2.4.1 Region wise MSME distribution Large Scale Units: Regional Distribution District wise Distribution of Large Units...

Transcription

1 Contents Introduction Background Need and Approach Objectives: Methodology and Database Scope and Limitation Synoptic overview of the report Industrial Scenario in Gujarat Major Economic Sector in Gujarat- Current Status Brief History of Industrialistion in Gujarat Structure of Industrial Sectors in Gujarat Industrial Development- Regional analysis Region wise MSME distribution Large Scale Units: Regional Distribution District wise Distribution of Large Units Costal Industrialization Polluting Industries in Gujarat Regional Distribution of Red, Orange and Green Units: Critical districts Industrial Pressure and Impact Industrial Hazardous Waste Generation and Management Inventory: Generation Sector Wise Contribution in the Generation of Hazardous Waste: Treatment and Disposal Options Status of Effluent Treatment in Gujarat Quality of Treated Effluent (CETPs): Waste Management at Alang Critically Polluted Industrial Clusters/Areas- The Case Studies

2 5. Gujarat State s Response to Industrial Environment Industrial Environmental Management Initiatives in Gujarat State level environmental initiatives: Policy, Planning and Management initiatives by GIDC Institutional Building Performance Monitoring by Regulatory Body Industry level initiatives: Initiatives Taken for Cleaner Production Initiatives at Alang Conclusion Selected Bibliography

3 List of Tables Table 1-1 : Framework, Attributes, and Source of data/information Table 2-1 : Progress of Micro Small Medium Units in Gujarat, 2006 To Table 2-2 : Progress of Large Scale Industries Table 2-3 : Major Industries in Coastal Regions in Gujarat Table 2-4 Proposed Special Investment Region in Coastal Region in Gujarat Table 2-5 Ports in Gujarat under Gujarat Maritime Board Table 2-6 No of Ships dismantled every year at Alang Ship Breaking Yard Table 3-1 : Categorization of units in terms of Red, Orange and Green, In Gujarat to Table 4-1 : Authorization Granted under Hazardous Waste Regulations as Amended from time to time Table 4-2 : Total Hazardous Waste Generated in Gujarat Table 4-3 : Category wise Hazardous Waste (MTAP) Generated in different Regions of Gujarat (2007), Table 4-4 : Sector Wise Contribution in Generation of Hazardous Waste in Gujarat (2007) Table 4-5 : Details of registered recyclers and Installed Capacity (2012) Table 4-6 District wise TSDF in Gujarat as of Table 4-7 Common Hazardous Waste Incinerators in Gujarat (2012) Table 4-8 Status of CETPs in Gujarat (As on March 2012) Table 4-9 Discharge of Treated effluent from CETP Table 4-10 Discharge of Treated Effluents from Various Regions of Gujarat Table 4-11 The CEPI Scores for Critically Polluted Industrial Areas / Clusters in Gujarat Table 5-1 Industry level initiatives Table 5-2 Benefits to industrial units after CP demonstration Table 5-3 : Authorization Granted & RFMP Sanctioned at Alang over the years

