Industrial Water Balance Diagram Generator

Sector-specific process water flow: sources → uses → ETP/STP → recycle / ZLD / discharge

Project & Industry Sector

All values in KLD (kilolitres/day = m³/day)

Water Sources

Every route by which water enters the site.
SourceKLD
Total Source Supply–

Process Water Uses

Every internal use. "Consumptive Loss %" is water that does not return as liquid (evaporation in a cooling tower or boiler, water incorporated into product, etc.) — the remainder becomes wastewater and is routed to the destination you choose.
UseKLDConsumptive Loss % ⓘWastewater Routed To ⓘ
Total Process Demand–
Total Consumptive Loss–
Total Wastewater Generated–

Treatment

The non-recovered fraction is sludge — a real disposal stream in its own right (typically sent for co-processing, secure landfill, or (for organics) further treatment).

Recycle & Final Disposal

Zero Liquid Discharge (ZLD) means no treated wastewater ever leaves the site as liquid — the leftover water is evaporated (via an evaporator) into a solid residue instead of being discharged. Several sectors (textile dyeing, tanneries, distilleries, pulp & paper, and many pharma/chemical clusters) are required to do this by CPCB/state pollution boards.

Water Balance Flow Diagram

Auto-generated from Tab 1 — path thickness is proportional to flow. Edit Tab 1 and this updates automatically.

Water Balance Summary

Sector Coverage

The Industry Sector search (Tab 1) currently loads starting templates for 36 sectors, grouped the way CPCB groups them for consent purposes — type to search, or clear the box to browse the full grouped list:

GroupSectors Included
RedTextile, Tannery, Distillery, Sugar, Pulp & Paper, Synthetic Organic Chemicals/Dyes, Pharmaceutical, Pesticide, Petrochemical/Refinery, Fertilizer, Chlor-Alkali, Integrated Iron & Steel, Sponge Iron/DRI, Cement, Thermal Power, Non-Ferrous Smelting, Electroplating, Dairy, Battery Manufacturing
OrangeFood Processing, Automobile Manufacturing, Ceramics/Glass, Foundry, Rubber & Tyre, Stone Crushing/Granite Processing, Cotton/Textile Spinning (dry process), Ready-Mix Concrete
GreenAgro-Processing (rice/flour/cotton ginning), Cold Storage, Brick Kiln/Fly Ash Bricks
SpecialMining & Ore Beneficiation, Saltpan/Solar Salt Works, Common Effluent Treatment Plant (CETP), Common Hazardous Waste TSDF, Common Bio-Medical Waste Treatment Facility (CBWTF)
OtherGeneric/Custom — for any sector not listed above

CPCB's own classification runs to several hundred sub-sectors (419 in the latest 2024 revision) — this library covers the major, commonly-encountered manufacturing sectors in Indian EIA/CTE practice, not every listed sub-sector. If your sector isn't an exact match, pick the closest template (or Generic/Custom) and edit every row to fit — nothing here is locked.

Notes on the Model

  • Consumptive loss is water that leaves the liquid-water cycle at the point of use — steam vented from a boiler, evaporation from a cooling tower, moisture incorporated into a product. It is not available for treatment or recycling.
  • ETP (Effluent Treatment Plant) treats trade/process effluent; STP (Sewage Treatment Plant) treats domestic sewage. Real sites often keep these streams physically separate because treatment chemistry differs.
  • ZLD (Zero Liquid Discharge): the fraction of treated water not recycled is routed to an evaporator (e.g. Multiple-Effect Evaporator / Agitated Thin-Film Dryer) rather than discharged, leaving a solid salt/sludge residue instead of a liquid effluent. CPCB's original 2015 sector guideline named four sectors — textile wet processing, tanneries, distilleries, and pulp & paper — and ZLD conditions have since extended to many pharmaceutical/bulk-drug clusters and specific chemical units via NGT and state pollution board orders, particularly in water-stressed basins and critically polluted areas. Every template's default ZLD setting reflects this, but requirements are ultimately state- and consent-specific — always verify the current applicable mandate for your sub-sector and location.
  • Saltpan template note: solar salt works don't fit the factory source→use→treatment model cleanly — the "process use" here represents the evaporation-pond cascade itself, and the "wastewater" output represents bittern (mother liquor), a saleable by-product feedstock for other chemical recovery (e.g. potash, bromine) rather than a true effluent. Adjust the labels and routing to match your specific site.
  • CETP template note: a Common Effluent Treatment Plant has no manufacturing process of its own — its entire received inflow is already wastewater from member industries. Use this template for the CETP's own combined treat-and-discharge balance; model each member industry separately if you need their individual internal balances.
  • This tool performs a straightforward mass-balance accounting of the values you enter — it does not independently estimate any component. If your project also needs natural-hydrology inputs (rainfall-runoff, natural recharge, dewatering inflow), derive those with dedicated methods — the Rational Method/SCS-CN for runoff, the Water Table Fluctuation method for natural recharge, or an excavation dewatering estimate — and feed the results in as a Source or Use row here; this tool focuses specifically on the industrial process side.
For each scenario below, go to Tab 1 · Setup, load the named Industry Sector template (it will pre-fill Sources, Uses, Treatment and Recycle values automatically), and read the results off Tab 3 · Balance Summary. Then come back here and enter what you found. Your answers are graded against the tool's own mass-balance calculation, with a small tolerance for rounding.
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Score—
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