Industrial water benchmarking study for india

Industrial Water
Benchmarking Study
for India

F O R E W O R D
The introduction of The Sustainable Development Goals (SDGs) has provided a new
dimension to the global growth and transformation agenda. It is no longer
sufficient to just grow; the imperative now is to grow in a way that helps address
the world’s largest developmental challenges. As corporates, we are uniquely
positioned to shape the developmental agenda envisaged by the SDGs for 2015-30.
However, it may be critical to prioritize and address these goals in a phased manner.
From India’s perspective, the risks related to water are imminent and merit
immediate attention. In fact, 3 out of 17 goals included in the SDG framework
relate to water risks (goal 6: clean water and sanitation; goal 12: responsible
consumption; goal 14: life below water).
ONGC recognizes the criticality of risks posed by water and the urgent need for
organizations to better understand the resulting challenges as well as the best
practices to mitigate the risks. The industrial water study represents a small yet
significant first step that ONGC has taken in this direction. The study seeks to
explore water related trends and challenges faced by the industrial sector in India.
In its first phase, the study focuses on two industrial sectors in India – (i) Thermal
Power Generation (which accounts for the largest share of industrial water
consumption), and (ii) Iron & Steel (which poses a significant risk to the water
bodies in the form of effluents and wastewater discharge). The study also highlights
some of the best practices adopted by the leading performers in India as well as by
global organizations.
I would like to express my sincere gratitude to all the organizations that have
contributed to this study in the form of leadership insights, survey responses and
site visit permits. I would also like to commend Global Compact Network India and
its knowledge partner Accenture Strategy for all their efforts in conducting this
study. I genuinely believe this study can play a critical role in accelerating action on
water challenge – an action that can only be realized through active collaboration
at all levels and continual thrust on innovation. This alone would ensure that as a
nation we shape a sustainable growth model, which allows us to sustain
momentum in industrial growth in harmony with the requirements and constraints
associated with one of the most critical natural resource – water.
(Dinesh K Sarraf)
Chairman and Managing Director,
Oil and Natural Gas Corporation Limited
President,
Global Compact Network India
Dinesh K Sarraf
1
Industrial Water Benchmarking Study for India

2
P R E F A C E
Global economy is in an interesting transformation phase, a phase characterized by razor-sharp focus on
sustainable growth and development. There is a rising impetus on adopting the Sustainable Development Goals
(SDGs) launched by the United Nations, which are expected to shape the global transformation agenda during
2015-30.
In this rapidly evolving global context, India faces its own set of opportunities and challenges. On one hand, we
are marching towards becoming the third largest economy in the world by 2030 and on the other hand, we are
grappling with critical resource constraints that could potentially impede our progress. Water represents one such
major risk that the industry faces today. Given the recent spate of droughts, we have already witnessed how the
risk of water can potentially disrupt industrial operations in high water stress areas.
In this context, the Industrial Water Benchmarking Study for India presents a strong forum for different
stakeholders to understand the nuances related to industrial water usage in India. This is perhaps the first of its
kind industrial water study in India. The study identifies the most pressing water related issues as viewed by the
business leaders and water managers in India. It also illustrates interventions and global best practices that can
help address the situation. The Industrial Water Benchmarking Study for India has leveraged two key channels to
generate insights - as a first step, it involved capturing insights and perspectives of business leaders through an
online survey. Thereafter, these insights were validated through site visits to some of the prominent Iron & Steel
and Thermal Power Plants in India. While the sample of survey responses and site visits may not be entirely
representative of the focus industrial sectors in India, I do hope that it provides an authentic and reliable platform
to understand the underlying challenges and drive informed actions.
I would like to take this opportunity to congratulate my Global Compact Network India Team and Accenture
Strategy for conducting this critical Industrial Water Benchmarking Study. I would also like to express my sincere
thanks to all the stakeholders who have participated in this study. I am confident that the insights and
perspectives captured through this study will help lay a sound foundation to address the looming water crisis
that the industrial sector faces in India.
(Desh Deepak Misra)
Chair, Asia Pacific Resource Centre &
Director - Human Resource
Oil and Natural Gas Corporation Limited
(FROM ONGC)

3
P R E F A C E
The introduction of Sustainable Development Goals (SDGs) has provided a holistic framework to tackle world’s
biggest development challenges, including challenges related to water. It is worth recognizing that the role of
businesses in addressing these global challenges is more critical today than ever before. Accenture
Sustainability Services is globally committed to the SDGs and has been one of the pioneering organizations
supporting clients across the world in leveraging SDGs as a lens for sustainable growth and differentiation.
Accenture is a knowledge partner of Global Compact through United Nations Global Compact (UNGC) as well
as Global Compact Network India (GCNI). At the forefront of sustainability services, Accenture partners with
UNGC to engage with global leaders and conducts the largest triennial CEO study on sustainability, the latest
being in 2016. With GCNI, we have collaborated and produced path breaking publications such as the ‘India
CEO Study on Sustainability’ in 2013 and ‘SDGs - Broadening the Horizon for India’s Growth and
Transformation’ in 2016.
This study is a unique opportunity to demystify water related challenges faced by the industrial sector in India.
In particular, the study focuses on two industrial sectors in India (Thermal Power Generation and Iron & Steel)
and highlights how improvements in productivity, often achievable through better technologies, could be
critical to address the impending water crisis.
We would like to express our sincerest gratitude to ONGC for sponsoring this study, to GCNI for their valuable
support and contributions, and to all the participating organizations for their rich insights.
(FROM ACCENTURE)
(Vishvesh Prabhakar)
Managing Director, Sustainability
Accenture Strategy, India
(Sundeep Singh)
Principal – Sustainability,
Accenture Strategy