4 List of Figures Figure 2-1 : Type Wise Distribution of MSME, Gujarat, Figure 2-2 Type wise distribution of LOI+ LOP+ IEM projects in Gujarat (up to ) Figure 2-3 : Region Wise Progress of MSME Units Registration in Gujarat, To Figure 2-4 : Percent Distribution of MSME in Major Districts Figure 2-5 : Region wise progress of Large Units in Gujarat, to Figure 2-6 : District wise Percent Distribution of Large Units Figure 3-1 Region Wise Percent Share of Red Industries Figure 3-2 Concentration of Red Industrial Based on the Percent Distribution Figure 3-3 Region Wise Percent Share of Green Industries Figure 3-4 : Region Wise Percent Share of Orange Industries Figure 3-5 District Wise Percent share of Red Industries Figure 4-1: District wise Hazardous waste generating units Figure 4-2 : Average waste Composition of Hazardous Waste for Figure 4-3 : Total Hazardous Waste Generated in MMTPA for year Figure 4-4 : District wise Generation of Hazardous Waste as on Figure 4-5 : Composition of Hazardous Waste Generated in Gujarat Figure 4-6 Treatment and Disposal Options of Hazardous Waste Figure 4-7: Hazardous Waste Co-Processed in various Cement Plants in Gujarat Figure 4-8 : Authorized Recycling units and installed Capacity in Gujarat (2012) Figure:4-9 - Number of Recycling Units and Installed Capacity of recyclers of Non-Ferrous Hazardous Waste (2012) Figure: 4-10 Number of Recycling units & Installed Capacity of Recyclers of Waste/Used oil (2012) Figure: Number of Recycling Units & Installed Capacity of recyclers of Lead based Hazardous Waste (2012) Figure 4-12 : Hazardous Waste Treated & Disposed by TSDF over the Years Figure 4-13 Common Incinerator at Kutch Figure 4-14 TSDF at Bharuch Figure 4-15: Location of TSDFs in Gujarat as on March Figure 4-16 : Hazardous Waste Treated in different Districts of Gujarat for the year (MTPA) Figure 4-17 : CETP at Vatva (The Green Environment Services Co-op.Society Ltd.) Figure 4-18 : CETP at Odhav (Odhav Enviro Project Ltd.) Figure 4-19: Location of Functioning CETPs in Gujarat (as on March 2012) Figure 4-20 : Number of CETPs and Member Units in Gujarat & Total Capacity of CETPs in Gujarat Figure 4-21: Total Treatment capacity & Total Members of CETPs in Gujarat (2012) Figure 4-22 : Treated Effluent Discharged into Sea Figure 4-23 : Treated Effluent Discharged into River Figure 4-24 : Total Numbers of ETPs in Gujarat Figure 4-25 : ph Level Treated Effluent of CETPs Discharging into River Figure 4-26 : ph Level of Outlet Discharge into River Figure 4-27 : BOD Level of Treated Effluent of CETPs Discharging into River Figure 4-28 : BOD (mg/l) Level of Outlet Discharge into River

5 Figure 4-29 : COD Level of Treated Effluent of CETPs Discharging into River Figure 4-30 : COD (mg/l) Level of Outlet Discharge into River Figure 4-31 : TSS level of Treated Effluent of CETPs Discharging into River Figure 4-32 : TSS (mg/l) Level of Outlet Discharge into River Figure 4-33 : TDS level of Treated Effluent of CETPs Discharging into River Figure 4-34 : TDS (mg/l) Level of Outlet Discharge Into River Figure 4-35 : NH-3 level of Treated Effluent of CETPs Discharging into River Figure 4-36 : NH-3 (mg/l) Level of Outlet Discharge into River Figure: 4-37 BOD Concentration in River Sabarmati near final discharge point Figure: 4-38 COD Concentration in River Sabarmati near final discharge point Figure 4-39 : ph level of Treated Effluent of CETPs Discharging on Land Figure 4-40 : ph Level of Outlet Discharge on Land Figure 4-41 : BOD level of Treated Effluent of CETPs Discharging on Land Figure 4-42 : BOD (mg/l) Level of Outlet Discharge on Land Figure 4-43 : COD level of Treated Effluent of CETPs Discharging on Land Figure 4-44 : COD (mg/l) Level of Outlet Discharge on Land* Figure 4-45 : TSS level of Treated Effluent of CETPs Discharging on Land Figure 4-46 : TSS (mg/l) Level of Outlet Discharge on Land Figure 4-47 : TDS level of Treated Effluent Of CETPs Discharging on Land Figure 4-48 : TDS (mg/l) Level of Outlet Discharge on Land Figure 4-49 : NH3 level of Treated Effluent of CETPs Discharging on Land Figure 4-50 : NH3 (mg/l) Level of Outlet Discharge on Land Figure 4-51 : ph level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea 71 Figure 4-52 : ph Level of Outlet Discharge into Creek/Gulf/Estuary/ Sea Figure 4-53 : BOD level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-54 : BOD (mg/l) Level of Outlet Discharge into Creek/Gulf/Estuary/ Sea Figure 4-55 : COD level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-56 : COD (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea Figure 4-57 : TSS level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea 75 Figure 4-58 : TSS (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea Figure 4-59 : TDS level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-60 : TDS (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea* Figure 4-61 : NH3 level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-62 : NH3 (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea Figure 4-63 Hazardous waste generated at Alang Figure 5-1 Water Sampling Stations at Alang for the Study

