odor and microbes. If the rinse water is
2560
free of all the above contaminations it is directed to
the raw water tank
6 Paramix Vacuum pump Sealing water to passed through a plate heat exchanger
sealing water recovery with chilled glycol circulating through the tubing. 5120
7 Homogenizer seal
12000
cooling recovery
8 Interlocking of Final As soon as Bottle washer stops infeed water also stops
rinse water in Bottle 10000
washer with main drive
9 AF RO Reject recycles AFRO reject is sent to the ETP and final reject is sent to
through secondary a solar pond 8892
treatment.
10 Aquafina rejected The rejected water is collected in a tank and then
bottle water recovery treated with coagulation system (Coagulation tank-
500
Intermediate tank- Sand filter- Carbon filter- 5u - UV)
and then used for the final product
3.2.3 Cement
Major water uses in the cement sector include:
1. Raw mill
2. Coal Mil
3. Dust suppression

4. Washing/rinsing/hosing
5. Cooling
6. Boilers
The following is a list of water conservation projects implemented by various cement manufacturers
that has resulted in the reduction of SWC for their respective units.
Typical
Typical water
S.No. Brief description of the project water saving
conservation projects
potential (m3)
1 Closed water cooling Cooling tower
systems for cement 112000
mills
2 Air cooled condenser Less water consumption and waste water
11850
generation
3 Thermo scope Thermo scope (camera used inside the kiln)
cooling water into requires a constant supply of water for cooling.
2376
cooler tank The return water is directed to the cooler tank
and surplus is used for gardening
4 High efficiency MMC Cooler, High efficiency preheator fans,
108000
equipments Membrane bags in Raw Mill Bag house
5 Fresh air damper Installation of fresh air damper at cooler outlet
to control hot gas temperature, thereby reducing 1020
the water consumption
6 Dry sieving through Samples of cement subjected to wet sieving for
sieve shaker determination of cement fitness every hour. Wet
490
sieving is replaced with dry sieving through sieve
shaker
7 Reuse of crusher Crusher compressor return water connected to
compressor return return line instead of pumping to mines 3650
water
8 Collection and Steam was condensed and pumped into the
recycling of autoclave process area tank 9125
steam
9 Size reduction of raw Size reduction of raw mill feed resulting reduction
mill feed in consumption of water required for material 24090
bed formation
10 Pond ash in cement Use of Pond Ash in Cement Mills resulting
14600
mills reduction in cooling water requirement
3.2.4 Engineering
Major water uses in the engineering sector include:

1. Steam Generation
2. Auxiliary cooling
3. Washing/rinsing/hosing
4. Cooling towers
5. Domestic purposes and
6. Gardening
The following is a list of water conservation projects implemented by various engineering companies
that has resulted in the reduction of SWC for their respective units
Typical
Typical water
conservation projects
potential (m3)
Spray system in the ventilation plant is replaced
Spray system
with CELDEK Media, wherein a small quantity of
replaced with Celdek
1 water with the help of 3 hp pump-set is sufficient 3000
system for ventilation
for pumping water to cool air through CELDEK
plants.
Media.
Ultrasonic Treatment in cooling tower of
Ultrasonic Treatment
2 compressor and eliminating use of chemicals & 1000
in cooling towers
desalting agent.
Natural draft cooling Replacement of forced cooling draft towers with

3 3120
tower natural cooling towers decreasing drift losses
FRP cooling tower

4 720
instead of wood type
Air cooled Replacing water cooled compressors with air

5 1095
compressors cooled compressors.
Closed loop water Introduction of closed loop water system in air

6 14040
system compressor water circuit
Mechanical seal
Providing Mechanical seal in place of gland
7 inplace of gland 340
packing to pumps to arrest leak
packing
Direct utilization
Roof top rain water is collected and pumped to
8 of rain water for 380
cooling tower water tank after filtration
industrial purposes
Water consumption in surface treatment and
Rotameters at bath cleaning lines could be monitored and controlled
9 13140
inlets easily so that each bath gets the optimum flow
rate reducing water wastage

Optimization of batch production by increasing
10 Electroplating plant batch sizes. Introduction of spraying system in 6000
rinse process
3.2.5 Fertilizer
Major water uses in the fertilizer industry may include:
1. 80% water is used for cooling application
2. Steam generation
3. Boiler application
4. Gardening
5. Domestic
Typical
Typical water conservation
projects
potential (m3)
Recovery of CO2
1 Modification of piping 7920
Compressor condensate
Reduction is cooling tower Installation of cellular type of drift

2 175200
drift losses eliminator
Utilization of vaccum pump Used as cooling water for the sulfuric acid
3 seal water as forecooler dilution coolers in thePhosphoric acid 144000
cooling water plant
Utilization of phosphoric
acid plant cooling Blowdown water used as cake wash water
4 72000
blowdown water in in the Phosphoric acid plant
phosphoric acid plant
During plant upset conditions effluent
contains higiammonical nitrogen content.
Installation of Water To make this water reusable, it is sprayed
5 Spraying system in into a guard pond and ammonia is 28000
Ammonical Guard Pond stripped as the sprayed water comes in
contact with air. This water is then used as
RO feed, irrigation etc.
Inter-stage condensate of Condensate produced in Interstage
6 compressor area as cooling cooling at air compressor, 2 compressor is 25000
water make up pumped to cooling water return header
Installation of water cooler
A water cooler was installed instead of
7 to control Diesel tank 5000
spraying water over the diesel tank
temperature

Recycle of Captive power
8 plant steam condensate to 25000
DM plant
An ejector was installed to divert service
Utilization of service boiler
boiler flue gas to effluent pit. The re-
9 flue gas for neutralizing 10000
circulating effluent was used as a motive
alkaline effluent of DM plant
fluid for the ejector
Atmospheric air is cooled upto 15 deg.
C at the gas turbine inlet through LIBR
Recycling of Gas turbine air
10 chiller. The condensate from the gas 80000
condensate to cooling tower
turbine inlet air chilling is diverted to
cooling tower supply
3.2.6 Paper
Excerpts from CPCB report - DEVELOPMENT OF GUIDELINES FOR WATER CONSERVATION IN PULP
AND PAPER SECTOR (Submitted by NPC), 2006
Water in a paper plant is used in the following applications-
1. Raw material preparation
In raw material preparation section water is primarily used for de-pithing, wet cleaning (in case of
agro residues), log washing, chipping (in case of wood).
2. Pulping section
In pulping section, water is primarily required for following unit processes /operations:
(a) Blow heat recovery system
(b) Brown stock washing
(c) Bleaching, washing and bleach chemical preparation
(d) Decker thickener showers
(e) Pulp dilution at different stages
(f) Pump gland cooling/sealing & floor washing
In waste paper pulping section water is primarily required for following unit processes/operations:
(a) Hydropulper
(b) De-inking plant (floatation cells)
(c) Decker thickener shower
(d) Pulp dilution
(e) Centricleaning
3. Paper machine section – stock preparation & paper making
The major processes in stock preparation and paper making section are the chemicals preparation,
pulp dilution, paper making. In this section water is primarily required for following unit processes

/operations- a. Pressure washing: Pressure washing is
(a) Chemical preparation similar to vacuum drum, but differs by
spraying water under pressure through
(b) Pulp dilution the pulp mat as the drum rotates.
(c) Centricleaning b. Diffusion washing: Diffusion washing is a
(d) Felt cleaning shower counterflow process that takes place in
(e) Wire section high pressure shower one or more stages. Pulp flow is upward
and is carried on a perforated plate.
(f) Couch press roll lubrication tower
Water flows downward through a series
(g) Felt lubrication shower of baffles.
(h) Pick up roll lubrication c. Chemi or Belt washing: A chemi or
(i) Breast roll shower belt washer is perhaps the simplest
(j) Broke pit showers, couch pit showers, washing system in terms of design. It
etc. offers excellent washing with reduced
water usage. Belt washing is a counter
(k) Thickener showers flow process where pulp enters the
4. Chemical recovery plant washer area on a wire belt. Washing
takes place under a series of showers.
In chemical recovery plant the water is
Clean water enters on the opposite end
primarily required for the following unit
from the pulp and is sprayed vertically
processes /operations:
through the pulp. The used wash water
(a) For maintaining barometric leg in the is then collected and reapplied to the
evaporator (Old evaporators without dirtier pulp by the next washing head.
surface condenser) and in the lime kiln Countercurrent to the direction that the
(b) Vacuum pump sealing, centrifugal pump pulp moves. This process is continued
gland cooling/sealing through at least seven stages until the
(c) Spout cooling wash water is saturated with liquor after
washing immediately coming pulp. The
(d) Evaporator tube cleaning wash water is then sent to the recovery
(e) Lime kiln dryer bearing and roller cooling process. Diffusion washing and belt
(f) Floor washing washing can reduce the amount of water
used per tonne of pulp in brownstock
5. Utilities washing by 50% or more according to
(a) DM plant – feed, back wash, cooling published data.
tower make up Due to long payback period, Chemi
(b) Boiler house – cooling tower make up, washer is more feasible in a new
compressor, ID Fan bearing, pump gland installation or when new washer is
cooling & sealing, dust suppression, etc. required to replace a vacuum drum
Water Conservation Opportunities – washer that has reached the end of its
service life.
1. Use of Better pulp washing technology
instead of obsolete technologies like d. Twin roll press washer: Twin wire roll
potcher washing press washer consists of a twin-wire

