Page 176 - CW E-Magazine (18-3-2025)

Special Report Special Report

Grasim’s water management success story: From prioritized capability, equipment reliability, our experts and Veolia’s collaborated of water from the RO process alone. To
tackle the issue of RO reject and achieve
and the trustworthiness of technology closely, addressing equipment construc-
scarcity to sustainability in partnership with Veolia suppliers throughout this collaboration,” tion, operating parameters, chemical ZLD, Veolia further innovated by intro-
explains Grasim’s Suresh. It needs to be usage, dosage patterns, recovery tech-
ducing thermal solutions. One critical
s reports of alarming water Nagda started production in 1954, and ability in the Textile and Apparel sector underlined here that developing such niques, and membrane selection. This aspect of the project was sodium
table depletion and contami- since then has diversifi ed into various and Industries in 2020; ‘The Economic projects typically involves years of collaboration resulted in the creation of sulphate, which, though environmentally
Anation continue to rise across new sectors and industries, including Times Promising Plants 2021’ for its conceptualization before reaching frui- a pioneering recycling plant, marking a benign, raised concerns among certain
Planet Earth, an extraordinary fi rst-of- the production of cement, sponge iron 155-ktpa VSF plant at Nagda. Veri- tion. The partnership between Grasim signifi cant milestone in our industry.” stakeholders. The partners then inno-
its-kind tale of successful collaboration and chemicals. tably, the Grasim Nagda story serves and Veolia commenced in late 2018 and vated a solution which combined
for industrial water management, has as an unprecedented case study, illus- continued through 2019-2020 even as Mission clarity Veolia’s expertise with Grasim’s, resulting
emerged from 23.4453° N, 75.4098° E. Ergo, the growth of its industries trating a remarkable success in water COVID struck industries and businesses The project derived its success from in an optimal brine treatment, RO, and
has not only served to accentuate management within the global VSF across the world. clear objectives which were as follows: evaporation process by Veolia. Grasim
The location in Central India is of the water requirements for the ABG Group, industry. The solution is the outcome of Firstly, the aim was to achieve ZLD com- offi cials reduced the brine concentrate
Grasim Industries Ltd.’s plant in Nagda. but has naturally led to its commitment a collaborative effort, ‘co-invented’ by The joint venture progressed smoothly, pliance, which involved treating various volume by extracting sodium sulphate
A flagship company of the $65-bn towards water stewardship and concern Grasim and global water technologies overcoming challenges, and delivering effl uent streams and recycling the treated and then returned it to Veolia for fi nal
Aditya Birla Group (ABG), and a leading for the environment. With excellence specialist, Veolia Technologies. a successful solution. By August 2021, water to reduce the reliance on fresh processing further highlighting the
global producer of viscose staple fi bre in water management practices being the project was not only operational but water. Additionally, it aimed to provide project’s commitment to sustainability.
(VSF), the Grasim plant has adopted integral to its approach to growth, the Profi table partnership also thriving, showcasing exceptional comprehensive solutions that included
cutting-edge technologies in its efforts company has been at the forefront of A background update would be in- effi ciency and success. Suresh is naturally effl uent collection, membrane-based recyc- Project exemplar
to revolutionize water management innovations to improve the effi ciency structive here. In 2019, with a growing delighted with the outcomes achieved at ling, and crystallization processes. The uniqueness and exemplary status
practices at its manufacturing unit. of processes to reduce consumption and need to address environmental concerns his plant which celebrates its 70th anniver- Another critical objective was to optimize of the project stems from its innovative
reuse of water multiple times. For this, and to further cut down on production sary in 2024. “Nearly two years after com- recovery rates, thereby reducing the need solutions, which bring forth a multitude
The Nagda plant today leads the Grasim has adopted state-of-the-art costs, Grasim extended invitations to missioning the plant, we remain satisfi ed for evaporators and crystallizers in the of benefi ts. Notably, this high recovery
way with the VSF business being the novel technologies, such as membrane prominent players in the water industry – with its performance. We aim to replicate water treatment process. Maintaining a solution achieves an impressive reco-
lowest water consumer globally. The processes, which clean up and recycle this included the world’s three fore- this model in our six other VSF plants consistent Total Dissolved Solids (TDS) very rate of over 98 percent, setting a new
facility also meets water needs of the the wastewater. With its unwavering most specializing in membrane techno- worldwide and make this environmen- level of less than 200-ppm in the treated global benchmark for ZLD plants. Unlike
