In an exclusive interaction with Paper Mart, Dr. Ajay Satia, Chairman & M.D., Satia Industries, stated that the company has achieved stable freshwater consumption levels, significantly below prescribed norms. Going forward, the company plans to deploy advanced water treatment solutions- such as membrane filtration, zero liquid discharge (ZLD), or ion exchange, along with side-stream treatment and improved raw material management to strengthen process control. These initiatives will further increase water reuse and optimize distribution across critical and non-critical operations, while ensuring consistent machine performance and product quality.
Paper Mart: After implementing water reuse, recycling, and closed-loop systems across your mill, what is your current specific freshwater consumption (m³/tonne), and has this figure stabilized in recent years?
Ajay Satia: Our current specific freshwater consumption is well below the prescribed standards. After implementing water reuse and recycling measures, the value has significantly reduced over the past 3-4 years and has now stabilized around current level, with only marginal yearly variation.
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PM: Under your present operating regime, where water reuse and recycling systems are already in place, what operational challenges have emerged in terms of process stability, machine performance, or water quality?
AS: With increased water reuse and recycling, we have observed challenges related to buildup of dissolved solids and organics, leading to wet-end instability, higher chemical demand, and occasional machine runnability issues such as deposits, foaming, and reduced drainage efficiency. These are being managed through process control and targeted chemical dosing.
To achieve further reductions in freshwater consumption beyond current reuse and recycling systems, we would need to implement advanced water treatment technologies such as membrane filtration, evaporation/ZLD, or ion exchange, along with side-stream treatment and enhanced process control.
PM: At your current level of system closure and reuse, what process, raw material, or product quality requirements limit further reduction in freshwater consumption?
AS: At the current level of system closure, further reduction in freshwater consumption is primarily limited by buildup of dissolved solids and organics in the process water, which affects wet-end chemistry, equipment reliability, and microbial control. Additionally, the agro-based raw materials used, introduce silica and extractives that accumulate in closed loops. Product quality requirements such as brightness, cleanliness, and sizing efficiency also necessitate the use of relatively fresh water in critical sections, thereby limiting further closure without advanced treatment technologies.
PM: In highly recycled operating conditions such as yours, do you periodically purge water from the system? What operational factors make this necessary, and how does it define your minimum freshwater intake?
AS: Yes, periodic or continuous purging is practiced under highly recycled conditions to control buildup of dissolved solids, organics, silica, and microbial load. These contaminants accumulate in closed loops and affect process stability, equipment and machine reliability. Further reduction would require significant investment in advanced treatment, side-stream polishing, or process modification.
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PM: Beyond your existing systems and processes, what types of improvements or changes would be necessary to reduce water consumption further?
AS: To achieve further reductions in freshwater consumption beyond current reuse and recycling systems, we would need to implement advanced water treatment technologies such as membrane filtration, evaporation/ZLD, or ion exchange, along with side-stream treatment and enhanced process control. Additionally, upstream raw material management and water allocation optimization across sensitive and non-critical processes would allow safe increase in water reuse while maintaining machine performance and product quality.
The agro-based raw materials used, introduce silica and extractives, that accumulate in closed loops. Product quality requirements such as brightness, cleanliness, and sizing efficiency also necessitate the use of relatively fresh water in critical sections, thereby limiting further closure without advanced treatment technologies.