dewatering unit which allows controlled water is required as a make up for the
washing of the pulp. The two-sided evaporation loss.
dewatering and strong turbulence of 3. Optimum use of wastewater from sealing
the washer facilitate two to three times & cooling of vacuum pumps
higher capacities per unit of width than
conventional washer technologies. In most of the industries, fresh water is used
An additional main feature of this for sealing/cooling in vacuum pumps of paper
technology is that the ash and fines machine section. Vacuum pumps are used to
removal can be controlled depending supply vacuum to vacuum drum pulp washers,
on the targeted levels. This technology wire section, press section and dryer section
can be used for high consistency pulp of the paper machine. Vacuum pumps are
washing and resulting in reduced water typically liquid ring pumps which use water for
consumption. sealing and cooling. Water usage is continuous
and high depending upon the size of the pump.
2. Optimum use of cooling wastewater
The wastewater is mostly non-contaminated
In every mill, cooling with water is required and suitable for recycling back after passing
at various sites like pump gland cooling/ through a cartridge filter. At present, the
sealing, steam turbine cooling, compressor wastewater from this source is either
cooling, refiner gland cooling, rewinder brake discharged outside directly or sent to ETP. This
cooling, etc. In most of the industries, fresh filtered water can also be used in the pulp mill
water is being used for pump jacket cooling on for pulp dilution, decker thickener showers,
once through basis. This water is most of the brown stock washing, etc.
time non-contaminated. There are different
alternatives in which this water use can be 4. Installation of Vacuum flume tank to
optimized as described below: recycle vacuum pump sealing water
(a) Collection of once-through cooling Sealing wastewater from all the vacuum pumps
water and reuse it in different in paper machine section is collected in a
process operation: Collection involves tank and by the action of centrifugal action,
installation of several small sumps or suspended particles are separated from it. 50%
tanks from which water is subsequently of the clear filtrate goes back to vacuum pump
pumped to process water tanks. It is as sealing water and rest is collected in water
also possible to directly use the water conservation tank. In the water conservation
for specific applications like shower tank, fresh water is added as make up and is
systems. The higher temperature of recycled back to the plant for different uses as
cooling wastewater is advantageous to mentioned above.
the shower system as it increases the Saving in fresh water consumption by this
water drainage property of the web. option has been estimated to be 14.3 m3/
(b) Converting once-through system into tonne of product.
a closed –loop system: This requires 5. Replacement of water seals in Process
installation of cooling tower, a Pumps
temperature controller and a cartridge
filter to remove any suspended particles Seal water used in various pumps can be
present in the waste cooling water.
Further, periodic injection of fresh

eliminated by replacing with mechanical face regular monitoring of low pressure and
and lip seals. Seal water flows are typically not high-pressure showers and in the paper
very high, but are continuous and can add up to machine section
large volumes over time. Replacing water seals Paper machine showers are one of the largest
with mechanical seals usually increases energy users of fresh water in any pulp and paper mill,
consumption due to friction. Sealless pumps it is necessary to optimize water use in paper
are commonly used in Chemical industries. machine shower system. Design of an efficient
An example of a sealless pump is a diastolic shower system depends on the total number
tube pump where magnetically coupled pump of shower nozzles, type of nozzle: needle jet,
transmits power from the motor to the pump flat type, etc., the locations of the nozzles, jet
with a magnetic pump. Pumps with braided angles and the distance between nozzles.
packing seals and a self – lubricating compound
are also available. These lubricants have a For new plants, it is advisable to have only
colloidal mixture of lubricants amalgamated optimum numbers of paper machine felt/wire
with Aragraphe fibers. Replacement of water to minimize the water use. Further, it has been
lubricated seals not only reduces water observed during field studies that most of the
consumption but also reduces the occurrence pulp and paper mills do not have any pressure
of equipment damage, maintenance time and gauge attached to the showers. Further, nozzle
wastewater generation. shape gets deformed due to corrosion and
other reasons with time. This results in large
In some mills, pressurized air has been found consumption of fresh water.
to be used instead of water as sealing agent in
vacuum pumps. 8. Use of high-pressure low volume showers
6. Use of efficient Decker thickener/ vacuum It is known fact that high-pressure showers
drum showers consume lesser quantity of water and therefore
can save water.
It was found that in most of pulp and paper
mills, Decker thickener as well as vacuum drum 9. Use of back or recycled water in low-
shower contained drilled perforation instead pressure showers
of nozzles. This results in large consumption Clarified paper machine wastewater can be
of fresh water. An optimum nozzle design (e.g. used in low pressure showers used as felt sprays
Needle jet type, flat type, etc) with maintenance after passing through a multiplex filter unit or so
of appropriate pressure in the pipeline ensures depending upon the quality of clarified paper
optimum water consumption. Also with the machine wastewater achieved in the save all.
passage of time, nozzle diameter gets widen
The various locations where this water can be
due to corrosion. It is therefore recommended
used are: Wire section: Breast roll, wire turning
to monitor the functioning of showers regularly
and wire-return rolls, knock – off shower, trim
maintaining required pressure in the showers.
knock – off shower, wire cleaning shower (low
Further by installing oscillating showers at
pressure).
bleaching and high pressure nozzles at pulp and
paper sections improve the washing efficiency Press section: Cleaning of rolls
and reduce quantity of water required for The characteristics of recycled water that can
washing. be used in the paper machine section is as
7. Use of efficient shower system and given below-

Solids con- Recommended use (b) Vacuum washers,
tent (mg/l) (c) Centri cleaner reject dilution,
0 - 50 Equivalent to filtered fresh wa- (d) Pulp dilutions before bleaching stage
ter and can be used anywhere (e) Johnson screen showers
50 - 75 Can be used in fixed orifice noz-
zles of 1mm diameter and larger Further, clarified water storage tank can be
modified to enable further separation of fibres
from the filtrate. One such design has been
zles of 1.5mm diameter and
suggested by Arjo Wiggins called ‘Stowford‘
larger
separator.
zles of 3 mm diameter and larger 13. Recycling of treated effluent for use
within the mill for non-process for large
10. Use of self-cleaning showers in paper integrated paper mills
machine section In most of the mills, fresh water is used for
It has been found that mills having self-cleaning plantation, gardening, floor washing & toilet
showers in low-pressure showers only in paper flushing. Since quality of water is not essential
machine section consume fresh water 55 to for these activities, treated wastewater from
60% less. ETP can be used. This will reduce fresh water
consumption. The saving in fresh water
11. Choosing right type of save all system consumption by this system is expected to be
There are several proven technologies to clarify 50 – 100 m3/day.
paper machine wastewater or also called white 14. Tertiary treatment of wastewater for
water. Some of the popular ones used in the recycling
industry are listed here:
In order to recycle the wastewater completely
(a) Poly disc filtration system back to the system, biologically treated
(b) Krofta / Gravity sedimentation type wastewater requires to undergo a number of
saveall treatment processes to achieve nearly inlet
(c) Drum filters water quality. In a pulp and paper mill, color
removal is an important requirement to use the
(d) Inclined/Hill Screens finally treated wastewater as process water.
12. Optimum use of paper machine clarified The wastewater after primary treatment
wastewater in sections other than paper involving physio-chemical separation is given
machine secondary treatment. Secondary treatment
In order to make maximum use of paper machine uses microorganisms to accelerate the natural
clarified wastewater, it is important to have a decomposition of organic waste. The two main
sufficient storage capacity. The requirement of methods used are aerated stabilisation and
backwater in other sections is not regular and activated sludge treatment - both are known as
is often intermittent. The various applications aerobic treatments.
of this water are- The efficiency of these two systems varies
(a) Decker thickener showers, widely, depending on climate, influent quality,
pulp type, fibre source and mill practice. In

ideal conditions, activated sludge performs better at reducing BOD and removing suspended solids.
Other methods include anaerobic processes like USAB processes followed by aerobic systems have
been successfully been used in the pulp and paper industry.
The secondary treated wastewater is then sent to tertiary treatment plant. In tertiary
treatment, Aluminum oxide, ferric oxide and polyelectrolytes assist coagulation of waste in the
effluents, which are then sand filtered.
The quality of treated wastewater after the tertiary treated is fit for recycling back completely to the
system especially in wastepaper based mills and partially for other mills.
3.2.7 Pharmaceuticals
Major water uses in the pharma industry may include:
1. Steam generation
2. Cooling of compressors
3. Refrigeration equipment
4. Washing of containers
5. Washing of equipments,
6. Auxillary cooling
7. Boiler application
8. Multi effect evaporators
The following is a list of water conservation projects implemented by various pharma companies that
has resulted in the reduction of SWC for their respective units
Typical
Typical water conservation
projects
potential (m3)
Ecology condensate water
Utilization of condensate that is of
1 utilization in cooling towers 2142673
very good quality water
increased
Installation of Reverse Osmosis RO plant Installed for the treatment
2 22240
for reuse / recycle of effluent of the industrial effluent
Collected the roof water and stored

3 Roof Top Rain Water Harvesting 1488
in water storage tanks
Phase 5&1 0 BAVacuum pump

Heat exchanger used to cool the hot
4 water recycling through Heat 186060
water
exchanger
Ecology Secondary Boiler blow
Boiler blowdown water used for the
5 down reduced and used for 110400
washing
ecology plant washings