6 Abbreviations AEPS AERB AIE APCM ATPA BOD CCA CEPI CECB CETP CIAPM COD CP CPCB CRZ DISH DMIC DPMC DPSIR EOU ETP GEC GERMI GIDC GMB GPCB GSDP HW IEM KSPCB KLA LOI LOP LDT MMTPA MT MPCB MTPA MoEF MSI MSME Ankleshwar Ecology Protection Atomic Energy & Regulatory Board Ankleshwar Industrial Estate Air Pollution Control Management Ahemdabad Textile Processors Association Biochemical Oxygen Demand Consolidated Consents And Authorization System Comprehensive Environmental Pollution Index Chhattisgarh Environment Conservation Board Common Effluent Treatment Plant Centre for Industrial Area Planning & Management Chemical Oxygen Demand Cleaner Production Central Pollution Control Board Costal regulation zone Directorate of Industrial Safety & Health Delhi Mumbai Industrial Corridor Disaster Prevention Management Centre Drivers, Pressure, Status, Impact And Response Export Oriented Units Effluent Treatment Plant Gujarat Ecology Commission Gujarat Energy Research & Management Institute Gujarat Industrial Development Corporations Gujarat Maritime Board Gujarat Pollution Control Board Gross State Domestic Product Hazardous Waste Industrial Entrepreneurs Memorandum Karnataka State Pollution Control Board Kilo Liters per Annum Letter Of Intent Letter Of Permission Light Displacement Tonnage Million Metric Tons Per Annum Metric Tons Madhya Pradesh Control Board Metric Tons Per Annum Ministry Of Environment And Forest Manufacture, Storage And Import Micro, Small And Medium Enterprise 9

7 MSMED NAPCC NCPC OSPCB POP RFMP SIR SMB SPCB TDS TSDF TSS VMEMCL XGN Micro, Small And Medium Enterprise Development National Action Plan on Climate Change National Cleaner Production Center Orissa State Pollution Control Board Persistent Organic Pollutants Recycling Facility Management Plan Special Investments Regions State Maritime Board State Pollution Control Board Total Dissolved Solids Treatment, Storage And Disposal Facilities Total Suspended Solids Vapi Waste and Effluent Management Co Extended Green Node 10

8 Introduction 1.1. Background Gujarat is one of the most industrialised states in India. The industrial growth of the state has not only been faster but is consistent over the last decade having utilised the benefit of liberalisation and globalisation. The industrial investments have given good results in attracting large business houses in recent times with big ticket projects such as Tata Motors, Ford and Maruti-Suzuki in automobile industries. Large investment with mega projects in petro-chemicals has been possible due to planned industrial development at Dahej in Bharuch. More and more industrial investments are likely to come to Gujarat, in view of taking advantage of proposed Delhi Mumbai Industrial Corridor (DMIC) development project in near future. The government and corporate initiatives have been planning to set up mega industrial complexes by proposing Special Investments Regions (SIRs) in the state. Many of these mega industrial regions have been planned and are likely to invite international proposal for investment. Dholera and Aliabet SIR have been planned and negotiation is ongoing to attract the domestic and foreign investments in heavy and light manufacturing industries and a huge entertainment industry at both the SIRs respectively. Gujarat is the pioneering state to enact the SIR laws which proposes the establishment of a Regional Development Authority in each SIRs to take care of a balanced industrial development. However, the rapid industrialisation may have environmental consequences in future as Gujarat is also known for the environmental hotspot due to industrial development (MoEF, ). The case of Ankeleswar Industrial Estate alongside the golden corridor of industrial development in South Gujarat is a point of discussion in today s context of environmental degradation due to industrialisation. The focus of the study therefore, is to understand the environmental aspects of industrial development in the state Need and Approach There have been various attempts to prepare State of Environment Report by the State of Gujarat in the past. The last such report published in 2005 attempted to bring out the status of environment by examining the various sectors of economy as the major drivers. It is realised that the rate of industrial growth has been faster during the last 11

