CPI

Cleaner Production Institute

PAK

stewardship
P a k i s t a n
 Growth inhibition of bacterial species (responsible for removing organic pollution)
Value of pH
under highly acidic and alkaline conditions.

Corrosion of water carrying systems and structures with acidic wastewaters having low
pH levels.
Malfunctioning and impairment of certain physico-chemical treatment processes
under highly acidic and alkaline conditions.

Depletion of Dissolved Oxygen (DO) levels, of the receiving water body, resulting in
Temperature
growth inhibition of aquatic life.
Malfunctioning of wastewater treatment systems, under high temperatures.

Effluent Characteristic Ranges Reduced light penetration in natural waters and consequent reduction in
Colour
photosynthesis.
Parameter Units ETPI PISD
NEQS Aesthetic nuisance.
Pulp Mill Paper Mill Pulp and Paper Mill
Organic Depletion of Dissolved Oxygen (DO) levels, of the receiving water body, below limits
pH - 6.5 – 7 6.7 – 7.9 5.19 – 11.72 6–9 Pollutants necessary to maintain aquatic life (4-5 mg/l).
BOD mg/l 4,000 – 8,000 100 – 500 219 – 3,292 80
Sedime ntation in the bottom of water bodies covers the natural fauna and flora on
Suspended Solids
COD mg/l 6,000 – 14,000 200 – 1,000 892 – 3,460 150 which aquatic life depends.
TSS mg/l 1,000 – 4,000 300 – 500 358 – 4,232 200 Localized depletion of DO in the bottom layers of waters bodies.
TDS mg/l - - 1,164 – 5,824 3,500 Reduced light penetration in natural waters and consequent reduction in
Temp ?C 34 – 36 35 - 40 photosynthesis.

Ref: PISD Database Aesthetic nuisance.

Reduced re-aeration in natural surface bodies, because of floating oil and grease film
Oil and Grease
and consequent depletion in DO levels
Reduced light penetration in natural waters and consequent reduction in
Wastewater Generation Unit Wastewater Generation photosynthesis.
Category
(avg. m3/y) (avg. m3/ton)
Aesthetic nuisance.
Integrated Paper and Pulp Mill 5,491,999 202
Chromium Acute renal tubular necrosis and liver necrosis in humans at higher doses.
Wastepaper Mill 1,817,082 96
Gastric irritations and ulcers in humans at lower doses.
Ref: PISD Database
BWMP-01 Conduct training of workers and management

Category Water management, energy conservation, pollution reduction

Description
Conduct training of workers and manage ment on water conservation, energy efficiency and pollution
reduction aspects. Experts, trainers and consultants can be hired to conduct these trainings.
Investment PKR 200,000-300,000 depending on the size of the organization and extent of trainings.

Benefits
Trained human resource is beneficial in reducing resource waste and contribute in the profitability of the
organization.

BWMP-02 Installation of water flow meter

Category Water management
Description
Water management is not possible without monitoring of water consumption and setting benchmarks.
Installation of water flow meters in water consuming areas is needed to determine water consumption and
benchmarks (m3 /ton) for water management.
Investment PKR 10,000-200,000
Benefits
PKR 11,000-220,000/year, payback in 11 months.
Water management through monitoring. Water management results in reducing chemicals, energy and
wastewater hydraulic load.

BWMP-03 Leakage control, maintenance of pipelines and piping improvement

Category Water management, energy conservation, pollution reduction
Description
Improper maintenance or lack of preventive maintenance result in leakages which cause resource wastage,
pollution generation, untidiness and safety hazard in occupational areas.
Investment PKR 10,000-100,000
Benefits
PKR 20,000-200,000/year, payback in six months.
Preventive maintenance results in resource management, pollution reduction and safety for workers.

BWMP-04 Reuse of cooling water

Category Water management

Description
Collection and reuse of cooling water from singeing, chillers, compressors, therm oil heaters, cooling drums,
caustic recovery plant etc.
Investment PKR 15,000-100,000
Benefits
PKR 30,000-200,000/year, payback in six months.
BWMP-05 Use of reduced sized diameter water hoses BWMP-10 Installation of automatic level control switches in water storage tanks
Category Water management Category Water management
Description Description
Water hoses with large sized diameters are used on production floors which result in large quantities of In some production units, water is wasted as it overflows from water storage tanks since there is no
unnecessary water consumption and wastage. Management should use appropriately sized water hoses in mechanism to turn off water pumps or turbines when tanks are full. These tanks should be equipped with
water use points. automatic level control switches so that water turbines switch off and restart when the water level drops.
Investment PKR 20,000-100,000
Investment PKR 10,000-50,000
Benefits
Benefits
PKR 30,000-150,000/year, payback in eight months.
PKR 11,000-55,000/year, payback in 11 months.