C O N T E X T
4
Water is globally recognized as a critical risk and there
are concerted efforts underway to address the situation
Recent decades have witnessed unprecedented
population growth coupled with rapid urbanization and
industrialization. This has resulted in an increased
consumption of natural resources, such as water.
Although water is available in abundance on the surface
of the earth, fresh water needed for human sustenance
is a finite resource and represents only about 3 percent
of the total water. This poses a risk that can negatively
impact the growth and development of nations across
the globe.
The risk of water availability is recognized globally and
several organized efforts are being undertaken to
address it. For instance, in 2015 the United Nations (UN)
launched the Sustainable Development Goals (SDG)
framework, which was formally adopted by 193 member
nations of the UN. SDGs are a set of 17 development
goals designed to address the world’s most critical
developmental issues over the 2015-2030 timeframe.
From India's perspective, these goals are also aligned to
the development agenda set aside by the Indian Prime
Minister to ensure sustainable growth and
transformation of India.
Figure 1: Water related goals captured in SDGs
1NO
POVERTY1NO
POVERTY
7AFFORDABLE AND
CLEAN ENERGY
13CLIMATE
ACTION 14LIFE
BELOW WATER 15LIFE
ON LAND 16PEACE, JUSTICE
AND STRONG
INSTITUTIONS
17PARTNERSHIPS
FOR THE GOALS
8DECENT WORK AND
ECONOMIC GROWTH 9INDUSTRY,INNOVATION
AND INFRASTRUCTURE 10REDUCED
INEQUALITIES 11SUSTAINABLE CITIES
AND COMMUNITIES 12RESPONSIBLE
CONSUMPTION
AND PRODUCTION
2ZERO
HUNGER 3GOOD HEALTH
AND WELL-BEING 4QUALITY
EDUCATION 5GENDER
EQUALITY 6CLEAN WATER
AND SANITATION
0
0
1
0
0
1
Three out of the 17 development goals included in the SDG framework relate to water related issues. These include Goal 6
(“Clean Water and Sanitation”), Goal 12 (“Responsible Consumption”), and Goal 14 (“Life Below Water”). Together, these
three goals seek to achieve universal access to clean drinking water and sanitation, curtail water pollution, promote water
efficiency and protect marine and coastal ecosystems by 2030.

5
The impending water crisis in India underpins the
importance of water related SDGs and the need for
urgent action
Currently, India faces a severe water crisis in major parts
of the country. In fact, 10 out of 29 states face
drought-like conditions due to erratic monsoon
patterns1
. The situation is further exacerbated by other
water related challenges such as excessive water
pollution and inadequate access to clean water, which
are negatively impacting our communities, wildlife, and
biodiversity on land and in water. Around 37 million
people in India are affected by water borne diseases,
resulting in a loss of about 73 million working days every
year2
. Around 30 fish species in the Western Ghats have
been added to the endangered species list, with 15
species identified as critically endangered species3
.
What does this mean for the
industrial sector?
Contributing to this ongoing situation of water stress is
the industrial use of water. The share of freshwater use
for industrial purposes is set to rise. As per an estimate
in 2010, India’s annual water demand was 813 billion
cubic meter (BCM). This is expected to rise to 1,093 BCM
by 2025 and 1,447 BCM by 20504
. It is noteworthy that
supply is not expected to match the pace of increase in
water demand. According to another research study,
water supply in India is projected to meet only 50% of
total demand by 20305
. This growing demand-supply
imbalance could have significant implications from the
perspective of water sharing across industrial sector,
domestic sector and irrigation needs.
How much is a BCM of water?
One cubic meter is equal to a cube of 1 meter holding water equivalent to 1000 1-liter water bottles.
One BCM of water is equivalent to a billion of such cubes.
SDG Illustrative targets (non-exhaustive)
Goal 6: Clean water and sanitation
• By 2030, expand international cooperation and capacity-building support to
developing countries in water and sanitation-related activities and programmes,
including water harvesting, desalination, water eﬃciency, wastewater treatment,
recycling and reuse technologies
• By 2020, protect and restore water-related ecosystems, including mountains,
forests, wetlands, rivers, aquifers and lakes
Goal 12: Responsible consumption & production
• By 2030, achieve the sustainable management and eﬃcient use of natural
resources
• By 2030, ensure that people everywhere have the relevant information and
awareness for sustainable development and lifestyles in harmony with nature
Goal 14: Life below water
• By 2025, prevent and significantly reduce marine pollution of all kinds, in
particular from land-based activities, including marine debris and nutrient
pollution
• Minimize and address the impacts of ocean acidification, including through
enhanced scientific cooperation at all levels
Figure 2: Water related development goals and targets outlined in SDG framework
6CLEAN WATER
AND SANITATION
12RESPONSIBLE
CONSUMPTION
14LIFE BELOW
WATER