9 decade, hence a rapid assessment of industrial sectors focusing environment parameters would be worth reporting for the use of various stakeholders including the people of Gujarat. The report would also be utilised for further investigation in industrial environmental sector as it will prepare an essential data base and simple logical explanation of linkages between industrial sector and environmental ecology in the state. The study explores various dimensions of industrial development in the state that has direct and indirect bearings on the environment. The earlier state of environment report of Gujarat has followed Drivers, Pressure, Status, Impact and Response (DPSIR) approach while dealing with sectoral issues. The present study has tried to follow the DPSIR approach, however, it may look into the ecosystem approaches and would identify the hotspots for further detailed investigations selecting few case studies in Gujarat. Ecosystems approach fundamentally focuses into the life support system for humans as well as all other forms of life. Healthy ecosystems support human well being through the provision of ecosystem services. These include the supply of food, fresh water, clean air, fertile soil, and biological diversity in a given ecosystem. The balance in any ecosystem is maintained and regulated through energy transfer and biogeochemical cycles. The ability of ecosystems to function and provide these services is determined by many factors including their biological diversity, ecological and evolutionary processes, climatic inputs of energy and water, and anthropogenic impacts related to economic activities. The balance in ecosystem gets disturbed due to the various changes brought in environmental media of ecosystem. Industrial activities are likely to make negative changes in any ecosystem, if not regulated. Therefore, environmental management tools need to be applied to study the industrial environment whenever necessary during this study Objectives: The followings are the major objectives of the study: 1. To examine the environment pressure and possible impacts due to recent industrial development in Gujarat; 2. To identify the various initiatives in terms of industrial response to reduce or and eliminate the negative environmental externalities and 12

10 3. To understand the policy implication on industrial environment with respect to above objectives Methodology and Database In order to make a rapid assessment of industrial sector in Gujarat, the overall pattern of industrialisation taking district as unit has been analysed for half a decade period i.e. during and based on the secondary data available at Industry Commissionarate, Department of Industries and Mines, Government of Gujarat. This would provide better idea of the types of industries that have come up in the state during recent past. It is important to see the structure and concentration of industries by their types such as polluting and non-polluting industries at regional and district level. The spatial distribution of various types of industries (those registered with GPCB) categorized as Red, Orange and Green, on the basis of their respective pollution potentials have also been assessed at the district level. Critical districts have been identified with the help of spatial distribution of Red, Orange and Green industries at regional level. This has helped identifying the hotspot of industrial environment to prepare detailed case studies of couple of industrial locations for urgent policy implications. The impact of industrialisation on environment has been assessed, based on the information of generation and management of industrial waste and their resultant pollution. Status of hazardous waste and effluent of industries and their treatment capacity have been assessed in the study. An attempt has also been made to capture the entire gamut of state s responses, whatsoever in regards to environmental protection and management. Table 1.1 presents a synoptic overview of framework, attributes and their respective sources of database. 13

11 Table 1-1 : Framework, Attributes, and Source of data/information Analysis (Drivers) Growth of Industrial Sector Attributes and Parameters GSDP Contribution from Industrial Sector Data Sources Socio, economic review Gujarat , , , , , (Drivers and Industrial Status) Structure and Regional pattern of industry (Pressure) Distribution of polluting,nonpolluting industries, Concentration of polluting industries (Possible Impact) Levels of industrial pollution in selected Estates (Response) Government and industry initiatives 14 Progress of MSME, Large units Employment and investment for time period of 2006 to Trend and distribution of Red, Orange and Green category industries at state, regional and district level for the period of 2007 to 2012 Region wise distribution of waste and effluent generation Distribution and capacity of CETP, TSDF and incinerators for the year 2012 State level responses Industrial Estate level responses and/ unit level responses GIDC Annual report 2009, Industries in Gujarat, Statistical information 2010 and 2009, Industries Commissionerate, Director Industrial Safety and Health, Labor & Employment Department, Government of Gujarat, FDI synopsis report on Gujarat, RBI s Regional Office Ahmedabad) Industries in Gujarat, Statistical information 2010 and 2009, Industries Commissionerate, Gujarat Pollution Control Board, Annual Report GPCB 2005, 06, 07, 08, 09, 10,11,12 CPCB 2005, MoEF MOEF Annual Report and , GIDC, GCPC, and Others Environmental Protections Sustains Development: Some Initiatives in Gujarat GPCB, (2011). Environmental Management-Gujarat

12 Response and Initiatives GPCB, (2011) Scope and Limitation The study focuses on bringing out status of industrial environment in terms of industrial pressures and its related impacts. State s response to environmental protection has also been captured to assess the role of other stakeholders in responding to various negative consequences of industrial development in terms of environmental contamination and pollution. One of the limitations of this study is that it does not attempt to provide any information of industrial emission that goes to air environment. A separate chapter in this regards is being compiled for this SoER, Synoptic overview of the report Section one of this report introduces the study with background, need of the study, aims and objectives along with prescribed methodology and database. It also highlights the scope and limitation of the study. Industrial profile in terms of sector contribution, structure and pattern of industrial development in recent times viz-a-viz units, investment and employment has been presented in the section two. Section three deals with consequences of the industrial development in terms of industrial pressure in detail. The status of industrial pollution in terms of generation of hazardous waste and industrial effluents has been critically analysed in the section four, while section five tries to capture the various responses so far undertaken in environmental protections and management by the various stakeholders including the Government of Gujarat. Section six brings out a conclusion of the study. 15

