When sustainability and low carbon are targets, a factory near Chennai sets an example

The company set up its own water treatment facility, resulting in the reduction of dependence on the reverse osmosis water from Koyambedu sewage treatment plant.

Among the hundreds of industries functioning in the Sriperumbudur industrial belt of Kancheepuram district, one factory seems to stand out as far as efficient use of natural resources of water and sunlight is concerned. A solar panel manufacturer has pioneered the art of saving water through the ‘Zero liquid discharge’ (ZLD) project, with zero waste generation.

First Solar, a US-based wholly owned subsidiary of First Solar, Inc, operating within a water-intensive industry segment, is engaged in the manufacture of solar panels for Independent Power Producers (IPPs) located in the SIPCOT Industrial park of Pillaipakkam near Sriperumbudur.

The 3.30 giga watt (GW) solar panel manufacturing factory, spanning more than 130 acres, has actualised the mantra of ‘reuse, recycle, and repurpose’ in the manufacturing process through efficient use of water and manufacturing waste.

N.L. Selvakumar, head, environment and recycling, First Solar, who is in charge of the ZLD system, said the factory floor, spanning more than 24 lakh sq.ft., needs water for two purposes — cooling the factory and manufacturing.

The company, which requires almost 3.60 million litres of water per day, had tied up with Metrowater to supply tertiary-treated reverse osmosis (RO) water from the Koyambedu sewage treatment plant for the factory’s needs. But subsequently, the company set up their own water treatment facility (ZLD), resulting in the reduction of more than 50% dependence on the sourced RO water from Koyambedu plant.

The ZLD system, which has been set up and managed in-house, extracts water from the discharged wastewater, and enables its reuse by producing ‘ultra pure water’ for the manufacturing and cooling processes, thereby drastically reducing the intake of water requirements.

The system has enabled the creation of solar modules in the State with the lowest water footprint in the world, compared to traditional polysilicon-based solar panel production, according to the company.

The factory, employing more than 1,400 persons, has also set up a sewage treatment facility, which operates a Membrane Bioreactor (MBR) sewage treatment plant that utilises the treated water for watering the garden. Over 80 kilolitres per day of treated water is being generated, Mr. Selvakumar added.

Sujoy Ghosh, Country Managing Director, First Solar, says the company’s commitment to the environment not only lies in water conservation but also in generating clean electricity. He said as part of this, the company had installed their own captive solar plants of 53.66 mega watt (MW) in southern parts of the State.

Mr. Ghosh further said the company’s green footprint was 35% renewable energy, and ongoing solar projects promise expansion to 116.80 MW.

Unlike the manufacturing waste generated by polysilicon-based solar panel producers, the factory, which generates 2% of industrial wastes, recycles them into minerals to be used again for solar panels and crushed glass.