Cleaning water system reduced such
6 Batch column cleaning as Batch column cleaning quantity 26200
from 5.0 m3 to 4.0 m4
Continuous column cleaning quantity
7 Continuous column cleaning 365000
from 6.0 m3to 4.5 m3
Sprinkler system & Drip For irrigation sprinkler and drip
8 irrigation- Gardening purpose systems installed to minimize the 9268
fresh water consumption
Back washing water of sand Turbidity of the backwash water
9 & charcoal filters at pump house was less than 50 ppm and used for 3600
is used for gardening purpose gardening
Replaced steam and water
10 ejector vacuum system by low oil Low oil vacuum system installed 200
vacuum system
3.2.8 Service
There exists a wide range of opportunity for
improving water efficiency in buildings-
Common water efficiency measures for
buildings include –
• Use based charging- install water
meters for individual users & introduce
a fee accounting system based on actual
consumption. The incentive for cost
savings can only be realized by making
water users aware of their consumption
habits and linking their water bills to
actual rates of consumption.
• Detecting leaks- water leakage from
toilets, faucets, or plumbing fixtures
can result in about 10-30% of water
losses. By conducting regular checks,
considerable amount of water can
potentially be saved.
• Dripping taps, faucets and shower • Leakage in toilet flushes- two of the
heads: A dripping tap can waste common problems include a misplaced
between 4,000 to 5,000 liters of water flap that causes water to continously
every year. Damaged seals can be easily flow into the toilet bowl and continuous
and inexpensively replaced. overflow when the shut off level is
not properly adjusted or when the
movement of float arm is obstructed.
• Storage tanks – in commercial buildings,

water is stored in tanks prior to use. The be monitored more closely, and controlled.
structural ability of the tanks deteriates Proper measurement and monitoring can
over a period of time and this can lead ensure reduction in the consumption of water
to leakages. This can de detected by between 5-15%. However the percentage
monitoring the water level in the tank reduction depends on the present operating
during a period when no water is being practices of the building.
extracted from the tank. Water pressure:
• Cooling towers- overflow from cooling High water pressure can result in wastage as
tower basins leads to leakage in flow rates of taps and showers are increased.
institutional & commercial buildings. Correct water pressures should therefore be
• Pipes, joints and valves- old pipes, specified and pressure reducing valves used, if
joints and valves with worn out sealing necessary.
are potential sources of water losses in Wash hand basin taps:
buildings.
Large quantities of water can be wasted when
Water efficient fixtures taps are left running. This is often the case in
Low water use fixtures are designed to use wash hand basin taps. To reduce wastage the
less water while maintaining the same level following measures can be taken:
of performance as older fixtures. A variety of • Flow rates: Taps with flow rates of
water-efficient fixtures and appliances are under 6L/minute should be specified.
available in the market. Faucets, showerheads Where flow rates are higher than this,
and toilets are just a few examples of the constrictors and aerators can be used to
fixtures available in water efficient models. reduce flow rates.
Although water efficient fixtures use less water,
they provide the same or even improved level • Usage: The length of usage can also
of performance compared to non-efficient be controlled through metering and
models. Water efficient fixtures can be slightly demand taps or taps fitted with
more costly than older fixtures. But when you proximity sensors.
add the savings on your monthly water bill, Electronic Taps (e-taps):
money saved far outweighs any additional
The latest trend in industries is to install
amount spent on the actual fixture. There are
electronic taps (e-taps). The advantages of
a number of aspects and components of water
using e-taps are as mentioned below:
systems in any plant area and commercial
buildings that can contribute to achieve water • Unlike conventional taps, there is no
conservation in domestic water usages. These twisting or turning in e-taps. They have
are described below: a sensor, which cuts off water supply
completely when not in use. This helps
Water meters:
in saving 40% water during hand wash
The mains water meter in a building should be
• E-taps enable hands free operation.
located where it can be easily read, in order to
No fear of cross contamination or
monitor consumption. In addition, sub metering
contact with germs. E taps score very
should be provided for areas with substantial
high on hygiene. It is the most ideal
water requirements such as large irrigation
choice for multipurpose and multi user
systems. This allows water consumption to

washrooms. of water that is used
• E-taps can work efficiently up to raw Hot water pipes:
water TDS of 2000 ppm. Large amounts of water are wasted when people
• The touch free electronic taps, available run taps waiting for water to become warm.
in AC and DC models consume minimal This wastage can be reduced by minimizing the
power only. The AC model has an length of piping from the point at which water
efficient battery back-up, while the DC is heated to where it is used. Therefore solar
model runs on just 4 alkaline batteries. water heaters and geysers should be located
• Operation of Electronic Taps as close as possible to areas where hot water
will be consumed. In addition, hot water pipes
should be insulated to ensure that water in the
pipe is still warm when the hot water taps are
next switched on.
Toilets:
Toilets which require large amounts of water
This has been successfully implemented in should be avoided. Ideally, toilets that do not
several hotels & restaurants. Of late, several require any water, such as composting toilets,
industries have also started installing E-taps should be used. However, if this is not possible,
in their premises. Thus, it’s a proven fact that toilets that use the minimum amount of water
there is always a good potential to optimize possible should be used. This can be achieved
the fresh water consumption by replacing the through specifying low flush toilets which do
existing taps with e-taps. not require more than 9L/flush or through
dual-flush mechanisms that enable users to use
Foam taps: a half flush, of say of 4.5L, when full flushes are
Conventional taps are used in all hand wash not required.
areas which results in large quantity of fresh • The cisterns in toilets are old
water. conventional type which consumes
Foam taps are a better fit in these high large quantity of water during flushing.
consumption areas. They consume 25-30% less The old type of closet consumes about
than the conventional taps. 11 litres per flush.
Showers: The latest model closets are water efficient and
operate in dual mode with single flush releases
Where possible, baths should be avoided 3 litres and dual flush releases 6 litres per flush.
and showers, which use less water, should be This results in large quantity of water savings.
specified. The specification of showerhead and
controls can support efficiency in the following Composting toilets:
ways: These toilets eliminate the use of water
• Flow rate: Maximum flow rates of 10L/ and don’t create black effluents. If properly
minute should be specified for showers. managed, they can produce sterile humus that
is free from unwanted smells.
• Usage: Usage can be controlled by
shower valves that control the amount Urinals:

Waterless urinals have become increasingly 170,000 liters) of water per urinal per year.
popular now a day among most of the Other companies do not use a cartridge;
corporate. These use valves or chemicals to instead they have developed an outlet system
avoid using water to flush urinals and can that traps the odor, preventing the smell often
result in significant water consumption savings. present in toilet blocks. They can be installed
It is however important to understand, and in high-traffic facilities and in situations where
address, the maintenance requirements of providing a water supply may be difficult or
this equipment to ensure that this remains where water conservation is desired. Due to
effective. Where water is used for flushing high-level water restrictions, Brisbane has
urinals, highly efficient devices should be mandated conversion to waterless urinals and
specified, and flush rates set as low as possible. flush urinals are rarely seen.
The latest trend in industries is to install e-flush
urinals. The advantages of using e-flush urinals
are as mentioned below:
• E-flush urinals are fitted with a sensor,
which senses the usage and flush with
water for few seconds after use. This
helps in saving 70% water during urinal
flush
• E-flush urinals enable hands free
operation and score very high on
hygiene. It is the most ideal choice Water consuming devices:
for multipurpose and multi user Large water consuming devices such as
washrooms. E-flush urinals can work swimming pools and large ornamental ponds
efficiently up to raw water TDS of 2000 should be avoided as their water consumption
ppm. requirements as a result of evaporation can
• The touch free e-flush urinals available be high. If however, these cannot be avoided,
in AC and DC models consume minimal they should be replenished from rainwater
power only. The AC model has an storage and covered when not is use to reduce
efficient battery back-up, while the DC evaporation.
model runs on just 4 alkaline batteries. Reuse & Recycle of water
Waterless Urinals: While recycling is a term generally applied to
A more recent innovation is urinals that use aluminium cans, glass bottles, and newspapers,
no water at all. The innovation is secured with water can be recycled as well. Water recycling
several patents. Models utilize a trap insert is reusing treated wastewater for beneficial
filled with a sealant liquid instead of water. The purposes. Recycled water is most commonly
lighter-than-water sealant floats on top of the used for non-potable (not for drinking)
urine collected in the U-bend, preventing odors purposes, such as agriculture, landscape,
from being released into the air. Although the public parks, and golf course irrigation. Other
cartridge and sealant must be periodically non-potable applications include cooling water
replaced, the system saves anywhere between for power plants and oil refineries, industrial
15,000 and 45,000 gallons (approx. 55,000 and process water for such facilities as paper mills

and carpet dyers, toilet flushing, dust control, users can supplement their demands by using
construction activities, concrete mixing, and recycled water, which can free considerable
artificial lakes. Water is sometimes recycled amounts of water for the environment and
and reused onsite; for example, when an increase flows to vital ecosystems.
industrial facility recycles water used for Water Recycling Decreases Discharge to
cooling processes. A common type of recycled Sensitive Water Bodies:
water is water that has been reclaimed from
municipal wastewater, or sewage. The term In some cases, the impetus for water recycling
water recycling is generally used synonymously comes not from a water supply need, but from
with water reclamation and water reuse. a need to eliminate or decrease wastewater
discharge to the ocean, an estuary, or a stream.
Benefits of Water Recycling: By avoiding the conversion of salt water
In addition to providing a dependable, locally- marsh to brackish marsh, the habitat for two
controlled water supply, water recycling endangered species can be protected.
provides tremendous environmental benefits. As water demands and environmental needs
By providing an additional source of water, grow, water recycling will play a greater role in
water recycling can help us find ways to our overall water supply. By working together to
decrease the diversion of water from sensitive overcome obstacles, water recycling, along with
ecosystems. Other benefits include decreasing water conservation can help us to conserve and
wastewater discharges and reducing and sustainably manage our vital water resources.
preventing pollution. Recycled water can also
be used to create or enhance wetlands and A number of terms are used while referring
riparian habitats. about recycling and reusing water for industries
or other purposes.
• Water reuse - making use of water from
diverse sources, other than the fresh
drinking water supply.
• Direct reuse - involves using rainwater,
greywater, stormwater or wastewater
without treatment
• Recycled water (sometimes called
‘reclaimed water’) - wastewater or
stormwater treated to a high standard
as appropriate for particular uses in
homes, agriculture or industry.
Water Recycling Can Decrease Diversion of
Freshwater from Sensitive Ecosystems: • Sewer mining - the process of tapping
directly into a sewerage system, (either
Plants, wildlife, and fish depend on sufficient
before or after a sewage treatment
water flows to their habitats to live and
plant), and extracting wastewater for
reproduce. The lack of adequate flow, as a
treatment and reuse as recycled water.
result of diversion for agricultural, urban, and
industrial purposes, can cause deterioration • Greywater- the wastewater generated
of water quality and ecosystem health. Water in homes, except from the toilet.
Depending on the purpose, greywater

