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UNIDO Country Office in Bangladesh

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Responsible Water Use in Industry:Promoting water efficient, cleaner production

market

May 5, 2018

Zaki Uz ZAMANUNIDO Country Representative in Bangladesh

and

René VAN BERKEL,UNIDO Representative, Regional Office in India


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UNIDO at a Glance

Specialized agency of the United Nations that supports inclusive and sustainable industrial development in its developing country member states Inclusive and

Sustainable Industrial

Development

Advancing economic

competitiveness

Safeguarding the

environment

Creating shared

prosperityFactories that are fit for the

future, as were already needed yesterday


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Build resilient infrastructure, promote inclusive and sustainable industrialization and foster innovation

Ensure availability and sustainable management of water and sanitation for all

Ensure sustainable consumption and production patterns

Conserve and sustainably use the oceans, seas and marine resources for sustainable development


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Water Trends in Bangladesh• The total water requirement has

been estimated at 24,370 Mm3 which includes

• 14,209 Mm3 for agriculture,• 9,910 Mm3 for navigation• 170 Mm3 for domestic and

industrial use.• Large increases in water demand

are predicted for irrigation, industry, urbanization and domestic consumption.

Sustainable Industrial Water Use

Preventing and reducing

water pollution at

source

Reducing water

intensity of production

Recycling and reusing (treated)

waste water

Banglapedia: National Encyclopaedia of Bangladesh


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Responsible Industrial Water Use

WATER USER1. Water use efficiency2. Pollution reduction3. Effluent treatment

WATER STEWARDCatchment management Water balancing

Zeroing out the discharges of polluted effluents and the net extractions of clean water


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On Site Reuse & Recycling

Good House‐keeping

Input Change

Better Process Control

Equipment Modifi‐cation

Technology Change

Production of Useful Byproduct

Product Modifi‐cation


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RECP Practice Description Common Water‐Related ExampleGood Housekeeping Maintain a clean, organized and

productive (‘neat’) workplace to eliminate avoidable ‘wastage’

• Switch off what is not in use (e.g. taps)• Repair what is broken or leaking (e.g. pipes )• Remove dry‐debris before factory wash down

Input Change Choose inputs that are efficient, effective and/or pose minimum harm to the environment and health

• Use secondary, recovered water• Use less harmful chemical substances (dyes,

detergents, etc.)• Enzyme‐enhanced bleaching, scouring

Better Process Control Monitor and control processes and equipment so that they always run at highest efficiency and with lowest wastage

• Establish and follow Standard Operating Procedures (SOP)

• Sub‐meter use of water• Install automatic shut‐off and overflow

prevention valvesEquipment Modification Make existing equipment more

efficient and less wasteful• Align and debottleneck production line• Close, hot and cold, process equipment

Technology Change Change over to new technology that is more efficient or produces less waste

• Waterless dyeing• Additive, 3D printing

On‐Site Reuse & Recycling Use previous ‘waste’ for similar or alternative purpose in company

• Counter‐current or cascaded use of water • Condensate recovery

Production of Usefull By‐Product

Convert a previous ’waste’ for a useful use elsewhere

• Provide used cooling water for external heating or cooling purposes

Product Modification Redesign product to reduce its environmental impact during production, use and/or disposal

• Produce easy care textiles that require minimal water by consumers


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Examples of UNIDO Interventions • Tannery ‐ Bangladesh, India• Textile‐ India• Automotive‐ Thailand• Ceramics –India• Food Processing‐ Vietnam


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Cleaner Technology: Tannery in BangladeshInterventions Results Remarks

Water management (Batch washing instead of open valve washing)

Reduced water consumption to 20‐25 litres/kg of hides

30% of Process water can be saved and 30% of effluent can be reduced

Hair save unhairing (A screw type filter for recovering hair from the liming‐unhairing float)

Reduce 40% of BOD and COD, 20% of SS load and save 1.30 BDT/sqft

Contributes to substantial improvements in the waste water discharge.