13 2. Industrial Scenario in Gujarat 2.1 Major Economic Sector in Gujarat- Current Status Gujarat s economic growth has been faster in recent years while sustaining a double digit growth for a considerable period of time. Gross State Domestic Product (GSDP) of Gujarat at constant ( ) prices in has been estimated at Rs Lakh crore as against Rs. 3.0 Lakh crore in , registering a growth of 10.2 percent in a year. As per quick estimates, GSDP at current prices in has been estimated at Rs Lakh crore as against Rs. 3.6 Lakh crore in , registering a growth of 16.8 percent compared to last year (Socio-Economic Review ). Industrial sector has been a major contributor to state economy in recent decades. The higher growth in the economy during the year can be mainly attributed to manufacturing, electricity, construction and communication sectors, which have contributed to the tune of 11.0 to 34.6 percent growth during the year at constant ( ) prices (Socio-Economic Review ).The share of primary, secondary and tertiary sectors in GSDP at constant prices was recorded at 14.2 per cent, 38.6 per cent and 47.2 per cent respectively in the year at base year. It is the tertiary sector that has been contributing to Gujarat economy the most followed by secondary and primary sector, which is comparable to Indian economy on overall contributions from these major sectors. One may infer that Gujarat s strong and sustained economic base has been supported by secondary sector especially by Manufacturing Sector as well as Tertiary Sector. Recent data shows that Manufacturing Sector contributes 27 percent to the overall GSDP. The share of manufacturing sector in the state has remained almost constant following economic crises of in recent years, due to its open industrial policy which also depends on the external economic environment globally, (Kumar and Subramanian, 2012). 16

14 2.2 Brief History of Industrialistion in Gujarat Gujarat has diversified its industrial base substantially over a period of 60 years ever since it has acquired Statehood from the erstwhile Bombay State. Textiles and Auxiliary sectors were the major contributor to industrial economy of the state during 1960s. The industrial spectrum has completely transformed in the span of over 50 years. At present 12 major industry groups together account for 86 percent of factories, 96 percent of fixed capital investment, 94 percent of value of output and 95 percent of value addition in the states industrial economy. Recently, refined petroleum products has emerged as one of the largest industrial groups having 33 percent share, followed by chemicals having 21 percent share of entire industrial sectors (Industries Commissionerate, 2012). Gujarat has also succeeded in spreading its industrial base spatially covering almost every part of the state. During 1960s, the industrial development was confined only to four major cities namely Ahmedabad, Baroda, Surat and Rajkot and some isolated locations such as Mithapur and Valsad. At present almost all the districts of the state have witnessed industrial development in varying degrees. Such a massive scale of industrial development has been possible on account of judicious exploitation of natural resources, such as minerals, oil and gas, marine resources, agriculture and animal wealth. The discovery of oil and gas in Gujarat in the decade of 60s has played an important role in setting up of petroleum refineries, fertilizer plants and petrochemical complexes in the state at suitable locations. The state government has also established a strong institutional network i.e. Gujarat Industrial Development Corporations (GIDC), in 1960s which oversees industrial estates in the state (Sukhadia, 1997). GIDC s major responsibility is to providing developed plots and built-up sheds to industries. Institutions were also set up to provide term finance, assistance for purchase of raw materials, plant and equipment and marketing of products. Later, District Industries Centres (DICs) were set up in all the districts to provide assistance in the form of support services in setting up industrial units. 17

15 These early initiatives have determined the present regional distribution of industrial sectors in the state. It has also influenced the basic structure of industries in terms of size and potential to create employment at regional level. 2.3 Structure of Industrial Sectors in Gujarat This section presents structure and pattern of industrialization in the state in terms of size and type of the various industrial sectors. The purpose is to also see the growth trends of various industrial sectors in terms of number of units, total investment, and employment during the last five years in order to understand the impact of the open industrial policies adopted in Gujarat Development and trends of MSME Government of India has introduced Micro, Small and Medium Enterprise Development (MSMED) Act, 2006 which has been implemented in Gujarat. As per the recent data Gujarat has 4130 micro, small and medium enterprise registered in This has increased to by 2010 with a total investment of Rs crore and a total employment of 7.72 Lakh. (see Table 2.1). Table 2-1 : Progress of Micro Small Medium Units in Gujarat, 2006 To 2010 No. of Units Growth Rate Investment (Rs. In Crore) Growth Rate Growth Rate Period Registered Employment 2006 to to to to Total Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate 18