may be used treated or untreated. reservoirs are recharged at a rate higher than
• Blackwater- all of the components of natural conditions of replenishment.
domestic sewage. Need of water harvesting
• Stormwater - runoff from roofs, roads • To increase the ground water level from
and driveways. Stormwater must the present level and thus to arrest the
generally be treated for use. Water drop of ground water level.
caught in rainwater tanks is suitable for • To compensate the low availability of
some uses. surface water for domestic as well as
3.2.9 Trends industrial application.
Sector Specific Water Per Capital • The urbanization has reduced the
Consumption Water Con- natural infiltration of water due to civil
sumption construction as well as paving of open
Automobile 5 to 6.5 m3/ 110-170 lpcd area.
vehicle According to a report by the Central
Cement 0.3-0.35 m3/ 110-170 lpcd Groundwater Board published in 2007, the
MT selection of a suitable technique for artificial
Pulp & 55-70 m3/MT 120-140 lpcd recharge of ground water depends on various
Paper factors. They include:
Non-ferrous 6-8 m3/MT 150-180 lpcd a) Quantum of non-committed surface run-
Engineering 4-6.5 m3/prod- 110-140 lpcd off available
uct b) Rainfall pattern
Beverages 2-6.5 liters/liter 60-75 lpcd c) Land use and vegetation
of product
c) Topography and terrain profile
Pharmaceu- 300-400 m3/ 35-55 lpcd
tical ton of eq. d) Soil type and soil depth
product e) Thickness of weathered / granular zones
Power 1.3-1.7 m3/ 80-100 lpcd f) Hydrological and hydrogeological
MWh characteristics
Petro 3.0-4.5 m3/MT 450-550 lpcd g) Socio-economic conditions and
chemical infrastructural facilities available
Fertilizer 4.5-5.5 m3/MT 200-300 lpcd h) Environmental and ecological impacts of
artificial recharge scheme proposed.
Source: CII (Triveni Water Institute) publication
- Water Use Efficiency in Urban India The report lists the following recharge
techniques-
4. WATER HARVESTING Artificial Recharge Techniques
Water harvesting or more precisely rain water Techniques used for artificial recharge to
harvesting is the technique of collection and ground water broadly fall under thefollowing
storage of rain water at surface or in sub- categories:
surface aquifer, before it is lost as surface run
off. In artificial recharge, the ground water I) Direct Methods

A) Surface Spreading Techniques freshwater as well as used for recharging the
a) Flooding aquifer.
b) Ditch and Furrows

c) Recharge Basins
d) Runoff Conservation Structures
i) Bench Terracing
ii) Contour Bunds and Contour Trenches
iii) Gully Plugs, NalahBunds, Check Dams
iv) Percolation Ponds
e) Stream modification / augmentation
B) Sub-surface Techniques
a) Injection Wells (Recharge Wells)
b) Gravity Head Recharge Wells Some of the techniques are described below:
c) Recharge Pits and Shafts Storage:
II) Indirect Methods

A) Induced Recharge from Surface Water
Sources
B) Aquifer Modification
i) Bore Blasting
ii) Hydro-fracturing
III) Combination Methods
In addition to the above, ground water
conservation structures like Subsurface
dykes(Bandharas) and Fracture Sealing While designing a rainwater harvesting system,
Cementation techniques are also used to the most preferred option to harvest the
arrestsubsurface flows. rainwater is to construct a storage system.
Recharge structures can also be categorized The ultimate objective of the plant should be
based on the possibilities in urban and rural to store as much rainwater as possible and to
areas. substitute freshwater consumption with the
rainwater harvested.
4.1 Rainwater Harvesting Techniques in
Urban Area 4.1.1 Roof top rain water harvesting
through Recharge Pit
In urban areas rain water is available from roof
tops of buildings, paved and unpaved areas. • This technique is suitable for building
This water could be stored and used to replace with minimum 100 Sq. M roof area.
• Alluvial areas where permeable rocks

are exposed on the land surface or are similar to recharge pit arrangement
at very shallow depth, roof water mentioned above
harvesting can be dome through 4.1.3 Roof top rain water harvesting
recharge pit. through Existing Tube Wells
• Recharge pit of 1 to 2 M wide and 2 to 3 • In areas where the shallow aquifers
M depth may be constructed. The filter have dried up and existing tube wells
bed can be prepared by providing about are tapping deeper aquifer, roof to rain
5 to 20 cm boulders at the bottom water harvesting through existing tube
followed by 5 to 10 cm of gravel and well can be adopted to recharge the
finally a layer of 3 to 5 cm graded sand. deeper aquifers.
• The roof top to be connected to the pit • PVC pipes of 10 cm diameter are
through pipe with arrangement to flush connected to roof drains to collect
out the first rain water. rainwater. The 1 roof runoff is let off
• Mesh should be provided on the roof through the bottom of drainpipe.
top to prevent the flow of leaves and Rainwater from roofs is taken to
solid debris to the pit. collection/ desilting chambers located
• The top layer of the sand should be on ground. These collection chambers
cleaned regularly to maintain the are interconnected as well as connected
recharge rate. to the filter pit through pipes having a
slop of 1:15.
4.1.2 Roof top rain water harvesting
through Recharge Trench • The filter pit may vary in shape and size
depending upon available runoff and
• Recharge trenches are suitable for are back-filled with graded material,
buildings having roof area of 200-300 boulder at the bottom, gravel in the
sq. m and where permeable strata are middle and sand at the top with varying
available at shallow depths. thickness (0.30- 0.50m) and may be
separated by screen.
• The pit is divided into two chambers,
filter material in one chamber and other
chamber is kept empty to accommodate
excess filtered water and to monitor the
quality of filtered water.
• A connecting pipe with recharge well
is provided at the bottom of the pit for
recharging of filtered water through
well.
• The initial rain water should be drained
• Trench may be 0.5 to 1 m wide, 1 and subsequent rain water could be
to 1.5m deep and 10 to 20 m. long charged.
depending upon availability of water to 4.1.4 Roof top rain water harvesting
be recharge.
• The filter arrangement all other set up

through Trench with Recharge Well spreading techniques are common since
In areas where the surface soil is impervious and space for such systems is available in plenty
large quantities of roof water or surface runoff and quantity of recharged water is also large.
is available within a very short period of heavy Following techniques may be adopted to save
rainfall, the use of trench/ pits is made to store water going waste through slopes, rivers,
the water in a filter media and subsequently rivulets and drains.
recharge to ground water through specially
constructed recharge wells.
This technique is ideally suited for area where
permeable horizon is within 3m below ground
level. Recharge well of 100- 300 diameter
is constructed to a depth of at least 3 to 5 m
below the water level. Based on the lithology of
the area well assembly is designed with slotted
pipe against the shallow and deeper aquifer.
A lateral trench of 1.5 to 3m width and 10 to
30 m length, depending upon the availability
of water is constructed with the recharge well
in the centre. The number of recharge wells in 4.2.1 Rain water harvesting through Gully
the trench can be decided on the basis of water Plug
availability and local vertical permeability of
• Gully Plugs are built using local stones,
the rocks.
clay and bushes across small gullies and
The trench is backfilled with boulders, gravels streams running down the hill slopes
and coarse sand to act as a filter media for the carrying drainage to tiny catchments
recharge wells. during rainy season.
If the aquifer is available at greater depth • Gully Plugs help in conservation of soil
say more than 20 m, a shallow shaft of 2 to and moisture.
5 m diameter and 3-5 metres deep may be
• The sites for gully plugs may be chosen
constructed depending upon availability of
whenever there is a local break in slope
runoff. Inside the shaft a recharge well of 100-
to permit accumulation of adequate
300 mm diameter is constructed for recharging
water behind the bunds.
the available water to the deeper aquifers.
At the bottom of the shaft a filter media is 4.2.2 Rain water harvesting through
provided to avoid choking of recharge well. Contour Bund
4.2 Rainwater Harvesting Techniques • Contour Bunds are effective methods to

conserve soil moisture in watershed for
in Rural Areas long duration.
In rural areas, rain water harvesting is taken • These are suitable in low rain fall
up considering watershed as a unit. Surface areas where monsoon run off can be
impounded by constructing bunds on
the sloping ground all along the contour
of equal elevation.