BWMP-06 Reuse of reverse osmosis (RO) reject water

BWMP-12 Dry cleaning of floors
Category Water management
Category Water management, pollution reduction
Description
RO reject water is high in TDS which is generally discarded. This is poor
porr quality water which can be used in Description
places where high quality water is not required. Examples can be toilets, for floor and vessel washing, water Spills and leakage of chemicals on floors should not be washed with water as it increases the pollution load
showering in wet scrubbers etc. of wastewater. Instead floors should be dry cleaned with cloths, saw dust or any other solid material. This
practice will reduce water consumption and pollution.
Investment PKR 30,000-60,000
Benefits Investment PKR 5,000-10,000
PKR 60,000-120,000/year , payback in six months. Benefits
PKR 6,000-11,000/year, payback in 11 months.

BWMP-07 Reuse of wastewater as showering water

Category Water management
BWMP-12 Improve clarification process of white water and its reuse in processes
Description
Category Water management, pollution reduction
Water showering is carried out in wet scrubbers or cyclones attached with solid fuel boilers in production
units. Wastewater, which is less polluted, can be used as an alternate for showering water in these scrubbers Description
and cyclones. White water can be reused in processes if it does not contain a substantial amount of suspended solids. The
white water clarification can be improved and reused. The various application of clarified paper machine
Investment PKR 25,000-100,000
whitewater is in Decker thickener showers, vacuum washers, pulp dilutions and Johnson screen showers.
Benefits There are different technologies available to clarify white water.
PKR 30,000-120,000/year, payback in 10 months. PKR 50,000-150,000
Investment
Benefits
BWMP-08 Control of floor and other washings PKR 55,000-165,000/year, payback in 11 months.
Category Water management
Description BWMP-16 Installation of temperature and pressure gauges in process vessels
Workers generally use water liberally to wash floor. Mill management should take appropriate control Category Energy conservation
measures to reduce water consumption at washing points.
Description
Investment PKR 10,000-50,000 Generally when temperature and pressure gauges are not installed in process vessels and pipelines, energy is
Benefits unnecessarily used to heat water and other contents.
PKR 12,000-60,000/year, payback in 10 months. Investment PKR 5,000-50,000
Benefits
BWMP-09 Installation of water trigger nozzles in water hoses PKR 6,000-60,000/year, payback 10 months
Category Water management

Description
Workers consume large quantities of water to wash floors and other vessels and drums using water hoses.
Often water hoses are kept running and thrown on floors thus wasting large quantities of water unnecessarily.
These water hoses should be equipped with water trigger nozzles so that controlled water is utilized and waste
avoided.
Investment PKR 10,000-15,000
Benefits
PKR 15,000-25,000/year, payback in eight months.
BWMP-18 Performance monitoring of electric motors BWMP-23 Boile r blow down after TDS monitoring
Category Energy conservation Category Energy conservation
Description Description
Generally electrical parameters of motors are not monitored and consequently their performance is not Blow down occurs in a boiler to manage TDS in it. Generally boiler operators conduct blow down at fixed set
evaluated. Manage ment should use energy analyzer, regularly monitor electrical parameters and evaluate intervals without measuring the TDS of boiler water. Therefore, unnecessary blow downs are conducted and
motors’ performance. In case motors don’t operate as per required parameters, they should be rectified or energy is. Blow down should always be conducted after measuring TDS.
replaced.
Investment PKR 10,000-20,000
Investment PKR 50,000-300,000 (energy analyzer cost)
Benefits
Benefits PKR 30,000-60,000/year, payback in four months.
PKR 75,000-450,000/year, payback in eight months.

