Within the Factory Fence

Key Insights from Industrial Water Research

Valerie NaidooWater Research Commission

NCPC / DTi Industrial Efficiency ConferenceICC Durban 2015

22nd July 2015

2

Global Risk Assessment (WEF)…..900 leaders

3

End-of pipe treatment

Cleaner production Reuse/Recycling

Beneficiation - Industrial ecology

Research focus in industry

Water consumption

Effluent production

focus

factory

Industrial Research focus - summary

ManagementEnd-of pipe treatment

(technologies)Cleaner

production

Reuse/RecyclingIndustrial ecology

Beneficiation - Biorefinery

Move towards not only meeting standards or municipal discharge requirements to treating to an acceptable industrial

grade water and beneficiation

Industry Overviews 

Top 80% water users Top 80 % effluent production

Amatholeautomotive food textile   automotive food textile  

City of Cape Town        brewery textile pulp & paper beverage

City of Joburgyeast beverage electroplating dairy        

Ekurhuleni Metro               

eThekwinitextile petroleum pulp & paper poultry pulp & paper petroleum textile beverage

Nelson Mandela Metrobrewery automotive chemical dairy brewery automotive textile food

Tshwanebrewery recycling beverage textile brewery food textile  

High water usersHigh effluent

producers

Management (Alignment)

3 Guideline documents to facilitate legal compliance with respect to Industrial waste management

In line with DEA National Environmental Management Act (NEMA): Waste Bill

Volume 1 – Industry GuideVolume II – Contractors GuideVolume III – Authority’s GuideReview of Local Bylaws against Waste Bill Frameworks : eThekwini Case Study

Management (Guidelines)Technical Guidelines for Cleaner Production

Mining sector / General Cleaner Production (case studies)LegislationUnderstandingToolsChecklistsCase studies (local and international)

Guidelines for Waste Minimization Clubs WhatHow to?Training Manual

Industry

Regulators

Service providers

Industry Overviews 20 National Survey Types Reports

OverviewLegislation (local bylaws)

Water Use (SWU)Wastewater GenerationBest Practices

1 Malt beer brewing 20132 Metal Finishing 20133 Soft drinks & carbonated water 20134 Dairy 20135 Sorghum malt 20146 Edible oil 20147 Red meat 20148 Laundry 20149 Poultry 2015

10 Tanning & leather finishing 201511 Sugar 201512 Pulp and paper 201413 Textiles 201514 Wine  x15 Oil refining and re-refining  x16 Power Generation  x17 Steel 201418 Fruit and Vegetable Processing  x19 Pelagic fishing industry  x20 Fish processing X

National Survey Data – Revision 2015Industry SWI Min SWI Max SWI Target SWI Units Total Water

use (kL / yr)Total

OutputOutput units n Location

Textiles 176.91 95 458.94 - kL per tonne 30 000 000 - tonnes -W. Cape, E. Cape, & Natal

Pulp and paper – Entire 54.75 17 92.5 - kL per tonne - 3,000,000 tonnes 21 -

Poultry- Entire 18.15 21.79 24.29 17.5 kL per 1000 birds 6 000 000 330,000,000 birds 140 -

Laundry – Entire 15.1 8 58.4 - kL per tonne 3 000 000 - tonnes -Every city throughout SA

Malt beer brewing 7.15 5.5 8.8 5 kL per kL of beer 8 700 000 1,200,000 kL 8 -

Dairy – Entire 4.71 2.73 7.97 2.71 kL per kL - - kL 150 Throughout SA

Sorghum malt 3.4 2.5 12.3 3.4 kL per kL 630 000 185,400 tonnes 33Gauteng (40%) & Natal (25%)

Edible oil – Entire 3.25 2.65 3.85 - kL per tonne 1 750 000 - tonnes 16 -

Sugar 3 1.5 5 - kL per tonne of sugar - 12,000,000 sugar 16 -

Soft drinks & carbonated water 2.7 - - 2.3 kL per kL of soft drink 4 000 000 1,500,000 kL - Most large

cities

Wine – Entire 2.53 0.97 4.23 0 kL per output 0 900,000 kL - W. Cape & N. Cape

Sorghum beer brewing 2.5 2.3 4.8 2.5 kL per kL 2 750 000 1,100,000 kL 36Gauteng (40%) & Natal (25%)