Generation Sector and Iron & Steel Sector. The next two
phases of the study will cover other sectors and seek to
develop a comprehensive water index for the industrial
sector in India. This study focuses on the following two
industrial sectors in India:
Thermal Power Generation sector: This sector
accounts for over 70% of the total industrial water
consumption in India. Aligning specific water
consumption for thermal sector in India with global
benchmarks would be critical to control the upsurge in
quantity of water needed by the industrial sector.
Iron & Steel sector: In India, around 2.3 BCM of
untreated industrial wastewater is generated annually.
The approximate cost of treating this industrial
wastewater will be around INR 2,300 crores. Thermal
Power and Steel plants are the major contributors to
the annual industrial wastewater discharge8
. In
particular, wastewater discharged by the Iron & Steel
plants comprises of chemicals such as phenol, cyanide
and ammonia, which are toxic for the receiving
waterbodies when discharged untreated or partially
treated9
. These effluents can adversely impact aquatic
life as well as the entire food chain. These effluents
can also render fresh sources of water as unusable for
industrial or domestic purposes.
6
Our discussions with experts reveal that the growing
demand-supply gap will significantly impact the
industrial sector due to the relatively low priority
accorded to industries for water allocation. This could
potentially result in more stringent water use
regulations and intensify water related challenges
faced by the industry. Some of these challenges have
already begun to surface, disrupting operations in high
water stress areas7
.
Industrial units facing water supply cuts
due to scarcity
In early 2016, due to water shortages, the civic
bodies in several states imposed cuts on water
supplied to industrial belts. In Maharashtra
Industrial Development Corporation (MIDC), nearly
15,500 industrial units of various sizes suffered
almost 50% water cut.
2000
634
813
1,093
1,447
2010 2025E 2050E
Share of
industry:~19%
Potential water
savings that
can be
realized
by improving
productivity
Share of
industry:~8%
Waterdemand(BCM)
+78%
CAGR: 2%
Figure 3: India’s growing water demand6
Clearly, there is an urgent need to assess the industrial
water usage pattern and identify potential mitigation
measures to address the growing water concerns. This
study is organized across three phases. The current
phase (i.e. phase 1) includes the Thermal Power

Water related risks & challenges in India
To begin, we focus our attention on the different ways in which water related risks are perceived by the industrial sector.
These risks can be organized in four broad categories.
7
Figure 4: Water related risks
Category
Physical
Financial
Regulatory
Reputational
Brief description Water related risks*
Risks that jeopardize the physical
operations of a plant and can lead to
temporary or permanent shutdowns
1. Water access and availability
2. Declining water quality
3. Climate severities
Water risks that have a direct
implication in terms of rising costs
(and hence dropping profitability)
4. Rising water prices
5. Rising water treatment costs
6. Ineﬃciencies due to technology obsolescence
7. Need for sophisticated approach for water management
Risks that can expose the
organization to potential lawsuits,
penalties and fines
8. License to operate
9. Rising Government scrutiny
10. Statutory water withdrawal limits
Risks that can impact organization’s
brand image and potentially erode
consumer trust and loyalty
11. Impact of water discharge on environment
12. Rising stakeholder expectations
13. Impact on communities
14. Conflicts related to water sharing
*Some of these risks are relevant across more than one category but are mapped to the category where they are expected to have the
most significant impact

8
License to
operate
Climate
severities
(floods and
droughts)
Rising
stakeholder
expectations
Conflicts
related to
water sharing
Need for
sophisticated
approach for water
management
Declining
water quality
Impact on
communities
High impact risks
Impact Intensity
Immediate risks
Rising
water
prices/
treatment
costs
Rising
government
scrutiny
Ineﬃciencies due to
technology obsolescence
Water access
and availability
Impact of water
discharge on
environment
Statutory limits with
respect to water
withdrawal
Timeframeforriskrelevance
Figure 5: Water risk prioritization matrix
Based on inputs from the leading Thermal Power Generation and Iron & Steel organizations in India, it is evident that
these water risks vary in terms of their impact potential and impact time horizon.

Inadequate water supply making it tough for
enterprises to secure permits
In April 2016, three enterprises (which convert scrap into steel)
had each indicated a need for at least two lakh litres of water
per day for the proposed new factories in water stressed region
of Jalna Industrial Park in Maharashtra.
The State Expert Appraisal Committee (SEAC) deferred the three
proposals citing lack of adequate water supply as the primary
concern.
Regulatory water related risks are potentially jeopardizing the license to operate
Taking cognizance of the growing water stress condition in the country, the Government of India has introduced several
policy measures to drive responsible water consumption in the industrial sector.
Policy name Focus sectors Key features
The National
Manufacturing
Policy, 201110
National Water
Policy, 201211
National Steel
Policy, 201212
National Water
Mission13
Environmental
(Protection) Act
Amendment,
201514
• Mandates water audits and rainwater harvesting for all industrial units in
National Investment & Manufacturing Zone (NIMZ)
• Incentivizes water conservation
• Introduces lower priority allocation for water supply to industries compared to
domestic and agricultural needs
• Limits industries in the water stress regions to withdraw only make-up water or
return treated effluent to a specified standard
• Mandates regular audits in industries with audit and conservation guidelines
made available
• Aims to make reuse of water a general norm
• Encourages R&D in manufacturing processes to reduce water withdrawal and
pollution load
• Introduces penalty and reward system to bridge the gap between Indian
standard and international best practices of water usage
• Encourages initiation of water foot-printing and rainwater harvesting and
frame strategies for zero effluent discharge
• Encourages industries to engage in water conservation, augmentation and
preservation as part of CSR
• Incentivizes water positive technologies, recycling and zero effluent solutions
Manufacturing
sector
Overall Industry
Steel sector
Overall Industry
Overall Industry -
specific clauses for
thermal power
generation
companies
• Mandates Thermal Power Plants using Once Through Cooling (OTC)
technology to install cooling towers and limit specific water consumption to 4
m3
/ kWh within 2 years
• Mandates existing plants with cooling towers to limit specific water
consumption to 3.5 m3
/ kWh within 2 years
• Mandates new plants installed after 1st
Jan, 2017 to achieve zero wastewater
discharge and specific water consumption of 2.5 m3
/ kWh
Figure 6: Illustrative policy measures introduced by Government of India to drive responsible water consumption
While these policy measures provide a robust framework
to drive responsible industrial water consumption, they
also pose a compliance risk for the organizations
involved. There are already instances of organizations
facing challenges in securing operating licenses on
account of water shortage15
.
Our assessment of Iron & Steel and Thermal Power
Generation companies reveals that business leaders view
license to operate, rising government scrutiny and
statutory limits with respect to water withdrawals as
the most critical and immediate water related risks.
9