• Flowing water is intercepted before it course and with growth of vegetation,
attains the erosive velocity by keeping the bund becomes quite impermeable
suitable spacing between bunds. and helps in retaining surface water
• Spacing between two contour bunds run off for sufficient time after rains to
depends on the slope the area as the recharge the ground water body.
permeability of the soil. Lesser the 4.2.4 Rain water harvesting through
permeability of soil, the close should be Percolation Tank
spacing of bunds. • Percolation tank is an artificially created
surface water body, submerging in its
reservoir a highly permeable land so
that surface runoff is made to percolate
and recharge the ground water storage.
• Percolation tank should be constructed
preferably on second to third order
steams, located on highly fractured and
weathered rocks, which have lateral
continuity downstream.
• The recharge area downstream should
have sufficient number of wells and
cultivable land to benefit from the
• Contour bunding is suitable on lands augmented ground water.
with moderate slopes without involving • The size of percolation tank should
terracing. be governed by percolation capacity
4.2.3. Rain water harvesting through Gabion of strata in the tank bed. Normally
Structure percolation tanks are designed for
storage capacity of 0.1 to 0.5 MCM. It is
• This is a kind of check dam commonly
necessary to design the tank to provide
constructed across small streams to
a ponded water column generally
conserve stream flows with practically
between 3 & 4.5 m.
no submergence beyond stream course.
• The percolation tanks are mostly earthen
• A small bund across the stream is made
dams with masonry structure only for
by putting locally available boulders in a
spillway. The purpose of the percolation
mesh of steel wires and anchored to the
tanks is to recharge the ground water
stream banks.
storage and hence seepage below the
• The height of such structures is around seat of the bed is permissible. For dams
0.5 m and is normally used in the up to 4.5 m height, cut off trenches are
streams with width of less than 10 m. not necessary and keying and benching
• The excess water over flows this between the dam seat and the natural
structure storing some water to serve as ground is sufficient.
source of recharge. The silt content of
stream water in due course is deposited
in the interstices of the boulders in due

4.2.5 Rain water harvesting through Check the structure.
Dams / Cement Plugs / NalaBunds 4.2.6 Rain water harvesting through
• Check dams are constructed across Recharge Shaft
small streams having gentle slope. The • This is the most efficient and cost
site selected should have sufficient effective technique to recharge
thickness of permeable bed or unconfined aquifer overlain by poorly
weathered formation to facilitate permeable strata.
recharge of stored water within short
span of time. • Recharge shaft may be dug manually if
the strata are of non-caving nature. The
diameter of shaft is normally more than
2 m.
• The shaft should end in more permeable
strata below the top impermeable
strata. It may not touch water table.
• The unlined shaft should be backfilled,
initially with boulders/ cobbles followed
by gravel and coarse sand.
• In case of lined shaft, the recharge water
may be fed through a smaller conductor
• The water stored in these structures pipe reaching up to the filter pack.
is mostly confined to stream course • These recharge structures are very
and the height is normally less than 2 useful for village ponds where shallow
m and excess water is allowed to flow clay layer impedes the infiltration of
over the wall. In order to avoid scouring water to the aquifer.
from excess run off, water cushions are
provided at downstream side. • It is seen that in rainy season village
tanks are fully filled up but water from
• To harness the maximum run off in the these tanks does not percolate down
stream, series of such check dams can due to siltation and tube well and dug
be constructed to have recharge on wells located nearby remains dried
regional scale. up. The water from village tanks gets
• Clay filled cement bags arranged as a evaporated and is not available for the
wall is also being successfully used as beneficial use.
a barrier across small Nalas. At places, • By constructing recharge shaft in tanks,
shallow trench is excavated across the surplus water can be recharged to
Nalaand asbestos sheets are put on ground water. Recharge shafts of 0.5 to
two sides. The space between the rows 3 m. diameter and 10 to 15 m. deep are
of asbestos sheets across the Nalais constructed depending upon availability
backfilled with clay. Thus a low cost of quantum of water. The top of shaft is
check dam is created. On the upstream kept above the tank bed level preferably
side clay filled cement bags can be at half of full supply level. These are
stacked in a slope to provide stability to back filled with boulders, gravels and

coarse sand. impervious layer with wide valley and
• In upper portion of 1 or 2 m depth, the narrow out let.
brick masonry work is carried out for • After selection of suitable site, a trench
the stability of the structure. of 1-2 m wide is dug across the breadth
• Through this technique all the of stream down to impermeable bed.
accumulated water in village tank The trench may be filled with clay or
above 50% full supply level would be brick/ concrete wall up to 0.5 m below
recharged to ground water. Sufficient the ground level.
water will continue to remain in tank for • For ensuring total imperviousness, PVC
domestic use after recharge. sheets of 3000 PSI tearing strength
4.2.7 Rain water harvesting through Dug at 400 to 600 Gauges or low-density
Well Recharge polythene film of 200 Gauges can also
be used to cover the cut out dyke faces
• Existing and abandoned dug wells may
be utilized as recharge structure after • Since the water is stored within the
cleaning and desilting the same. aquifer, submergence of land can be
avoided and land above the reservoir can
• The recharge water is guided through be utilized even after the construction
a pipe from desilting chamber to the of the dam. No evaporation loss from
bottom of well or below the water the reservoir and no siltation in the
level to avoid scouring of bottom and reservoir take place. The potential
entrapment of air bubbles in the aquifer. disaster like collapse of the dams can
(Fig 3.10) also be avoided.
• Recharge water should be silt free and 4.3 Designing Rainwater Harvesting System
for removing the silt contents, the
runoff water should pass either through How Much Water Can Be Captured?
a desilting chamber or filter chamber. The basic rule for sizing any rainwater
• Periodic chlorination should be done harvesting system is that the volume of water
for controlling the bacteriological that can be captured and stored (the supply)
contaminations. must equal or exceed the volume of water
used (the demand). The very basic equation to
4.2.8 Ground water dams or sub-surface determine the possible amount of water that
dykes can be harvested from a given catchment area
• Sub surface dyke or under-ground is shown below:
dam is a subsurface barrier across Catchment area / roof area must be the
stream which retards the base flow and footprint / projected area. The collection
stores water upstream below ground surface is the “footprint” of the roof. In other
surface. By doing so, the water levels words, regardless of the pitch of the roof, the
in upstream part of ground water dam effective collection surface is the area covered
rises saturating otherwise dry part of by collection surface (length times width of the
aquifer. roof from eave to eave and front to rear).
• The site where sub-surface dyke In India the distribution of rainfall is very
is proposed should have shallow random and erratic. In some areas it is very

scanty as low as 100mm in some part of With known volume and convenient assumed
Western Rajasthan and some areas it is very depth the rest of the dimensions can be figured
heavy as more than 11500mm in North-East out and the best suitable combination can be
states. For proper designing the RWH structure adopted. In case if the dimensions are too large
to know the average annual rainfall and average to be practical, you can go for multiple numbers
intensity of rainfall is must. These data should of tanks of smaller sizes.
be considered for atleast 10 years recurrence
interval. 5. Case Studies
Runoff coefficient solely depends on the Case Study 1- Water Policy
roughness of the catchment or roof material. A leading automobile company adopted the
It varies between 0 to 1 and always lesser following water policy. A water policy should
than smoother the surface; higher the runoff reflect commitment from top management on
coefficient. water conservation over a period of time and
The following shows the value of runoff strategies for sustainable water management.
coefficient for various roof materials.
Type of catchment Coefficients

Roof Catchment
Tiles 0.8-0.9
Corrugated metal sheets 0.7-0.9
Ground Surface coverings
Concrete 0.6-0.8
Brick Pavement 0.5-0.6
Untreated ground catchment
Soil on slopes less than 10% 0.0-0.3
Rocky natural catchments 0.2-0.5
Untreated ground catchments
Soil on slopes less than 10% 0.1-0.3
Rocky natural catchments 0.2-0.5
Calculating Storage Capacity and Design of

Storage Tank:
Storage capacity depends on the maximum Case Study 2- Water Management Structure
quantum of water that can be harvested within A petrochemical industry in Gujarat established
the facility. Once we finalized the design volume a dedicated water management structure along
from either of the above method, the design of with cross functional team responsible for water
storage tank can be done accordingly. management in the organization. It is critical to
Volume of rectangular Tank = (Length X Width have a water manager with accountability so
X Depth) as to facilitate continuous and focused action
towards water management. The diagram
Vol. of Circular Tank = p/4 X (Dia) X Depth below shows how employees from strategic

level, tactical level and supporting level are and monitor different usage points to calculate
involved in water conservation activities. Major baseline consumption.
functions of each team member are outlined. Case Study 4 – Metering and Monitoring
It is also important to document the water System
management activities handled by the water
manager and cross functional team. One of the strategies adopted by a beverage
company to achieve water conservation is to
deploy tools to identify untapped opportunities
for water savings. The company carried water
balancing at each process step to identify the
saving potential, quantified the unaccounted
losses against main consumption and deployed
a strong system to account every liter of water
in the processes.
Case Study 3 – Metering and Monitoring

System
Water profiler tool:

• estimates plant water use
uses existing data to generate overall
You can’t manage what you don’t measure. water balance
Automobile company in Nashik implemented drills down to identify and quantify
a thorough metering and monitoring system primary water users
to achieve their goal of annual water savings.
identifies potential projects for
The water balance diagram below shows how
improvement in water use
municipal supply of 1600 m3 is used for cooling
(300 m3), paint shops (1000 m3) and domestic • provides calculators to estimate unmetered
(300 m3). The diagram also shows how the water use
company is a zero discharge company and the • provides data in an excel format
treated water is used for gardening, washing
and fire fighting. It is important to measure

Water profiler helped quantify identified ±± water saving of 60 m3 per day
opportunities. First 6 months of consumption ±± cost savings of Rs. 286, 890 per annum
was analyzed through water profiler and also
identified potential for further savings of 60 m3
per day.
Water Profiler Tool- a glimpse
Case Study 5 - 4R Approach of Recover, Reuse,
Reduce and Recycle
A printing and packaging company in Chennai
adopted 4R (recover, reuse, reduce and
recycle) strategy to implement water savings.
The company has been water positive for more
than 8 years in a row.
Nearly 70 meters are installed throughout

the site to monitor the water usage on a daily
basis. By implementing various conservation
initiatives listed below the company was able
to reduce specific water consumption from
0.227 m3 per pump to 0.113 m3 per pump.
Case Study 7- Rainwater Harvesting Storage
and Use in High End Applications
Hydrogeology of the site was studied and A FMCG facility in Bangalore is capturing 83%
appropriate recharge structures were designed. of rainwater harvesting potential. Rainwater is
Annual recharge to groundwater through harvested and stored in two ponds within the
rainwater harvesting (1,12,793 m3) is more premises with total capacity of 8,700KL, through
than annual withdrawal of groundwater (app. which 34% of the water requirement was met
72,000 m3 per annum). in 2010-11. The rainwater stored is used for the
Case Study 6- Reduction in Specific Water following applications after treatment:
Consumption 1. machine cleaning
Engineering company in Jaipur implemented 2. boiler feed water
various projects to achieve water savings.
3. process water
One of the projects implemented is replacing
underground pipes with above ground pipes 3. scrubbers
which has the following advantages: 4. toilet flushing
±± easy identification of leakages 5. utensil cleansing
±± easy maintenance 6.humidification in air handling units
for HVAC