16 The growth rate shows declining trends in units, investment and employment in MSMEs during and This indicates a decelerated growth rate in the MSME sector in Gujarat during the same period. Looking at the performance of MSME during the last 5 years in terms of investment employment ratio, there is a decline in per unit employment ratio from 18 persons/unit to 12 person/unit during to (see Annexure-I). MSMEs in Gujarat have been dominated by textile, machinery, apparel and dyeing and chemicals and chemical products Industrial Sectors under MSME Among different industrial sectors MSME has witnessed impressive development in textile which contributes 36 percent of total MSME units, followed by other sectors like machinery and metal products (14 percent), apparel products (11 percent) and chemical & chemical products (10 percent). Rest others are fabrication and basic metals and food processing industries till 2010(see Figure 2.1) Figure 2-1 : Type Wise Distribution of MSME, Gujarat, 2010 Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate 19

17 2.3.3 Large Scale Units All industrial units other than MSME s are considered as medium and large industries. Since 1991 Gujarat has received 10,457 Industrial Approvals comprising of 9,481 Industrial Entrepreneurs Memorandum (IEM) Acknowledgements, Letter of Permission (LOP) for 100 percent (Industrial commissionerate, 2011). Export Oriented Units (EOUs) and Letter of Intent (LOI) Table 2-2 : Progress of Large Scale Industries Progress as on 30, 2010 No. of Units Investment Employment (in cr) Projects implemented (169) Projects under implementation (210) Progress as on Projects implemented (163) Projects under implementation (168) Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate As on 2007, 5067 large projects were being implemented with an overall investment of Rs lakh crores. Out of this 37 percent projects were under implementation contributing Rs lakh crores of investment. The total large scale units being implemented have increased to 5384 with an investment of Rs lakh crores. However the percentage of projects under implementation were increased to 46 percent in 2010 from 37 percent in 2007 with four fold increase in the total investment amounting to Rs lakh crores, during the same period. There has not been any significant changes in the per unit employment during the same period implying that large industries in the state are of capital intensive. The large industrial sector is dominated by chemical & petrochemical and textile industries. 20

18 Figure 2-2 Type wise distribution of LOI+ LOP+ IEM projects in Gujarat (up to ) Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate The group-wise analysis of large scale projects under implementation indicates that chemical and petrochemicals sector put together accounts for 30 percent of total investment. The other important sectors having investment in Gujarat include textile (20 percent), engineering (7 percent), metallurgical industry (6 percent), food processing (6 percent) and others having (31 percent) till March Large industrial sector consists of 84 pharmaceutical units, 57 dyes and intermediate, 49 pulp & paper units and 23 cement units, which falls under most polluting category of industries as indentified by CPCB (see Annexure 2). These industries have very high potential for adverse environment implications on air, water and land and will have deleterious impact in the long run if not properly regulated at both local and regional level. 2.4 Industrial Development- Regional analysis Region wise MSME distribution It is observed from Figure 2.3 that South Gujarat region has registered highest number of MSME units followed by Central Gujarat during 2006 to Number of MSME registration have increased from 1958 to 30,305 in South Gujarat, while it has increased 21

19 from 1548 to 24,995 in Central Gujarat during the same period. Kutch has registered lowest MSME registration during 2006 to 2010 followed by Saurashtra and North Gujarat. Figure 2-3 : Region Wise Progress of MSME Units Registration in Gujarat, To 2010 Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate Percentage share of MSME- District level to 2010 MSMEs are concentrated in specific cluster or districts, it is important to see the district wise share of MSMEs units in the state. The major 5 districts such as Surat, Ahmedabad, Rajkot and Baroda and Valsad alone consists of more than 75 percent of total MSME units in the state as per the latest data available with Industries Commissionarate 2010 (see Figure 2.4). Figure 2-4 : Percent Distribution of MSME in Major Districts Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate 22