10
Industry is increasingly wary about the rising water prices and associated implications for the business and
society
Water is increasingly viewed as a scarce resource, which comes at a price and has financial implications. In particular,
given the water stress, organizations are grappling with identifying cost effective and sustainable ways to source fresh
water.
Price of water as a resource
Our discussion with a leading steel manufacturer with a plant capacity of about 10 MTPA revealed that the plant relies on
a nearby fresh water source and pays around INR 8.3 per m3
of water withdrawn. This is a significant increase from INR
5.0 per m3
that the organization paid in 2011. While this example illustrates how a leading steel manufacturer is subject
to rising price of water (i.e. price of water as a resource per se), there are significant variations in the way water is priced
for different industrial units.
Our study reveals that most organizations are only exposed to a nominal cess for their current water usage. This cess is
usually miniscule and does not reflect the true cost of water. For instance, some steel manufacturers currently pay a cess
of around 10 to 12 paisa per m3
of fresh water withdrawn.
True cost of water
Interestingly, even the organizations that are only exposed to nominal cess for their water usage are now recognizing the
‘true’ cost of water, which accounts for other associated costs (such as costs related to pumping, transportation,
treatment etc.).
Cost component Relevance Example
Plants relying on water sources
with varying degree of TDS
Cost of treatment
at source
Cost of
pumping and
transportation
Cost of water
treatment for
reuse
• The operating cost of a brackish water desalination plant
is INR 10 to 15 per m3
• The operating cost of a sea water desalination plant17,18
, is
INR 2 m3
Plants pumping water from
relatively far sources
• A leading steel plant with annual production capacity of
around 12 MTPA relies on sourcing water from a source that
is over 150 km away. The organization has laid one of the
largest pipeline for sourcing water in India and eﬀectively
incurs ~INR 25 per cubic meter of water withdrawn
(including treatment costs)
• The same plant incurs ~INR 8 per cubic meter for water
withdrawn from another source located around 40 km from
the plant
Plants operating in water stress
regions with high need for water
reuse
• Eﬄuent treatment costs pegged are around INR 10 per
cubic meter of treated water.
Figure 7: True cost of water – an illustration16
It is evident that though fresh water is largely available at a nominal cess in India, the true cost of water after
accounting for treatment and pumping costs is significant. It may vary anywhere between INR 10 to INR 30 per m3
of
water withdrawn. What does this mean from the business and society perspective?

11
90 mn
Tonnes
Industry’s annual
production
capacity
3.5 m3
/
tonne
Average specific
water consumption
297
mn m3
Annual water
withdrawal
10%
saving
Conservative
water saving
target
~30
mn m3
Quantity of water
saved in the year
~INR 30
Crore
Monetary saving
assuming INR 10/m3
price
~0.5 mn
individuals
No. of individuals
supported through
saved water (assuming
150 litres per day per
capita requirement)
973 mn
MWh
Industry’s annual
production
capacity
4.5 m3
/
MWh
Average specific
water consumption
4378.5
mn m3
Annual water
withdrawal
10%
saving
Conservative
water saving
target
~440
mn m3
Quantity of water
saved in the year
~INR 440
Crore
Monetary saving
assuming INR 10/m3
price
~8 mn
individuals
No. of individuals
supported through
saved water (assuming
150 litres per day per
capita requirement)
Figure 8: Potential financial and society impact from modest water savings for the Steel Sector
Figure 9: Potential financial and society impact from modest water savings for Thermal Power Generation sector

12
Presently, around 2.3 BCM of untreated industrial wastewater is generated every year with thermal and steel plants being
the major contributors. An idea about the magnitude of the untreated water volume can be had from the fact that over 9
lakh Olympic-sized20
swimming pools may be required to accommodate India’s annual untreated industrial water
discharge. This untreated waste could cost an approximately INR 2,300 crore for effluent treatment21
.
The consensus amongst the water experts in India is that the industry currently lacks sustainable mechanisms for
wastewater discharge. This is an area where the industry is looking for breakthrough, innovative solutions and merits
focused R&D efforts from the leading steel manufacturers.
Figure 10: Typical wastewater handling practices in India
Waste discharge mechanism Pros Cons
Bio-remediation
Concentration
and dumping in
secure landfill
Concentration and
transfer to
chemicals industry
to be used as
inputs
Dumping in sea
water
Dumping in
waste land
Naturally occurring bacteria feed on waste (such as RO
reject from steel industry) to break down hazardous
substances into less toxic or non-toxic substances
A natural process that uses
non-toxic chemicals and
hence environment friendly
Relatively slow process and
somewhat difficult to deploy
at a large commercial scale
Involves concentrating and crystallizing the RO reject
which can be dumped in secure landfills with
impermeable liners
Compact waste requires less
disposal area
Building secure landfills is
very expensive and requires
sizeable capital investments
Involves crystallizing the concentrated reject which can
be used as an input by chemical industry like fertilizer
plants
Promotes circular economy
principles as waste from
one industry goes as input
into another. It can also act
as an additional revenue
stream
Currently, very few chemical
companies are able to
absorb the waste water
reject as an input
Involves dumping the waste water and effluents around
50+ kilometers into seawater
Potentially infinite sink with
limited impact on TDS of
sink at significant depth
The toxic metals (especially
from steel industry)
adversely impact life below
water and fishery
operations
Involves dumping the waste into an open landfill few
kilometers away from the plant
Relatively low waste
processing cost (with
minimal capital
investments)
Infeasible at large scale due
to limited land availability;
during rainy season waste
tends to‘flow’into the food
chain
Dumping in river
water
Involves dumping waste water and effluents into the
nearby river water source or on the river banks
Relatively low investments
and costs
TDS level of river increases
over time rendering it
unsafe for communities and
also increasing fresh water
treatment costs for the
plant
Organizations view discharge of waste water as a serious challenge – experts recognize the need for
innovation as critical to develop sustainable discharge mechanisms
It is important to note that around 2% of water saving can be achieved by saving about 1m3
of water per hour through
the year and also simply by regular monitoring and tracking of water use19
.

