ANNOUNCEMENTS
Water is a critical input in industrial operations, especially in sectors such as mining and ferrochrome production, where it supports processes like raw material beneficiation, cooling, dust suppression, and cleaning. However, the increasing industrialization and the competing demand for freshwater from domestic, agricultural, and ecological sectors have brought the issue of water scarcity to the forefront. Odisha, a key region for chromite mining and ferrochrome production in India, faces acute water stress due to over-extraction of groundwater, low recharge rates, and climate variability. Seasonal water shortages, declining aquifer levels, and the impact of extreme weather events compound the challenge.
Despite this backdrop, traditional water management practices in the ferrochrome industry remain largely manual, reactive, and fragmented. Periodic physical audits and human-based monitoring are unable to capture real-time inefficiencies like leakages, unauthorized withdrawals, or process-level water wastage. This lack of real-time visibility often leads to significant preventable losses, inefficient responses, and regulatory non-compliance. Moreover, with increasing emphasis on the UN SDG, particularly SDG 6: Clean Water and Sanitation and growing attention to Environmental, Social, and Governance (ESG) criteria, there is an urgent need for industries to adopt sustainable and data-driven water governance systems. In this context, the Internet-of-Things (IoT) offers a promising pathway for digital transformation in water management.
The core objective of this study was to enhance water use efficiency in the ferrochrome industry through the implementation of IoT-based smart water monitoring systems. The research was carried out at two major industrial locations in Odisha- the Athagarh Ferrochrome Plant and the Sukinda Chromite Mine. The first objective was to transition from traditional, periodic water audits to real-time, continuous monitoring. This was achieved by installing IoT-enabled flow meters, pressure sensors, and data dashboards at 23 critical water-use points across both sites. These devices provided granular insights into water consumption patterns, enabling the early identification of inefficiencies such as leakages, high consumption zones, and unoptimized process flows.
The second objective was to map and analyse water consumption patterns across the entire industrial value chain from ore extraction to ferrochrome smelting. This comprehensive analysis was essential to identifying water-intensive "hotspots" and benchmarking baseline water use against industry best practices. The third objective was to assess the potential for internal reuse and recycling of treated wastewater. Given the heavy metal content particularly chromium—in ferrochrome industrial effluents, the study included laboratory-based analysis of wastewater samples and evaluated the feasibility of reuse in non-potable applications like slag cooling, dust suppression, and equipment washing. IoT sensors were also integrated into the wastewater systems to track discharge volumes and water quality in real time, supporting a shift toward Zero Liquid Discharge (ZLD) and enhanced regulatory compliance.
The methodology employed a combination of digital technology deployment, water audits, laboratory analysis, and the DMAIC (Define, Measure, Analyze, Improve, Control) process improvement framework. An initial baseline assessment involved site surveys and mapping of all critical water-using processes. IoT sensors were deployed at raw water intakes, process pipelines, cooling circuits, and wastewater discharge points to enable continuous data collection. The Define and Measure phases focused on identifying water loss zones and quantifying usage, while the Analyze phase used trend analysis to identify anomalies such as abnormal flows during non-operational hours indicating leakages or inefficient operations. Targeted interventions followed in the Improve phase, such as repairing damaged infrastructure, optimizing cooling tower operations, and modifying process water use. The Control phase ensured that the improvements were sustained using real-time alerts, dashboards, and a continuous improvement cycle.
Water quality testing further supported the reuse strategy. Parameters such as Total Dissolved Solids (TDS), chromium (Cr), iron (Fe), and lead (Pb) were measured, and treated water was benchmarked against BIS and CPCB standards. The findings demonstrated that with blending or minor treatment upgrades, wastewater could be effectively reused in industrial operations, reducing dependence on freshwater sources. Notably, the integration of IoT systems improved responsiveness to changes in water quality and flow, enabling data-informed decision-making across operations.
The study’s findings underscore the importance of transitioning from manual to smart, automated water management systems. The implementation of IoT-based monitoring has not only improved data accuracy and operational efficiency but has also enhanced regulatory compliance and environmental performance. Real-time visibility into water systems allowed for proactive maintenance, improved resource planning, and a significant reduction in water losses. Furthermore, water quality monitoring supported the safe reuse of treated effluent, promoting circular water use within industrial premises.
This research recommends the institutionalization of smart water systems in all major ferrochrome and mining units in India, especially those operating in water-stressed regions like Odisha. Adoption of IoT technology should be supported through policy incentives, capacity-building programs, and integration with regulatory frameworks. Additionally, industries must invest in upskilling their workforce to interpret and act on digital water data. Future research should expand the scope to include lifecycle water use assessment, carbon-water footprint analysis, and integration of artificial intelligence for predictive water management. The approach demonstrated in this study provides a replicable and scalable model for other water-intensive industries seeking to transition toward a more sustainable and digitally empowered future.