BWMP-24 Monitoring of chemical consumption in processes

BWMP-19 Use of high quality copper wire to rewind motors Category Pollution reduction
Category Energy conservation Description
Description In some production units, chemicals are added in process vessels without being properly measured. Estimated
Poor quality copper wire is generally used to rewind motors which affect motor performance. Management quantities of chemicals are added based on judgment which results in excessive use of chemicals. This not
should use high quality copper wires for rewinding. only increases production cost but also increases the wastewater pollution load. Workers should add
chemicals after exact measurement and calibrated jugs/mugs or weighing scales can be used to do so.
Investment PKR 50,000-200,000
Benefits Investment PKR 5,000-10,000

PKR 55,000-220,000/year, payback in 11 months. Benefits

PKR 10,000-20,000/year, payback in six months.

BWMP-20 Record keeping of rewound motors

BWMP-25 Storage of chemicals with catch pans
Category Energy conservation
Category Pollution reduction
Description
Motor performance records should be maintained and each motor load reading should be recorded and
Description
evaluated after rewinding. In case rewinding causes excessive current consumption, motors should be Generally chemical containers are not stored with any catch pans. In the event of a leak or spill chemicals are
replaced. washed away in the wastewater drain, adding to pollution. Catch pans should be placed over chemical
containers and their volume should be 110 per cent of the volume of the container placed in it.
Investment PKR 100,000-200,000 (motors replacement)
Investment PKR 50,000-200,000
Benefits
PKR 120,000-240,000/year, payback in 10 months.
Benefits
PKR 55,000-220,000/year, payback in 11 months.

BWMP-21 Reuse of steam condensate

BWMP-21 Proper disposal of solid waste
Category Water management, energy conservation
Category Pollution reduction
Description
Description
Some industries waste steam condensate instead of using it as boiler feed water. This is a clean and energy
Solid waste is sometimes dumped in wastewater drain lines which cause pollution. Solid waste should be
intensive water stream whose wastage results in substantial monetary loss. This stream should therefore be
collected and disposed off in appropriate sites.
properly collected and reused as boiler feed water.
Investment PKR 100,000-150,000 Investment PKR 10,000-50,000

Benefits Benefits
Pollution reduction, less pollution load on wastewater treatment plant and NEQS compliance.
PKR 625,000-1,200,000/year, payback in two months.
BWMP-27 Installation of automatic shut off valve in machines BWMP-29 Installation of temperature controllers, steam flow meters to control e nergy supply
Category Water management Category Energy conservation
Description Description
Water supply to machines is usually not synchronized with its operation. W hen machines stop, Water remains Energy wastage cannot be reduced unless it is monitored and control equipment is installed in machines.
running even when machines have switched off, adding to water wastage. Machines should therefore be Temperature controllers allow energy supply to be managed and steam flow meters help in managing steam
equipped with automatic shut off valves which allow water to be supplied only when machines are operating. consumption in various processes.

Investment PKR 400,000-600,000

Investment PKR 500,000-1,000,000
Benefits Benefits
PKR 165,000-330,000/year, payback in 36 months. PKR 265,000-400,000/year, payback in 18 months.

Optimize shower water use and installation of efficient showers in paper machines BWMP-30 Installation of energy efficient motors
BWMP-23
Category Water management, energy conservation Category Energy conservation