±± Proportional saving of power has been
achieved due to less pumping of water from
the river source.
In addition, weather station supplied by

Karnataka State Natural Disaster Monitoring
Centre is installed onsite. The station is solar
powered and data is recorded every 5 min. The
unit is making a CAPEX investment of 109 lakhs
in the year 2011-12 for an additional rainwater
harvesting pond to cover the remaining 17 %
of the land area and become 100% rainwater
harvesting.
Case Study 8 - Rainwater harvesting Case Study 9- Participatory Groundwater
substituting fresh water consumption Management
A steel company substitutes 22.7% of its A sugar and ethanol manufacturing company in
freshwater consumption with harvested Maharashtra adopted innovative participatory
rainwater. Water harvested is used for washing water harvesting and management approach
iron ore, dust suppression, gardening, car through the following initiatives-
washing and drinking after due treatment. ±± Revival of 8 rivers spread across 12.9 km
Rainfall in the region varied from 1064 mm to harvesting 11.77 million cubic feet of water
1278 mm. The site has a potential to harvest
5.8 million m3 per annum. Around 22.65% ±± Construction of 12 check dams and 35
of this potential is harvested. A detailed boribundh structures harvesting 16.32
hydrogeological study was done before the million cubic feet of water
rainwater harvesting structures were designed. ±± Construction of 7 percolation tanks & 193
75% of the rainwater is recharged while 25% farm ponds covering many villages and
of the rainwater is stored. Benefits from benefiting hundreds of farmers
implementing rainwater harvesting are:
±± Inter-linking water bodies
±± Withdrawal of water from source reduced
±± Recharging of 221 wells & 4 bore wells
by 22.27%.
In addition to water conservation, 18 gabion
±± Yield of wells has increased.
structures and 130 loose boulder structures
±± Total dissolved solvents in the water drawn were constructed for soil conservation. Other
from the recovery wells has come down. sustainable water management strategies

were also implemented like promotion of in yield was observed due to optimum use
micro irrigation covering an area of 192 acres, of fertilizers. This was done in public private
group lift irrigation, less water intensive and partnership with Government of Rajasthan.
horticulture crops.
The above initiatives resulted in reduced soil Case Study 11- Substituting freshwater with
erosion, increased in situ moisture, overcoming rainwater Background
water logging problems, increase in water Asia MotorWorks Ltd., Bhuj (AMW) is one of
table by 8 feet, increased water flow in rivers/ India’s leading HCV manufacturer offering
streams, increased tree density, ensured transport solutions for a new competitive age
efficient use of water in 192 acres. In order to in India’s fast-growing economy. The company’s
assure sustainability of the project, user groups manufacturing facility in Bhuj, Western India is
were trained in operations and maintenance. spread over 2 million sq. meters and produces
Ownership was created among the users as vehicles for a wide range of civilian and defence
they were involved in the planning stage. applications. The state-of-art manufacturing
The community was empowered through includes assembly, axles and drivelines, frame
awareness programs, street plays, exposure shop and automated cab painting facilities.
visits, promotional material in local language,
Details of Project
etc. A total of Rs. 4,52,60,975 was spent on the
various initiatives. The rain water collection from the roof area of
industrial shed, office building, paved area &
Case Study 10- Sustainable Groundwater
non-paved area (catchment area 9,00,000 Sq.
Management Beyond the Fence
Mtr.) is collected through masonry drain made
A beverage company in Rajasthan revived all along the main roads & branch roads inside
400 year old Bawari benefiting nearly 10,000 the campus to the reservoir no.1 (Holding
residents in the neighbourhood. In addition, capacity 1,00,000 cubic meter) and after that
farmers were trained on water efficient water is treated in pretreatment plant for
agricultural practices. 337 drip irrigation converting in to treated/ Industrial grade water
projects covering 165 hectares of land lead for downstream usages i.e. cooling tower
to annual groundwater savings of 1,98,600 system make up, fire system make up, soft
kiloliters. Apart from water saved, huge cost water, DM Water production, etc.
savings was also achieved due to reduced
In addition to this water from around 200
labour, reduction in fertilizers and electricity
acres land outside campus is collected into a
savings initially spent on bore wells. Increase

separate reservoir (Holding capacity is 165,000 to the amount of water used in all of their
cubic meter) through channel made all along products and production by 2020”.
the compound wall length of 4000 meter. The Under beyond the fence initiatives plant has
connection water line is being laid between worked with society to capture rain water by
Pond 2 & Pond 1 with pumping facility and after establishing rain water harvesting system,
pretreatment from Pond 1 that water is to be construction of check dams, recharge wells,
used for process water, cooling tower system surface water storages and village pond.
make up, fire system make up, soft water, DM Through all the projects taken in AP zone
water production, etc. plant has developed and provided rain water
Benefits of the project capturing potential of about 7,52,490 KL. In
100% of the harvested rainwater is used addition to this plant has also taken up projects
for high end water replacement as & when desilting of pond in village to provide potential
Narmada water supply is not available which of about 1,25,640 KL. Total water usage and
is the only source of raw water to the plant. water recharge through beyond the fence
There were more than 160 “Zero Water” days initiatives is as mentioned below for AP zone
in last 3 years due to unavailability of Narmada and overall HCCBPL.
Water Supply and one time 60 days continuous Water % Recharge Water
no Narmada supply than Pond water is used to Zone Usage Validated Recharge
run the complete plant. in KL by BU in KL
Source: CII Water Awards
Case Study 12- Beyond the fence by Coca-Cola AP 1,113,542 136 1,509,003
Beverages Pvt. Ltd.
Background Total
4,915,313 100
HCCBPL 4,930,278
Hindustan Coca-Cola Beverages Private Limited
(HCCBPL) is the largest bottling partner of ‘The
Coca-Cola Company’ in India. It is a part of The Case Study 13- Water Management by Tamil
Coca-Cola Company’s Bottling Investments Nadu Newsprint & Papers Ltd.
Group (BIG) and responsible for the Background
manufacture, package, sale and distribution
of beverages under the trademarks of The The vacuum pumps installed in the paper
Coca-Cola Company. HCCBPL has 24 bottling machine and other areas are water ring vacuum
plants at strategic locations in various states pumps which requires continuous water supply
spread across India. HCCBPL accounts for for water sealing. Apart from the sealing the
approximately 65% of bottling operations water is required for the gear box cooling and
for the Coca-Cola System in India. HCCBPL, mechanical seals. The heated water from the
Ameenpur, is located in Ameenpur village vacuum pump needs to be cooled down in
of Hyderabad district which manufactures cooling tower.
manufactures non-alcoholic ready to drink Hence, the cooling water from the vacuum
beverages. pump seal, gear boxes and pumps mechanical
Globally, as a Vision, Coca-Cola Company has seals was directed to the cooling tower for
pledged to “Balance an amount of water equal cooling purposes. However, the opportunities
were available to utilize the warm water where

fresh water is being used. Limited, Chennai is one of the leading
Details of the project automobile manufacturers in India. Renault
Nissan has a Green Plan, a new six-year
1. All Pumps’ mechanical seal water and environmental action plan that was launched
gear boxes cooling water to the tune of in 2011. Objective of Renault Nissan Green
around 24 m3 / hr is reused in cold blow plan is to reduce environmental impact caused
Heat Exchanger in continuous Digesters by operations with main focus on reduction of
meant for bagasse cooking and hot water CO2 emissions, water consumption and waste.
generated is used in Hot Water Tank from Under this initiative, the plant has taken targets
where it is used for bagasse bleaching. (2 to reduce 24% of specific water consumption
m3/ton of pulp). by 2016 compared to 2011 levels.
2. Around 65 m3 / hr of fresh water, is being
used in evaporator vacuum pumps as seal
water. This seal water outlet was diverted
to Hot Water tank of Bagasse ECF Bleach
Plant, through cold blow heat exchangers
(where fresh water was used previously)
and is used for ECF bleaching process. Rest Details of the project
of the available water, if any is diverted to The plant has set targets for specific water
bleach plant Hot Water tank. This resulted consumption based on comparison with
in a saving of about 1500 m3 / day (62 – 63 competitors and other sister plants of RNAIPL.
m3 / hr) of fresh water.
The plant has established online monitoring
3. All pumps seal water in Hard Wood fiber line system for water consumption and discharge
and Bleaching area is collected in a pit and through Building Management System. BMS
pumped back to Water Treatment Plant. reports are generated automatically and gives
4. The vacuum pump gear box cooling water warning signal for any abnormalities.
is collected and sent to warm water tank Projects implemented include:
supplying water for showers. Fresh water
1) Ultra-filtration system installed in STP
make- up has reduced.
Installation of ultrafiltration system enabled
5. The overflow water from uhle box filtrate
treated water for not only gardening but also
vacuum pump seal pit is diverted to saveall.
toilet flushing. The plant was able to save
By this around 1500 m3 / day of water is
46,800 KL/annum of water with an investment
saved.
of Rs. 25 lakhs. The plant got payback period of
Benefits less than 2 years.
Utilization of 100 m3 / hr of secondary 2) UV system in DM water supply
condensate which was drained, is possible and
Earlier due to microorganism growth, water
equal quantity of fresh water has been saved.
was required to be drained out frequently as
Case Study 14- Water Management by Renault growth of microbes was making it unsuitable
Nissan Automotive India Private Limited for using it in DM plant. In order to rectify this,
Background the plant installed ultra-violet system to control
growth of micro-organisms in water and reduce
Renault Nissan Automotive India Private