20 2.4.2 Large Scale Units: Regional Distribution Figure 2.5 shows the distribution of the large scale industries across the regions of Gujarat during 2006 and Till 2006, South Gujarat was leading in having large scale industry share with 683 units, followed by Central Gujarat with 596 units and North Gujarat with 553 units, while in 2010 the pattern has changed. Central Gujarat appeared to have maximum number of large industry, consisting 8872 large scale industrial units, which is 29 percent of total share of the state, followed by South Gujarat with 791 units comprising 25 percent of total large scale industries. Figure 2-5 : Region wise progress of Large Units in Gujarat, to 2010 Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate District wise Distribution of Large Units Figure 2.6 shows district wise distribution of large scale units in the state during 2006 and It is observed that top ten districts- Surat, Kutch, Bharuch, Valsad, Ahmedabad, Vadodara, Rajkot, Jamnagar, Mehsana and Godhra together accounts for more than 90 percent of the total large scale units in the state in However, there has not been any significant change during 2006 and 2010 as far as their respective share is concerned. Surat, Kutch, and Bharuch have consistently high share of large units among all the other districts during the last 5 years. 23

21 Figure 2-6 : District wise Percent Distribution of Large Units Source: Industries in Gujarat, Statistical information 2010, Industries Commissionerate As far as district wise distribution of industries in the state is concerned, Surat, Ahemdabad, Rajkot, Kutch, Bharuch have maximum concentration of MSME and Large Scale units as evident from the above discussion. There is an urgent need to identify critically polluted areas among these districts. One needs to also understand industrial pressures and identify the related negative impacts in terms of Industrial contaminations and pollutions. A significant number of industrial units both MSMEs and Large Scale are also being concentrated along the large coastal regions of the state. A brief account of industrialization in coastal areas has been given below in order to understand the expected environmental pressure on coastal and marine ecosystem Costal Industrialization Gujarat state has longest coastline of 1,600 km (one third of the total Indian Coastline of 4,800 km) among all the maritime states of the country, which makes it strategically serving as natural gateway to India. The Gujarat coast extends from Western Ghats in Valsad to Kori creek on the coast of Kutch in north. According to Gujarat Coastal Salinity Prevention Cell- a joint initiative of local NGOs and Government of Gujarat, out of 26 districts of Gujarat, 12 districts fall under costal region, which is given below in Table 2.3. Gujarat s coastal regions can be divided in to three zones, namely, Kutch, Saurashtra and Mainland Gujarat. There are 6 coastal Blocks (Talukas) in Kutch, 20 in Saurashtra and 16 coastal Blocks in Mainland Gujarat, bringing the total to 42. All the three regions differ in terms of physiography, geology, geo-hydrology and geomorphology and, their agro climatic conditions. 24

22 Table 2-3 : Major Industries in Coastal Regions in Gujarat Coastal Districts under Major type of industries region coastal region located in the district/s Kutch Kutch Port lead infrastructure projects, metallurgical, textiles, chemicals, cement etc. Saurastra Jamnagar, Rajkot, Engineering, Textiles & Bhavnagar, apparels, Chemicals & Amreli, Junagadh Petrochemicals Port & Infrastructure, ship breaking, cement etc. Mainland Ahmedabad, Dyestuff, Manufacturing and Kheda, Bharuch, engineering, Textiles, Surat, Valsad, and Chemicals & Petrochemicals, Vadodara Pharmaceuticals, Ports & Ship building, diamond processing etc. Agro climatic Environmental Conditions Average annual rainfall of mm; Sandy and saline soils; Cultivated and grass land. Average annual rainfall of medium black soil Cultivated and grass land. Average annual rainfall of Deep black, medium black to loamy sand (Goradu) soils. Most of the area cultivated some area non-cultivated under fallow and pasture forest. Source: compiled from Industries Commissionerate and Agriculture &Co-operation Department, GoG Major Industries in Coastal Districts Table 2.3 shows type of industries in the coastal regions of Gujarat. Among all the costal districts Ahemdbad, Surat, Vadodara and Rajkot are the traditional industrial center. But in last decade Bharuch and Kutch has become big industrial hub in terms of large scale industries. Two major industrial groups in Kutch are Chemical &Petro Chemical industries (93 units) and Engineering industries (79 units), which almost accounts for 50 per cent of all the units in the district. Other major sectors present in the district are 25