13
The recent drought situation faced by India highlights
how the production process for thermal and steel
plants is adversely impacted due to water shortage23,24
.
This is further exacerbated by the fact that many
industrial plants are located in the water stressed
regions of the country. More than 70% of India’s
existing and planned thermal and hydropower capacity
are located or expected in water- scarce or
water-stressed areas25
.
Given the relatively high water requirements, Thermal
and Steel Plants are highly susceptible to the vagaries
of nature. In the event of climate severities like
droughts, industries suffer the most due to the low
priority accorded in water allocation (as compared to
agriculture and households). For instance, India faced a
drought situation in 10 states in the last fiscal year. In
Maharashtra, the situation led to a 10% cut in water
supply to industrial units in the Aurangabad district22
.
To address the challenge related to water droughts,
leading steel and thermal plants have invested in
building back-up reservoirs and are undertaking
initiatives to increase reuse of water. For example, Tata
Steel plant in Jamshedpur has a man-made lake that can
provide water to suffice for upto 20 to 25 days of
operations.
Figure 11: Location of plants across India
Impact of droughts on thermal and steel
plants production – an illustration
Coal based thermal power plants have already lost
around 8.7 billion units of electricity generation because
of shutdowns due to water shortages this year.
A major steel plant in India is facing a shortage of 10
million gallons per day (MGD) water leading to a
shutdown of 3 units.
Climate severities such as droughts and floods exacerbate the already stressed water situation in India

How are leading organizations responding to water
challenges?
Leading performers are responding to water related challenges at multiple levels. At a
strategic level, there is growing evidence of industries viewing water availability as a
strategic issue that impacts expansion and growth. The organizations also place equal
importance on operational excellence by adhering to water guidelines, improved
monitoring, and R&D to drive innovation.
In the business-as-usual scenario, the specific water consumption for the steel industry is
expected to increase from 297 million m3
(current) to 1,500 million m3
(2030). Similarly,
for the Thermal Sector, it is expected to increase from 4,380 million m3
(current) to 7,402
million m3
(2030). This expected rise in water demand is not sustainable given the water
constraint in India. Therefore, it is critical for the industry to identify potential
interventions to improve productivity and rationalize water demand.
14

15
Water utilization in thermal power plants
~70% of the total industrial water usage in India is
accounted for by thermal power plants
Of the total industrial water requirement of ~69 BCM,
thermal power plants account for ~47 BCM
~98% of waste water from thermal plants is reusable
Going ‘Business-as-usual’ will need additional
3.3 BCM water by 2030
Business as usual (i.e. continue at current specific
water consumption of 4.5 m3
/MWh).
This would increase absolute water consumption by
around 69%, thereby aggravating water stress.
Specific Water Consumption (m3
per MWh)
7.5
4.8
4.3
4.0
3.5
2.5
2.5
2.0
1.6Global best - Thermal power plants
USA - Thermal power plants
China - Thermal power plants
India target - Plants installed
after 1st Jan 2017
India target (Apr 2017) - Cooling
tower based plants
India target (Apr 2017) -
OTC based plants
India - 660 MW plants
India -200 MW plants
India -110 MW old plants
Typical specific water consumption in India
India targets - till FY17 and beyond
Global benchmarks
Specific water consumption – benchmarking
Coal-based thermal power plants in India have a
specific water consumption of ~4.5 m3
/MWh.
Global best benchmark of ~1.6 m3
/MWh
represents a significant opportunity for
India-based plants.
Future outlook
Currently, India generates around 973 mn MWh
units from coal-based plants.
This is likely to increase to 1,377 mn MWh by
2025 and 1,645 mn MWh by 2030
What does this mean from water utilization
perspective?
Scenario A: Business as usual (i.e. continue at
current specific water consumption of ~4.5
m3
/MWh). This would increase specific water
consumption by around 69%, thereby aggravating
water stress.
Scenario B: Achieve national target of ~3.0
m3
/MWh by 2030. This can help to hold specific
water consumption in 2030 at current levels (despite
capacity expansion).
Scenario C: Achieve global benchmark of ~1.6
m3
/MWh by 2030. This can help save enough water
to support annual water needs of 87 mn people (total
population of 4 major metros today is ~48 mn!)
Water saving:
3,290 mn m3
(water needs of
~60 mn people)
Water saving:
1,480 mn m3
(water needs of
~27 mn people)
Current
BAU National Target Global best
2025
1,000
2,000
3,000
4,000
5,000
6,000
7,000
Millionm3
8,000
2030
Water Consumption @ Thermal Power Generation Sector – A closer look
Annual Water Consumption in
million m3
Additional
consumption of:
3,290 mn m3
(water needs of
~60 mn people)
Current 2025
3,000
4,000
5,000
6,000
7,000
8,000
2030