frequency of drain outs. Through installation designed and built a greenfield facility atChakan,
of UV system,the plant saved about 3,600 KL/ near Pune, Maharashtra to integrate the best in
annum. technology, environmental sustainability, social
3) High pressure jet for car washing responsibility, and operational excellence.
Spread across 700 acres and planted with
Plant switched from direct hose for car washing approximately 10,000 trees, Chakan offers a
to high pressure jet to bring down water flexible and eco-friendly manufacturing layout
consumption from 56KL/day to 12KL/day which for multiple Multi-Purpose Vehicles (MPVs),
resulted in savings of 13,200 KL/annum. sport utility vehicles (SUVs), and commercial
4) Water flow rate reduction in Hand Wash vehicles that allowto respond rapidly to
changing customer needs.
The plant switched to low flow taps from
conventional taps which reduced water Details of the project
consumption by 50% to save 15,000 KL/annum. MVML was conventionally operating ETP
5) Dish washing machine followed by RO and MEE. It was evident that RO
& MEE technology was proven and successful
The plant installed dish washing machine to
but had disadvantages like-
bring down water consumption by 60% to save
about 36,000 KL/annum. • Burning of fossil fuel in Multiple Effect
Evaporator (MEE),
Benefits
• Generation of hazardous waste out of MEE,
S. No. Project
• Requirement of skilled manpower (9
Savings (in Lakhs)
persons per day),
S. Savings • Intensive of operation & maintenance and
Project
No. (in lakhs) high operating cost.
Ultra-Filtration system In order to make process more environment
1 16.20
installed in STP friendly, MVML team decided to have an
Ultra-Filtration system innovated approach and explored a sustainable
2 2.16
installed in STP & cost effective alternative through High Rate
High pressure jet for car Transpiration System (HRTS). To understand
3 3.96
washing more about such technology, team met
Water flow rate reduction NEERI to discuss possibility of setting up such
4 4.5 technology in MVML. Being first of its kind in
in Hand Wash
5 Dish washing machine 10.80 the sector, MVML had to take all necessary
steps approval from MPCB.
Case Study 15- Water Management by HRTS:
Mahindra Vehicle Manufacturers Limited 1) HRTS is a cost effective and green tertiary
Background treatment. It consists of plantation of
varieties trees like Eucalyptus, Australian
Mahindra Vehicle Manufacturers Limited
bamboo, Saag, etc. which has high affinity
towards water on ridges made up of black
cotton soil.
2) Secondary treated water is passed through

furrows which contain filter bed media • Low lying north gorge area which is
made of bagasse, saw dust, coconut husk otherwise hostile for use for setting up
and gypsum with a layer of black cotton soil manufacturing facilities but has excellent
on top of it. potential for rain water harvesting has been
3) Filter bed media filters the water and uniquely utilized.
removes the pollutants through adsorption, • Perpetual source of water other than
ion exchange, precipitation and also ground water extraction has been created
stabilizes pollutants through microbial inside the manufacturing plant.
degradation. • Intra back dam has been built with patented
The required land for HRTS was chosen in close technology of Introjected backfill walls. This
proximity of ETP in order to reduce piping and technology has been applied for the first
pumping cost. While implementing HRTS, the time for this kind of application at MVML.
plant explored possibility of RWH and storage Benefits of HRTS system
of rain water.
Cost economics of the project
Integrated approach for HRTS & rainwater
harvesting:

6. Resources 4. India Water Portal: http://www.
indiawaterportal.org/
1. CII Triveni Water Institute- http://www.
greenbusinesscentre.com 5. Advanced Centre for Water Resource
Development and Management
2. CII Publications: The following website lists
(ACWADAM) www.acwadam.org
documents published by CII - http://www.
greenbusinesscentre.com/CII-Publication/ 6. Central Groundwater Board http://cgwb.
water_manag.html gov.in/
a. CII Northern Region Core Group “Water 7. Water Footprint: http://waterfootprint.
Manual”- The manual focuses on org/ media/downloads/The Water Foot
efficient use of water, adoption of water print Assessment Manual_2.pdf
minimization techniques, effective water 8. Centre for Science & Environment
management and recycling in the areas
of the process. 9. Rainwater Harvesting Club-http://www.
rainwaterclub.org/
b. CII publication “Our Cup of Joy”- is a
compilation of 51 best practices in water 10. American Rainwater Catchment Systems
management. Association- www.arcsa-usa.org
c. Directory on Water Management- 11. Bangalore Water Supply and Sewerage
This directory is a compendium of Board- http://www.bwssb.org/rainwater_
manufacturers and suppliers of water and harvesting.html
water related products, water treatment 12. Tamil Nadu Water Supply and Drainage Board-
& supply, waste water treatment http://www.aboutrainwaterharvesting.
technologies, water testing equipment com/
suppliers, water chemicals, service
providers, consultants, government 13. Artificial Recharge to Groundwater-
associations, etc. Guidelines Indian Standard IS 15792:2008-
These guidelines provide details of methods
d. Water Quality and Standards-Essentials- aimed at augmentation of groundwater
contains information relating to issues of resources by modifying the natural
industrial water management. movement of surface water.
e. A Pocket Guide on Water Management
3. CII Water Awards: The website lists
the presentations made by nominees
and winners. It lists various initiatives
taken by industries across the country.
h t t p : / / w w w. g r e e n b u s i n e s s c e n t r e .
com/site/ciigbc/viewevent.
jsp?eventid=264016&presentation=dd

Annexure A: Scope of the Rating System
GreenCo - Introduction and The proposed rating system would cover both
Background the Individual manufacturing & service related
facilities.
Businesses across the globe have begun to real-
ize the impending impact of their actions on the • Existing Facility
environment and its contribution to the phe- • New Facility
nomenon of climate change. The achievement The rating system would cover both the
of higher growth with optimal use of resources
and better emission and discharge standards is • Manufacturing and
need of the hour. • Service sectors
Several companies have taken proactive initia- Sector Coverage
tives to integrate environmental concerns in
The sectors that will be covered under this sys-
their businesses and have improved the envi-
tem are:
ronmental performance and business compet-
itiveness. • Automobile & Engineering
Pursuing “Green” has become the new driver • Cement
for companies on the quest towards growth, • Fertilizers
competitiveness and global excellence. Numer- • FMCG
ous benefits have been achieved by companies
• IT Services / service sector
restructuring their various business processes
towards ecological sustainability. • Pharmaceutical & Chemicals
Need for Development of Green Rating System • Tyre
for companies • Pulp & Paper
Companies across the globe have taken many • Glass
initiatives to reduce their ecological footprint, • Hotel
in several areas such as energy efficiency, wa-
• Iron, Steel & Non Ferrous Metals
ter, GHG, waste reduction, etc.
• Textile
With number of businesses going green on
the rise and several initiatives on different ar- • IT Hardware / Electronics
eas evokes a spark in an individual’s mind on • Refineries & Petrochemicals
“How Green is the Company”. A clear holistic • Textile
mechanism is presently not available for eval-
uating the performance of companies on the CII has been the pioneer organization in pro-
ecological front. Against this background, CII, moting green concepts across the country. To
through an extensive stakeholder consultation encourage industry tread this path, CII initiated
and interaction with experts have developed the voluntary programme “Mission on Sustain-
the ‘Greenco rating’ system for evaluating the able Growth” to facilitate ecologically sustain-
‘greenness of companies’. able business growth.
The Green Rating System will act as a milestone As a first step towards this direction, a CII -
for companies pursuing green to assess where Code for Ecologically Sustainable Business
they stand and help in defining the path for- Growth was developed aiming to involve the
ward.

top management of companies and seek volun- Water Conservation- Our requirements for
tary commitments towards reducing intensity water to meet our fundamental needs and our
of the consumption of energy, water and oth- collective pursuit of higher living standards,
er natural resources and promote ecologically coupled with the need for water to sustain
sustainable growth in their companies. our planet’s fragile ecosystems, make water
The initiative launched by CII in 2008 has unique among natural resources. The increase
evoked great interest from the Indian Industry. in global population coupled with the rising
More than 450 organizations in India are volun- economy increase the demand for water expo-
tarily committed to this initiative. nentially. According to World Bank estimates,
today about 700 million people live in coun-
This clearly indicates an increasing trend of tries experiencing water stress or scarcity. By
companies adopting measures towards reduc- 2035, it is projected that 3 billion people will
ing their ecological intensity in the years to be living in conditions of severe water stress.
come. Many countries with limited water availability
Off late there has been a continuous demand depend on shared water resources, increasing
from companies to formulate a system to eval- the risk of conflict over these scarce resources.
uate the actual performance of companies pur- Effective water management strategies are the
suing ecologically sustainable growth. call of the hour to address the water crisis. The
green business rating promotes sustainable
This rating system will act as a holistic frame-
use of water through “reduce, recycle, reuse
work to assess and evaluate the performance
and reclaim” strategies. It prescribes metering
of the company’s activities on the green front.
to monitoring water consumption, rain water
Benefits of the Green Rating System harvesting and water use reduction strategies.
Overall, this has the effect of reducing utility
for Companies
costs for businesses. The rating system also en-
Application of green rating for companies would courages companies to take efforts for ground-
address national priorities leading to benefits, water recharge beyond the fence.
such as energy efficiency, water conservation,
Renewable Energy- The adverse effects on en-
renewable energy, waste management, green
vironment caused by the production and con-
supply chain, etc.,. Some of the major benefits
sumption of energy have resulted in severe
are highlighted below:
environmental impacts across the globe. With
Energy Efficiency- Businesses consume energy world economies taking commitments to re-
for various reasons like operating machinery, duce their share of carbon emissions contribut-
running computers, office maintenance etc. ing to the global warming; it requires countries
The green rating system calls for energy mon- to look at alternate sources of energy meet
itoring and accounting system as well as tech- their growing energy demands. This not only
nology that is less energy intensive. The rating allows for use of energy that is clean but also
system would help the organizations to bench- reduces the dependence on fossil fuels, which
mark themselves at the national / international are major contributors of Green House Gases.
level, guides them towards becoming national Similarly, there are other sources of renew-
/ global levels of energy efficiency. Involvement able energy that need to be explored and uti-
of employees and building capacity of them are lized. The Green Rating System for Companies
also part of the rating system. encourages businesses to employ clean and
renewable energy. The ultimate goal is to off-