Description Description
Inefficient showers in paper machines consume large amounts of water and energy, and are inefficient in Old, standard and inefficient motors waste a lot of energy. Inefficient motors should be replaced with energy
washing pulp. Adjust total number of nozzles, their positions, jet angles and distance between nozzles and the efficient motors to reduce energy consumption.
paper machine felt/wire to minimize water use. Use different types of nozzles e.g. flat, needle jet. White water Investment PKR 1,000,000-2,000,000
can be used in low pressure showers instead of freshwater in the wire and press section. Efficient showers
consume less water and energy and are very effective in washing pulp. Benefits
PKR 925,000-1,850,000/year, payback in 13 months.
Investment PKR 2,000,000-3,000,000
Benefits
BWMP-31 Installation of efficient water turbine
PKR 660,000-1,000,000/year, payback in 36 months.
Category Energy conservation
Description
BWMP-24 Installation of medium consistency pulp screening in paper mills Generally water turbines are inefficient and waste a lot of energy. To reduce energy consumption they should
Water management be replaced with efficient turbines.
Category
Investment PKR 200,000-300,000
Description
Low consistency pulp screens consume a large amount of freshwater in dilution. A large amount of Benefits
wastewater is generated with greater perce ntage of fibre losses. Medium pulp consistency screens use less PKR 160,000-240,000/year, payback in 15 months.
water for the required consistency of pulp.
Investment PKR 2,000,000-3,000,000 BWMP-29 Installation of heat exchangers in hot wastewater streams
Benefits Category Energy conservation
PKR 660,000-1,000,000/year, payback in 36 months.
Description
Hot wastewater streams contain a substantial amount of energy, which is wasted in the drain. This energy can
be recovered by installing heat exchangers in these streams to heat freshwater for use in other processes.
BWMP-25 Disposal of boiler ash in dry state
Investment PKR 500,000-750,000
Category Water management, pollution reduction
Benefits
Description PKR 500,000-750,000/year, payback in 12 months.
Some production units wash fly ash from solid fuel boilers in drains with large quantities of washing water.
This causes water wastage and increase in wastewater pollution. Ash should be collected from scrubbers and
cyclones and disposed off in appropriate disposal sites instead of being washed with water in drains.
BWMP-30 Preheating of process streams with flue gases of generator exhausts
Investment PKR 300,000-3,000,000 Energy conservation
Category
Benefits Description
PKR 100,000-1,000,000/year, payback in 36 months.
Generator exhaust gases are emitted at a temperature of around 500oC. Process water streams can be
preheated through these flue gases by installing heat exchangers in the exhaust.

Investment PKR 1,000,000-2,000,000

Benefits
PKR 1,000,000-2,000,000/year, payback in 12 months.
BWMP-31 Inverters on motors BWMP-38 Establishing laboratory
Category Energy conservation Category Pollution reduction

Description Description
Inverters installed on motors with fluctuations in load will result in in controlled energy consumption over time. Impure chemicals are used more regularly and increase wastewater pollution. Management should establish
a laboratory to analyze incoming chemicals with respect to their purity. Only pure chemicals should be used
Investment PKR 200,000-400,000 in processes and impure chemicals should be discarded. Use of pure chemicals will reduce production cost
Benefits and also wastewater pollution load.
PKR 200,000-400,000/year, payback in 12 months. Investment PKR 500,000-1,000,000
Benefits
PKR 160,000-350,000/year, payback in 36 months.
BWMP-32 Installation of settling ponds to recover fibre from wastewater

Category Pollution reduction

Description
Paper mill wastewater contains a substantial amount of fibre which can be recovered through settling ponds
and be reused in making low grade paper boards. This will reduce resource loss and decrease the wastewater
pollution load.

Investment PKR 500,000-1,000,000

Benefits
PKR 150,000-350,000/year, payback in 36 months.

BWMP-33 Use of treated water in processes

Category Pollution reduction
Description
Untreated water uses more che micals in processes and the resulting product is of low quality. Water should
be treated with RO and softener, and then used in processes to reduce chemical consumption and
wastewater pollution load.
Investment PKR 1,000,000-2,000,000
Benefits
PKR 500,000-1,000,000/year, payback in 24 months.

BWMP-35 Automatic che mical dispensing system

Category Pollution reduction
Description
Manual feeding of chemicals allow excessive use of chemicals which ultimately causes resource loss and
increases wastewater pollution load. Automatic chemical dispensing systems allow controlled use of chemicals
in process recipes.
Investment PKR 2,000,000-3,000,000
Benefits
PKR 650,000-1,000,000/year, payback in 36 months.
 Conduct boiler blow down after measuring
17 10-20 30-60 4
TDS levels in the boiler water.
Wastewater Poll utio n Reduction
Monitoring chemical consumption in process
# Business Priority-01 Solution Options Financial Overview 18 recipes (use of calibrated beakers for 5-10 10-20 6
chemical dosing).
Investment Saving
Simple Payback Chemical storage with catch pans under
(PKR 000) (PKR 000/yr) 19 50-200 55-220 11
Water management chemical containers to collect leaks and spills.

Leakage control, maintenance of pipelines, Collect and dispose of solid waste at

1 10-100 20-200 6 20 10-50 - -
piping improvement. appropriate dumping sites.
Total 575-2,115 1,256-3,796 5-7
Collection and reuse of cooling water from
2 compressors, chillers, sealing water, etc in the 15-100 30-200 6
process.