16
Water utilization in iron and steel plants
Annual water consumptionby is 0.3 BCM and is
expected to increase as production grows by over five
times in the next decade and a half.
Over 80-85% freshwater consumed in the sector is
discharged as effluent26
.
Going ‘Business-as-usual’ will need additional
1.2 BCM water by 2030
Business as usual (i.e. continue to use water at specific
water consumption of 3.3 m3
/tcs).
This would increase the industry’s total water
consumption by almost 5 times, possibly affecting
close to 22 million people in term of their water needs.
Specific Water Consumption (m3
per tonne
of crude steel)
5.0
3.3
3.3
2.1
2.0
1.0
1.6
Global Best-Based on CSE
report
Indis’s target-specific water
consumption by 2025
India’s best-Based on CSE
report
India’s average-Based on
CSE report
India’s worst-Based on CSE
report
Range of specific water
consumption given by
World Steel association
Typical specific water consumption in Indian steel
plants
India targets- to be achieved till FY 25
Global benchmarks
Specific water consumption – benchmarking
Iron and steel plants in India have a specific
water consumption of ~3.3 m3
/tonne of crude
steel (tcs)
Global best benchmark of ~1.0 m3
/ tcs represents
a significant opportunity for water
conservation27
.
Future outlook
India is the third largest producer of steel in the
world with a capacity of 90 million tonnes28
.
The government aims to increase production to
300 MT by 2025 and the capacity is further
projected to increase to 500 MT by 203029
.
0
200
400
600
800
1,000
1,200
1,400
1,600
Millionm3
AnnualWaterconsumptionin
Water saving:
500 mn m3
(water
needs of ~9 mn
people)
Water saving:
500 mn m3
(water
needs of ~9 mn
people)
BAU National Target Global best practice
Current 2025 2030
Water Consumption @ Iron & Steel Sector – A closer look
What does this mean from water utilization
perspective?
Scenario A: Business as usual (i.e. continue to use
water at specific water consumption of 3.3
m3
/tcs). This would increase the industry’s total water
consumption by almost 5 times.
Scenario B: Achieve national target of ~2.0 m3
/tcs
by 2030. This can help to curtail rise in water
consumption at about 3.3 times saving 500 million m3
of water per annum.
Scenario C: Achieve global benchmark of ~1.0
m3
/tcs by 2030. This can help save enough water to
support annual water needs of 18 mn people as total
water consumption goes up by only 68% while
production increases to 5 times of current production
compared to BAU.
Annual Water Consumption in
million m3
Additional
consumption of:
1,203 mn m3
(water needs of
~22 mn people)
Current 2025
0
200
600
800
1,000
1,200
1,400
400
1,600
2030

Water - a strategic priority for JSW
With a specific water consumption target (for FY 2016-17) of
2.94 m3
per tonne of crude steel, JSW is one of the most efficient
steel manufacturers in India.
The organization includes responsible utilization of natural
resources as a part of its vision statement and has formed a core
water team led by an appointed management representative.
Additionally, the highest level of ownership and accountability
for water performance rests at JSW’s board level.
“ …Thermal power plants require huge amount of freshwater
withdrawals for electricity generation and therefore have a
significant impact on the ecosystem and the water resources. We
at OTPC are committed to sustainable practices including
efficient and economic utilization of water and in this respect
we have deployed combined cycle technology, use natural gas as
fuel and have employed recirculation of water for cooling
system. The specific water consumption of our plant should
typically be about 30-35% of that being required for a coal
based power plant thereby saving huge amount of water for
every unit of electricity generated…”
- Mr Satyajit Ganguly - MD, OTPC Limited
Most of the Thermal Power and Iron & Steel
organizations in India have put in place guidelines to
drive desired behaviors and actions related to water
conservation. In fact, 9 out of 11 participating
companies indicated that they have basic water related
guidelines in place. Interestingly, an executive in the
water department of a leading steel company in India
explained that business-as-usual outlook for the
industry is under severe water risk and these guidelines
represent a critical first step towards addressing the
situation. Leading organizations also demonstrate
willingness to adopt water as a strategic business issue
with significant attention from the senior leadership.
Based on the responses received from the leading
Thermal Power Generation and Iron & Steel companies,
it is evident that there are two overarching themes for
the water related targets. These relate to reducing
specific water consumption and reducing discharge. This
may partly be due to organizations’ response to
regulatory guidelines. For instance, in the Iron & Steel
industry the water consumption is around 3 to 5 m3
/
tonne of crude steel while the government has set a
target of 2 m3
/ tonne of crude steel production by 2025.
17
Figure 12: Key themes for water related targets – consumption and discharge
Type of target Thermal power generation Iron & Steel
NTPC: Reduce specific water
consumption by 2.5% over previous
year by March 2017; Reduce specific
water consumption for all stations to
less than 3.5 L / unit by December
2017
Maharashtra Power Generation
Company: Reduce specific water
consumption for BSL. St. to 5.0 L /
unit by 2018 – 19
Water
consumption
targets
Discharge
reduction
targets
JSW: Achieve specific water consumption of 2.94 m3
/ton
crude steel by the end of FY17
Rashtriya Ispat Nigam Limited: Maintain annual specific
water consumption to less than 2.6 m3
/ton crude steel
Tata Steel: Reduce specific water consumption from 5.54 m3
/ton crude steel in FY15 to 2.79 m3
/ton crude steel by FY20
NTPC: Achieve zero liquid
discharge across all stations over
the next five years
Tata Steel: Reduce treated eﬄuent discharge to near zero (0.5
MGD) by FY20
JSW: Achieve zero specific water discharge (FY2016 – 17)
Organizations are looking to drive improvements in water efficiency through well-defined water guidelines
backed with time-bound targets and senior leadership’s oversight