set 100% of the electrical energy / thermal by raw materials and discourages use of virgin ma-
renewable energy. Although the initial invest- terials. It even goes a step further in encour-
ment on installing equipment for generating re- aging businesses to ensure that not only they
newable energy is relatively high, the long term reuse/ recycle raw materials but their product
benefits of reduced maintenance cost, low too should be recyclable/ bio-degradable.
operating costs and cost savings on fossil fuels Green Supply Chain- As environmental aware-
makes it a lucrative proposition for businesses. ness among consumers increase, the demand
Waste Management- The waste management for products with lower environmental foot-
sector is contributing 3-5 per cent of global print will also increase. In keeping with consum-
man-made greenhouse gas (GHG) emissions, er sentiments, businesses will have to not only
equal to around the current emissions from in- green their operations, but also across their
ternational aviation and shipping, according to supply chain. This calls for a rethink of the busi-
some estimates. Since the waste collection and ness’s current procurement process. Studies
disposal facilities are not very good, most of have shown that improved green supply chain
the waste stagnates at its place of origin. This processes means lower waste-disposal, lower
leads to hazardous materials getting disposed environmental impact at the vendor premises
off to the environment and causing grave dan- and, often, reduced materials costs. The green
ger to living beings. The Green Rating System rating system aims to make businesses aware
for Companies recommends waste manage- of these benefits to their bottom-line so that
ment strategies that enable businesses to iden- they are encouraged to implement green sup-
tify and segregate different types of waste. The ply chain processes.
system presents guidelines on waste invento- Green House Gases Reduction - The global
ry study to enable businesses to quantify data average concentrations of various greenhouse
on amount of waste generated and hence em- gasses in the atmosphere reached their highest
power them to adopt suitable waste disposal levels ever recorded, and continue increasing.
strategies. The rating system also recommends The combustion of fossil fuels from human ac-
waste reduction strategies. For businesses, this tivities and land-use changes are largely respon-
means that the work area is healthy and the sible for this increase. The ill effects of green
clean surroundings present an inviting ambi- house gases generated by the consumption of
ence for prospective customers. The reduction fossil fuels are very well known. The green rat-
of waste generation also presents an excellent ing system guides businesses on reducing their
business case for the organization to pursue. Green House Gas emission by setting short
Material Conservation, Recycling and Recy- term goals while working on a long term strat-
clability- Material conservation and recycling egy. The ultimate goal is to make businesses
is closely related to waste management. It is “Carbon Neutral” i.e. they should be able to re-
self-evident that the more we conserve and move as much carbon dioxide from the atmo-
recycle/ re-use, the less waste we generate. sphere as they generate.
Apart from this, by reusing materials there is Product Stewardship- Product Stewardship is
a definite saving in costs. The cost savings is in ‘Extended Producer Responsibility’ over the
the form of reduced material costs (as we reuse Life cycle of a product beyond production,
the same material) as well reduced waste dis- during distribution, use and disposal of prod-
posal cost (since lesser waste is generated). The ucts. The rating system encourages businesses
rating system promotes reuse and recycling of to design and develop a product that has ‘Nil/

Least’ environmental impact (CO2, Water, ma- environment growing at a fast pace, green
terial and Toxic content) during its lifecycle. It rated companies will enjoy considerable
guides businesses to perform a comprehensive consumer support and goodwill
analysis of all their products on environmental 7. Many business owners/ managers wish to
impacts over the lifecycle of the product and adopt environmentally healthy practices
explore options for reducing such impacts but are not aware of what needs to be
Life Cycle Assessment – Several initiatives are done. The rating system can act as an
being taken to reduce the environmental im- excellent guide for such businesses
pact of products at different stages – produc-
tion, distribution, use and disposal. There is a Green Rating System: Overview &
need to have an evaluation of the impact of Process
the product throughout its life cycle, so that The Green Rating System for Companies advo-
ultimately, only those with minimum life-cy- cates a performance based approach. It aims to
cle impact are made available. The life-cycle provide leadership and guidance to businesses
assessment parameters such as GHG, toxicity, on how to implement green strategies. These
material and water can guide organizations to strategies are designed based on an iterative
move towards products of lower impact. The and consultative process that includes building
rating system facilitates in this direction. partnerships with stakeholders and employing
Business Specific Benefits Include: their cumulative knowledge and experience
to address issues related to ecological sustain-
1. Communicates the corporate commitment
ability. The rating system employs a holistic ap-
towards environmental sustainability to all
proach, wherein, it not only advises business-
stake holders es on strategy and actions required but also
2. Enhances the competitiveness of the provides mechanisms to quantify the impact
company through resource conservation of such actions and make course corrections if
and improved efficiency required.
3. Current Standing- The rating system is an
easy way for businesses/ companies to
compare themselves against their peers or
competitors
4. Businesses can use the recommendations
of the rating system to develop a long term
plan to improve competitiveness as well as
ecologically sustainable
5. Most governments are prescribing strict
environmental compliance guidelines for
companies. Companies that accept the
green rating system will have a ‘head start’
in complying with these requirements
and thus have an advantage over non-
complying competitors
6. With consumer awareness related to the

The rating system evaluates green features for Criteria and Weightages
companies against the following performance
parameters: S. Suggested
No Parameters Weightages
• Energy Efficiency
(Points)
• Water Conservation 1 Energy Efficiency 150
• Renewable Energy 2 Water Conservation 100
• Greenhouse Gas Emission 3 Renewable Energy 100
• Waste Management 4 GHG Emission Reduction 100
• Material Conservation, Recycling and 5 Material Conservation,
100
Recyclability Recycling & Recyclables
• Green Supply Chain 6 Waste Management 100
• Product Stewardship 7 Green Supply Chain 100
8 Product Stewardship 75
• Life Cycle Analysis
9 Life Cycle Assessment 75
• Other Areas (Ventilation, Surroundings, Site
Selection & Innovation) 10 Others (Ventilation, Site
100
Selection & Innovation)
Weightages (points) are assigned to varying de- Total 1000
grees of goals that are set for each of these pa-
rameters. For example, the points are awarded
** For few of the sectors like Cement, IT Ser-
for reducing energy consumption. But points
vices & Service sectors, the weightage points
awarded will be higher for a business that
have been redistributed as applicable.
demonstrates a higher degree of reduction
in energy consumption compared to another
business that demonstrates a lower degree of
reduction in energy consumption. The compa-
nies at various levels of efficiency (for example;
Top 5 energy efficient plants in the world) are
also suitably recognized in this rating system.
Level Points Greenco Rating

Level 1 350 – 449 points Certified
Level 2 450 – 549 points Bronze
Level 3 550 – 649 Points Silver
Level 4 650 – 749 Points Gold
Level 5 > 750 points Platinum

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GreenCo - Water Conservation | 5

11 | 1.1 Global Scenario

12 | 1.2 Current Status in India

12 | 1.2.1 Water Demand

12 | 1.2.2. Water Resources

13 | 1.2.3 Water Scarcity

14 | 1.3 National Initiatives

14 | 1.3.1 National Water Policy

14 | 1.3.2 National Water Mission

15 | 1.4 Industrial Water Usage

15 | 1.4.1 Fresh Water Contamination and Treatment

16 | 1.4.2 Water Intensive Sectors

18 | 2. Water Metering and Monitoring

18 | 2.1 Benefits of Better Water Measurement

18 | 2.2 Flow Water and Flow controllers

20 | 3. Water management in industries & best practices

20 | 3.1 Approach to water management within & beyond the fence

24 3.2 Approach to process water management

41 4.1 Rainwater Harvesting Techniques in Urban Area

43 | 4.2 Rainwater Harvesting Techniques in Rural Areas

46 | 4.3 Designing Rainwater Harvesting System

57 | Annexure A: GreenCo Introduction and Background

GreenCo - Water Conservation | 9

Everyone understands that water is essential

GreenCo - Water Conservation | 11

12 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 13

14 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 15

• dyeing and rinsing of yarn • electrostatic dip unit (DM water)

• humidification of the yarn • for cooling of the paint solution, water

• steam production • cooling applications

• pulp preparation • boilers for steam generation where

16 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 17

2. Water Metering and Monitoring  Mass flowmeters

18 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 19

20 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

Process The end use of harvested water is located close

GreenCo - Water Conservation | 21

22 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 23

24 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 25

26 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

Natural draft cooling Replacement of forced cooling draft towers with

FRP cooling tower

Air cooled Replacing water cooled compressors with air

Closed loop water Introduction of closed loop water system in air

GreenCo - Water Conservation | 27

Reduction is cooling tower Installation of cellular type of drift

28 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 29

30 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 31

32 | Confederation of Indian Industry – Sohrabji Godrej Green Business Centre

GreenCo - Water Conservation | 33

Collected the roof water and stored

Phase 5&1 0 BAVacuum pump

2. Water Metering and Monitoring Mass flowmeters