Use of reduced sized diameter pipes for water

3 20-100 30-150 8
use.

Reuse of RO rejected water/softe ner

regeneration water for showering in boiler wet
4 30-60 60-120 6
scrubber/cyclones or in the process where
high quality water is not required.

Use of wastewater instead of freshwater in

5 boiler wet scrubber and for cleaning of 25-100 30-120 10
wastewater mechanical screens.
6 Control of floor and other washing points. 10-50 12-60 10
Installation of water trigger nozzles with water
7 10-15 15-25 8
hoses.
Installation of automatic level control switches
8 10-50 11-55 11
at water storage tanks.
9 Installation of water flow meters. 10-200 11-220 11
Dry cle aning methods to clean wet floor
10 5-10 6-11 11
contaminated with chemicals.

Improved clarification process of white water

11 50-150 55-165 11
and reuse in the process.
Energy Conservation
Installation of temperature and pressure
12 5-50 6-60 10
gauges in process vessels.

Monitoring and evaluation of motor

performance and improved system (loading
13 50-300 75-450 8
adjustment, replacing over/under sized
motors).
Use of high quality copper wires for rewinding
14 50-200 55-220 11
of motors.
Record keeping of rewound motors and
15 replacement after three to four times of 100-200 120-240 10
rewinding.

Collection and reuse of steam condensate as

16 100-150 625-1,200 2
boiler feed water.
 # Solution Options Financial Overview
Investment Saving Simple Malik Board and Paper Industries implemented the following BWMPs:
(PKR 000) (PKR 000/yr) Payback - Monitoring and measurement of freshwater intake;
Water management - Collection and reuse of machine white water;
- Collection and reuse of machine back water;
Conduct trainings of workers and managers on
- Installation of efficient pulp feeding nozzles in paper machine headbox;
1 water conservation, energy e fficiency and 200-300 - -
pollution reduction aspects. - Controlled floor washings;
- Control water leakages;
Installation of automatic water shut-off valves - Improvement in steam conde nsate recovery system;
2 500-1,000 165-330 36
with machines.
- Low float techniques;
Installation of efficient showers in pape r - Installation of water flow meters;
3 2,000-3,000 660-1,000 36
machines. - Installation of steam flow meters with boilers;
Installation of medium consistency pulp - Installation of solar PV system with LED lights;
4 2,000-3,000 660-1,000 36
screening in paper mills. - Installation of new electrical motors with inverters;
Disposal of boiler ash in dry state instead of
5 300-3,000 100-1,000 36
washing it in the drain with water. Water Conservation 9% (554,751 m3/yr)
Energy Conservatio n Investment PKR 3.75 million
Installation of temperature controllers, steam Annual Saving PKR 1.33 million
6 400-600 265-400 18
flow meters, etc.
7 Installation of energy efficient motors. 1,000-2,000 925-1,850 13
8 Installation of efficient water turbines. 200-300 160-240 15
Installation of efficient steam and condensate
9 1,000-3,000 800-2,400 15
recovery system.
Installation of heat exchangers in hot
10 500-750 500-750 12
wastewater streams.
Preheating of process streams with flue gases of
11 1,000-2,000 1,000-2,000 12
generators exhaust.
12 Inverters on motors. 200-400 200-400 12
Wastewater Poll utio n Reduction
Installing settling ponds to recover fibre from
13 wastewater and use it in processes or its sale to 500-1,000 150-350 36
low quality grade board making units
Use of treated water with RO/softener in the
14 1,000-2,000 500-1,000 24
process.
15 Automatic chemical dispensing system. 2,000-3,000 650-1,000 36
Set up of laboratory for chemicals purity
16 500-1,000 160-350 36
monitoring.

Disposal of boiler ash in dry state instead of

17 - - -
washing with water in the drain.
Total 13,300-26,350 6,895-14,070 22-23

The paper sector's second priority set of BWMPs implementation also has a very clear business case. Amount
invested is in the range of PKR 13.3-26.4 million, depending upon the size of the industry, pays back in less than
two year with annual benefits of PKR 6.9-14.0 million, in terms of water conservation (5-30 per cent), chemical
savings, energy efficiency (5-10 per cent) and pollution reduction (10-30 per cent).