“…Water is the elixir of life and fundamental for the existence
of both flora and fauna on Earth. However, rising levels of
water pollution and declining availability of fresh water
sources puts a major risk on long-term availability of this vital
resource. Hence, water features in two of the UN Sustainable
Development Goals. An integrated and collaborative approach
from Industry is essential to address the concerns related to
water for ensuring long term sustainability of the business we
operate…”
-Mr TV Narendran - MD, TATA Steel
18
What do these targets imply for the industry? Our
discussion with global experts, specifically related to
water and SDGs, indicates that the nature of targets
adopted by the Indian industry represents a significant
first step towards driving water efficiency
improvements. However, there is an opportunity to
strategically align water targets to the global
transformation agenda for 2015-2030, as outlined by
the SDGs. This would require expanding the scope of
water targets adopted by the Iron & Steel and Thermal
Power sectors in India.
SDG Illustrative targets (non-exhaustive)
Goal 6: Clean water and sanitation
• By 2030, expand international cooperation and capacity-building support to
developing countries in water and sanitation-related activities and programmes,
including water harvesting, desalination, water eﬃciency, wastewater treatment,
recycling and reuse technologies
• By 2020, protect and restore water-related ecosystems, including mountains,
forests, wetlands, rivers, aquifers and lakes
Goal 12: Responsible consumption & production
• By 2030, achieve the sustainable management and eﬃcient use of natural
resources
• By 2030, ensure that people everywhere have the relevant information and
awareness for sustainable development and lifestyles in harmony with nature
Goal 14: Life below water
• By 2025, prevent and significantly reduce marine pollution of all kinds, in
particular from land-based activities, including marine debris and nutrient
pollution
• Minimize and address the impacts of ocean acidification, including through
enhanced scientific cooperation at all levels
Figure 13: Water related development goals and targets outlined in SDG framework
6CLEAN WATER
AND SANITATION
12RESPONSIBLE
CONSUMPTION
14LIFE BELOW
WATER

100% water monitoring and tracking
coverage - Tata Steel
Tata Steel recently made an investment of around INR
3.2 crores to strengthen its water monitoring
infrastructure. The company achieved 100% monitoring
coverage of its water lines through a network of flow
meters and remote monitoring system.
This resulted in a direct water saving of 3.3 million m3
/
year. Based on the true cost of water of around INR 11.5
per m3
(which includes water tariff, pumping costs etc.),
this represents a financial saving of around INR 3.8
crores (i.e. exceeding investment within the first year).
R&D to drive innovation related to water
management – Arcelor Mittal
Arcelor Mittal, world’s largest steel manufacturer,
actively identifies opportunities to recycle and re-use
water with the support of their global R&D division. The
organization also has a dedicated water treatment lab
located in Spain that investigates the application of
green technologies to minimise pollutants and increase
the life of equipment.
19
Despite the significant improvements in water related
processes and technology interventions, experts believe
that there is a growing need for increased R&D to
identify innovative and sustainable water solutions. In
particular, our discussions with experts indicate
following as some of the key areas that merit
innovation31,32,33
Energy efficient treatment technologies
Use of bio-based/ green technologies for effluent
treatment
Expanding the universe of wastewater reuse options
Real-time monitoring and control on a wide scale
enabled by intelligent water metering
Closed water systems
Innovative heat recovery technologies (for thermal
power generation companies)
Research indicates that at least 2% of water savings can
be achieved by just actively measuring and tracking
water use in an industrial plant30
. Some of the leading
organizations in India have already taken active
measures to build rigor in their water monitoring and
tracking through an extensive network of water flow
meters backed by state-of-the-art real time remote
monitoring systems based on digital technology. From a
financial feasibility perspective, these interventions tend
to be easily funded with the savings realized in the first
1-2 years exceeding the required investments.
Thermal Power Generation Companies such as NTPC and
OTPC and Iron & Steel companies such as Tata Steel and
JSW have already undertaken active measures to
strengthen their water monitoring and tracking
infrastructure.
Industrial flowmeters have witnessed many
technological advancements. For new and upcoming
plants, there are options to install intrusive flowmeters.
Alternatively, for the existing plants there is the option
of retrofitting pipelines with non-intrusive or external
flowmeters (which are based on doppler or ultrasonic
principles) without disrupting the operations. The cost of
these flowmeters ranges between INR 75,000 to INR 4
lakhs. Additionally, water quality measurement devices
like TDS meters help organizations meet regulations for
quality of effluent discharged apart from ensuring that
water used in different parts during the operations
conform to the standard quality requirements.
There is a shift towards rigorous water monitoring and tracking mechanisms
Investing in R&D to develop innovative water management solutions could be the next big opportunity for the
Indian industry