Red meat – Entire 1.55 0.71 3.8 - kL per cattle unit 5 800 000 3,745,000 cattle units 285 Main cities

Tanning & leather finishing 0.43 0.32 0.74 0.43 kL per hide 600 000 2,000,000 hides 20

Gauteng; Free State; Natal; W.Cape; E.Cape

Metal Finishing – entire 0.27 0.03 0.88 0.1 - 0.2 kL per m2 treated surface 9 000 000 - m2 treated surface - PWV

Textile Industry: Treat & Reuse

ANOXICANAEROBIC

AEROBIC

KEY:

FEED

ANAEROBIC ANOXIC AEROBIC MEMBRANEFILTRATION

PRODUCT

EGSB Modified Ludzack-Ettinger (MLE)

Q RECYCLE

Process Design Strategy

21

12

3

4

43

5

5

6

6

Industrial Water: Reuse of Brewery Effluent

aquaculture

High Rate Algal Ponds

Bre

wer

y ef

fluen

t

Technology Integration Approach

CSR

hydroponics

Water Efficiency and Wastewater Management

Toolso Zero Liquid Effluent

Dischargeo Green chemistryo Waste Minimizationo Life Cycle Analysiso Pincho Water Optimization

modellingo Water Footprints

Case Studies1. Green chemistry – textile industry2. Savings – general housekeeping3. Recommend RO vs IEx 4. Water savings 5. >10% water savings (Johnson &

Johnson and Eskom)6. Test value for different sectors

1. Extractives vs retail vs energy vs beverage

2. Upstream – focus internal policy

3. Within fence – target the high water use operational activities

Water Footprints

May 1, 2023File name 14

Freshwater

(finite resource)

Sustainability Discussions

Sustainability Discussions

Growing awareness that “water” needs to be considered in a broad range of decision-making processes

Highlights

Overall, it can be concluded that water footprinting is indeed a useful tool that companies can use as a first estimation of their water use and impact.

mine 1 mine 2 mine 3 Total0

500000

1000000

1500000

2000000

2500000

3000000

3500000

4000000

Grey WF

Blue WF

Green WF

m3/

year

Figure 64: Water footprint components for the individual mines at Matla

2009 2010 20110

500

1000

1500

2000

Total Green WFTotal Blue WFTotal Grey WF

Wat

er F

ootp

rint (

m3/

GWhr

)Figure 71: Total Water Footprint for the upstream and operations

Highlights

2009 2010 201137000000

37500000

38000000

38500000

39000000

39500000

40000000

40500000

41000000

Lost Return Flow

Evaporation

Incorporated

Cooling towers

Blue

WF

(m3/

yr)

Figure 68: Operational blue water footprint for Matla facility

Cooling towers99%

Evaporation0%

Lost Return Flow0.3%

Cooling towersIncorporatedEvaporationLost Return Flow

Figure 70: Components of the operational blue water footprint for 2009

Water Footprints

Take Home Messageo Important – Business Risko Policy

o Public o Business

o Operational Focus areaso Pincho Water Optimization

o Supply Chain focuso Retail – concentrate on agriculture SCo Beverage – concentrate on agriculture SC

catchment

Future: Look within and outside the factory fence

factory

Water consumption Effluent production

focuscatchment

focusSupply chain

So is there uptake of knowledge and behaviour?

May 1, 2023 File name 19

Bittersweet Relationship

May 1, 2023 File name 20

Regulation and Enforcement

May 1, 2023 File name 21

Investment

May 1, 2023 File name 22

Save Water

May 1, 2023 File name 23

Measure and Manage

Benchmark to improve!

File name 25

Set Targets

May 1, 2023 File name 26

HCD - Build Expertise

Build Partnerships

Water Sector Industry Partnerships

1. Strategic Water Partnership Network2. Alliance for Water Stewardship3. National Cleaner Production Centre4. Coaltech5. Sasol6. Eskom

• Support through research and networks UN CEO Mandate NBI Various Associations

Challenge can bring new innovations

30

Look at Community Engagement

Be part of the Water (Energy) Sensitive Design Revolution

SEZ’s and Industry should Design for :1. Off the grid2. Efficiency3. Self-sufficiency (generating)

WSD

For reports : Downloadwww.wrc.org.za

valerien@wrc.org.za