Low lime– sulphide liming with low float

Reduce 25 – 35% of chemical and 20 – 30% of water use


Ammonia free de‐liming Reduce N and NH4+ content in the

effluentWill reduce effluent treatment cost

HVLP/HT Spray Guns Reduce 30% bounce of sprayed chemical. Saves 1.2BDT/sqft


High Chrome Exhaustion Reduce 25% of Cr offer, 60% Cr content in spent chrome liquor and save 1.50BDT/sqft


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Cleaner Technology: Tannery in IndiaInterventions Results Remarks

Water mixing and management (Control of float level were demonstrated using three methods of measurement )

Reduced the water consumption by 20 to 30%

Reduction of pollutants like COD and TDS by 15% and 10% in the dyeing/fatliquoring bath contributed by increased uptake of chemicals

Hair save unhairing (A screw type filter for recovering hair from the liming‐unhairing float)

Reduced COD 32%, BOD 37%, Sulphide 66% and TSS 61%

Significantly lower volume of sludge, improvements in the waste water discharge due to fewer chemicals used

Processing fresh chilled hides TDS discharge in effluent is reduced by between 30% and 40%


Desalting of raw hides 15% reduction in TDS in the effluent stream due to desalting of raw hides / skins

Will reduce effluent treatment cost

VBR1VBR2

VBR1 You could replace with following slide which has pcitures embedded.VAN BERKEL, Rene, 4/30/2019

VBR2 It also includes reference to the e-learning portal with OHS and sustainable tanning technology, accessible already for BGDVAN BERKEL, Rene, 4/30/2019


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Kanpur Leather Development ProjectSafer Working Practices

Created learning modules on safe working practices

Over 1,400 industry staff trained in class room E‐learning portal already utilized by over

17,000 industry stakeholders in India


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Cleaner Technology in Textile Sector (Gujarat‐India)

Number of pilot industries 6

Electrical energy savings (kWhr/yr) 349,303

Fuel savings – coal (tons/yr) 2,027

Fuel savings ‐ agro‐waste (tons/yr) 900

Process water savings (m3/yr)

193,976

Reduction in chemical usage – caustic (tons/yr)

770

Monetary savings (Rs/yr) 42,260,500

Common measures that included:1. Reuse of condensate and cooling

water as boiler feed water2. Reuse of treated effluent for screen

washing3. Water use optimization 4. Caustic soda recovery system

Gujarat Cleaner Production Centre, 2015


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Greening Thai Automotive Supply Chain• 74 SMEs achieved

• Annual monetary savings of 7.9M EUR• Waste reduced by 2,161 ton/yr, average of 49%

•Waste water reduced by 118,230 m3/yr, average of 51%

• Energy reduced by 27%, contributing to 16,431 ton reduction of GHG emissions

• Improved rankings in GreenMark Certification• Improved access to financing


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Ceramics Industry (Gujarat, India)• 1 Modifying kiln cars for efficient transfer of heat (reduction of mass)

• Replace solid shelves with extruded shelves• Invested USD8‐20,000, payback < 5 months

• Use light weight filling materials

• Invested ~USD4,500, payback < 5 months

• Redesign spacers/holding racks

• Invested ~USD3,600, with payback < 1 month

2. 100% reuse of water and sludge in process (zero effluent discharge)• Material recovery and water conservation at very low cost

3. Electricity conservation• Power factor improvement with capacitators• Variable speed drive on ball mill motors• On‐off timers and other controls• Reduce and optimize use of compressed air• Improvement in kiln wall insulation


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Food Processing‐ VietnamVietnam

~45,000 USD/yr


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Business Case

Cost savings

Productivity enhancements

Quality improvements

Organizational efficiency

License‐to‐operate


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In Closing• Water efficiency and effluent reduction are among greatest challenges for the industries

• These are intrinsically linked to chemicals and energy use, productivity and quality, calling for integrated, and well proven approaches, such as Resource Efficient and Cleaner Production

• Rapid emergence of innovative technologies has potential to transform industry to significantly reduce water dependence whilst also uprooting global industrial value chains in a manner not witnessed before

• The transition to waterless future starts with using less water today and drastically minimizing discharges of pollutants in water bodies


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Your feedback please!

Zaki Uz ZAMANUnited Nations Industrial Development

Organizationz.zaman(at)unido.org

www.unido.orghttps://open.unido.org/projects/BGD/projects/

René VAN BERKELUnited Nations Industrial Development

Organizationr.vanberkel(at)unido.org

www.unido.orghttps://open.unido.org/projects/IN/projects/

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