20
Leading performers are augmenting strategic planning and monitoring with tangible operational initiatives to
drive improvements in water efficiency
Figure 14: Illustrative operational best practices deployed by Iron & Steel and Thermal Power companies
Initiative Brief description Remarks
Cooling towers account for
significant water losses. These can be
minimized by circulating water
multiple times in a closed loop before
being eventually discharged.
Increased cycles can lead to an increase in salt
concentration and may require appropriate investments
to prevent equipment corrosion.
Case study
Arcelor Mittal: At some of the steel
plants, each cubic meter of water is
recycled as many as 75 times before
being discharged34
.
Increased
cycles of
concentration
In direct dry cooling, turbine exhaust
steam is condensed inside finned
tubes that are externally cooled by
ambient air powered by
motor-driven fans35
.
Capital costs for dry cooling are 3 to 5 times higher than
wet cooling, but it results in about 80% water saving36
.
NTPC: NTPC’s North Karanpura Super
Thermal Power Project in Jharkhand
will be equipped with air cooled
condensers to reduce the water
requirement by 80%37
.
Direct dry
cooling / Air
condensers
Coke is cooled using an inert gas in
dry cooling plant, instead of cooling
by sprayed water in iron and steel
plants.
Retrofitting dry coke quenching system can cost
~$109.5/ton coke38
;A typical steel mill can save ~4 million
tons of water annually by installing two dry quenching
systems.
Tata Steel: Jamshedpur plant
implemented coke dry quenching in
FY13 with an investment of INR 100
crore and achieved water savings of
876 ML/year.
Coke dry
quenching
Water discharged with low TDS could
be recirculated after primary
treatment. It can be used for
purposes such as gardening, green
belt development, and dust
suppression, thereby minimizing net
discharge.
A ZLD plant operating at 5 ML per day will incur between
INR 50- 60 crores in CAPEX and spend INR 15,000-25,000
as OPEX per day39
.
JSW: Vijaynagar plant has
implemented a membrane
bio-reactor followed by reverse
osmosis ZLD plant and reuses more
than 95 per cent of process waste40
.
Zero liquid
discharge
(ZLD) system
WPA is a technique for reducing
water consumption and wastewater
generation through integration of
water-using activities or processes.
Research indicates that WPA can result in about 15 to
40% fresh water saving and 25 to 40% reduction in waste
water41
.
Tehran Oil Refinery: A study done
on Tehran oil refinery found that
re-design of water allocation in the
networks led to freshwater savings of
almost 44%42
.
Water pinch
analysis (WPA)
Given the practically infinite supply of
sea-water, it is an attractive option for
cooling applications in industries in
the coastal plants. However, it
requires investments in overcoming
corrosion challenges.
Corrosion problems associated with sea-water usage can
be avoided by using appropriate corrosion resistant
material, which increases costs by about 35 – 50%
(compared to fresh water towers of same capability43
).
Tata Power: Tata’s 4,000 MW power
plant at Mundra draws water from
Arabian sea for cooling purposes. This
allows them to meet cooling water
needs despite heavy competition for
water resources44
.
Use of
seawater for
cooling
This involves using technology to
settle the ash particles and pumping
ash water to the ash water recovery
system, where ash water is treated
with chemicals to separate it from
ash sludge45
.
Upto 70% of ash pond water can be recovered and
reused in ash handling plant . Capital cost for setting up a
60-MLD ash recirculation plant46
is INR 13 crore and the
annual O&M cost is INR 1.7 crore47
.
Jindal Power Limited: In their
Tamnar plant, make-up water is
added to bottom ash, and then it is
treated and recycled back to the
main plant for further ash disposal
cycles. This has led to water savings
worth 432,000 m3
per month48
.
Ash water
recirculation

Water intensive industries such as Thermal Power and Iron & Steel are located in
some of the most water stressed areas across the nation. This is animminent risk not
only to the industry’s license to operate but also to the water security for
communities thriving in those regions. Hence, it is imperative that industries
understand the impact of water to their respective eco-systems and make water
management decisions accordingly.
Three key takeaways emerge from this study. Firstly, there is a need to evaluate the
true cost of water to industries. This will improve the decision making process and
provide a holistic view of the water value chain. Secondly, fresh water is a limited
resource and maximizing its life cycle within an industry is a key priority. Introducing
circularity in water usage both from a process and business perspective can help
industries make a giant leap in that direction. Thirdly, the need to engage right
stakeholders to manage water usage is very important. Be it communities, regulatory
agencies or expert groups – involving a diverse set of stakeholders can promote
innovation and scale up solutions through customization and standardization. Lastly,
the time to act and enable change is “now” and not in the distant future.
C A L L F O R A C T I O N
21

Study Leads
Pooran C. Pandey
Vishvesh Prabhakar
Lead Authors
Sundeep Singh
Winsley Peter
Amanpreet Talwar
Nazneen Shaikh
The authors would like to thank the following people and
companies for their insights and assistance
Ritesh Kapoor, Jay Thakkar, Palak Kapoor and Pranshu Gupta
JSW Steel Limited
Tata Steel Limited
National Mineral Development Corporation
NTPC Limited
Tata Power Company Limited
ONGC Tripura Power Company Limited
Damodar Valley Corporation
Maharashtra Power Generation Company
Tata Sponge Iron Limited
Rashtriya Ispat Nigam Limited
NMDC Limited
Avant Garde Innovations
For further information, please contact:
Vishvesh Prabhakar
Managing Director
Sustainability, Accenture Strategy, India
vishvesh.prabhakar@accenture.com
Sundeep Singh
Principal,
Sustainability, Accenture Strategy
sundeep.singh@accenture.com
Pooran Chandra Pandey
Executive Director
UN Global Compact Network India
gcnindia@globalcompact.in
ACKNOWLEDGEMENTS
22

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