entire city, railway and irrigation needs focus on environmental impact deriv- logies – to collaborate on the creation tally friendly, cost-effective, and effi cient product was essential to meet water qua- many VSF plants that often bear substan-
of the farmers through the 30-billion ing inspiration from the UN SDG 6 of cutting-edge systems. This endeavour technology available to similar situations lity standards. Lastly, the challenge was to tial operational expenses, this plant was
litres storage capacity built by Grasim. to protect, conserve and regenerate presented a signifi cant challenge since globally, emphasizing resource recycling. develop an operationally effi cient system meticulously designed to address their
The Aditya Birla company’s emphasis the water eco-system, Grasim remains there was no Zero Liquid Discharge Currently, we recycle nearly 98 per cent with minimal manpower requirements, primary pain point, Opex, making it a
on the three R principles: Reduce, committed to improve the availability (ZLD) available which could effectively of the resources entering our plant and a reduced physical footprint, and a high standout success. The revolutionary aspect
Recycle, and Reuse to protect and con- of water, the most precious shared address the intricate aspects of viscose are actively working to further reduce the degree of automation, enhancing overall of this solution lies in its recognition of
serve water has also resulted in a signi- resource, for everyone. Suresh. R, effl uent treatment. Following extensive remaining 2 per cent.” system effi ciency and cost-effectiveness. the vast potential for resource creation
fi cant reduction in freshwater intake of Senior Vice President, Production, Grasim deliberations, followed by visits to These goals collectively addressed the and utilization within the VSF industry.
its fi bre production units. Industries refl ects on his company’s model plants across the world by Grasim Why Veolia? complex challenges associated with The process generates valuable sodium
water reform journey: “When I began offi cials, it was decided to harness energy Commenting on the choice of tech- industrial water management while sulphate and other usable salts, which are
It wasn’t always like this though. my career here, we consumed approxi- effi cient technologies which could nological partner and reasons for the emphasizing sustainability and regulatory subsequently sold in the market, estab-
mately 200 cubic meters of water daily. meticulously address the intricate aspects success of the ground efforts, Suresh is compliance. lishing an additional revenue stream.
Nagda, located in a region with limi- Through dedicated efforts spanning 35- of viscose effl uent treatment. The result led to explain, “The collaboration bet-
ted rainfall, has always posed a signifi - 40 years, we’ve reduced this consump- of this pioneering initiative was that ween Grasim and Veolia was driven by Innovative solutions In fact, this innovative approach has
cant challenge for Grasim’s water-in- tion to a mere 20 cubic meters per day. Veolia emerged as the player selected to Veolia’s status as a global leader in this Grasim and Veolia innovated a series proven to be a signifi cant revenue gene-
tensive industry, which relies primarily This reduction involved intensive work meticulously craft a state-of-the-art ZLD technology, which was paramount for of innovative solutions involving optimal rator for Grasim, capable of recovering a
on the Chambal River for its production on water consumption reduction, recyc- System. our company’s risk mitigation strategy. brine treatment, Reverse Osmosis (RO), substantial portion of the chemical solu-
requirements. ling, reuse, and process innovation.” Although we contemplated handling the and evaporation processes. The fi rst tion production costs, accounting for
“We had to collaborate with global project internally, the learning curve and notable installation was a patented clarifi er, 40-50 percent of Opex. In terms of tangi-
Over the past seven decades, water It is therefore easy to see why technology suppliers to ensure the sus- time constraints led us to prefer a glob- which played a pivotal role in enhancing ble benefi ts, the project not only positions
needs have surged from 200-million Grasim Industries has been at the fore- tainability of our facility. After tho- ally reputed and established vendor. We water treatment effi ciency. Subsequently, the plant as a producer of sodium sulphate
cubic feet (mcft) to nearly 1,300-mcft, front of receiving industry accolades rough evaluation, we selected Veolia as didn’t want to go with untested players. Veolia introduced the High PH RO and usable salts but also as a source of
leading to operational interruptions for industrial and environmental best our partner. Together, we visited Veolia’s track record with nearly 200 system, a cutting-edge recycling system. recycled water. It dramatically reduces
during peak summer months due to practices – this includes the prestigious numerous facilities to fi ne-tune techno- plants worldwide instilled confi dence This system proved highly effective, pollution discharge to near-zero levels,
water scarcity. Grasim’s VSF plant at Golden Peacock Award for Sustain- logy suitable for our environment. We in our choice. During the design phase, enabling the recycling of nearly 92 percent rendering Grasim Nagda’s water resources

176 Chemical Weekly March 18, 2025 Chemical Weekly March 18, 2025 177

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