23 Electrical and Electronics (35 units), Metallurgical Industries (34 units), Glass, Ceramics, Cement (32) and Food processing (29 units) (Industries Commissionerate, 2010). Kutch is the leading district as compared to others for having maximum number of salt producing units. It accounts for 34 percent of total production of salt in the state. It employs workers which are around 29 percent of total salt workers in the state (Industries Commissionerate, ). Apart from Kutch, other major salt producing districts are Jamnagar, Surendranagar, Bhavnagar, Rajkot and Bharuch. Baruch, Ahemdabad, Surat, and Vadodara ( falling under Mainland Coastal Region) is located on the 300 km long corridor referred to as the golden corridor have the maximum concentration of chemical and textile industries. Bharuch has large chemical estate at Ankleshwar, Panoli, Jhagadia, Vilayat and Dahej. Over 11,500 units of small and medium enterprises of different sectors, such as chemicals and petrochemicals, textiles etc. are present in the district (Industrial Comissionerate 2011). Significant development of large-scale industries has also taken place in Surat in recent years, and a number of units manufacturing chemicals and plastics have come up. Some of the major industries that have come up in and around Surat due to establishment of major port at Hazira are petro-chemical refinery, natural gas, cement, steel plant etc. Mega Industrial Clustering at Coastal Districts (SEZ and SIR) Gujarat has been at the forefront of SEZ led industrial development in the country. Asia s first EPZ was set up in Kandla in 1965 and Gujarat has established 2 SEZ in Surat prior to SEZ Act of Under 2005 SEZ Notification, 11 SEZ has been notified in Gujarat. The Government of Gujarat enacted SIR Act, 2009 in its initiative to create large size investment regions / industrial areas and develop them as global hubs for economic activity supported by world class infrastructure. Table 2.4 shows list of proposed SIR with potential industrial sectors in the state. Table 2-4 Proposed Special Investment Region in Coastal Region in Gujarat. Region SIR Potential Industrial Sectors Kutch Anjar Port and port based industries, mineral, agro based and 26

24 engineering Saurastra Pipavav, Simar, Okha, Navlakhi Logistics based industries, pre-cast structure, spinning, Engineering, energy, port & port related activities, pharmaceutical, CRO, biotechnology. South Gujarat PCPIR, Aliyabet, Entertainment, aquaculture, marine engineering, Refinery downstream, high performance chemicals, Source: Gujarat Industrial Development Center, 2011 Gujarat is the only state in India to have enacted a Special Investment Regions Act, As mentioned above 11 SIR have been proposed in the state; out of which seven of them have been proposed in coastal region. Saurastra has four SIR falling under districts of Bhavangara, Junagadh, Jamanagar and Rajakot, followed by Bharuch (2) and Kutch (1). Major and Minor Ports in Coastal Gujarat Gujarat is a principal maritime State endowed with favourable strategic port locations. There are 41 ports, of which Kandla is a major port. Out of the remaining 40 ports, 11 are intermediate ports and 29 are minor ports under the control of Gujarat Maritime Board- a subsidiary of Government of Gujarat. Further the State ports are organized into 10 major groups. The individual group detail of these ports is given in the Table 2.5. Table 2-5 Ports in Gujarat under Gujarat Maritime Board Region Individual group No. of ports Kutch Mandvi Group, Navlakhi Group 4 Saurastra Bedi Group, Okha Group, Porbandar Group, Veraval Group, Pipavav Group, Bhavnagar Group, South Gujarat Bharuch Group, Magdalla Group 14 Source: Gujarat Maritime Board, accessed on 1 st July

25 The state s ports are geographically dispersed across South Gujarat (14), Saurashtra (13) and Kutch (4). In , Gujarat ports handled cargo traffic of MMT compared to a total traffic of 108 MMT handled for the year of Now Gujarat maritime board is aiming to create total port capacity 557 million tonnes at the end of fiscal year (GMB, 2011). Port lead industrial development in the state is likely to put greater environment pressure on coastal and marine ecosystem. These activities need appropriate planning and regulatory measures for a sustainable and better industrial development in coastal region. Shipbreaking Yard at Alang The ship breaking yard at Alang is located in the Saurashtra region of Gujarat off the Gulf of Cambay. It was set up in 1983 on a small scale basis along a 10-km stretch of sandy beach. The tidal, geographical, and climatic features make Alang an ideal ship breaking location. Coastal waters of Alang are connected with Bhavnagar coast on one side and Dahej coast on other side. The Alang and Sosia Ship- Breaking Yard (ASSBY) is the largest ship-breaking yard in World. More than 90 per cent of the ship dismantling in India is done at the Alang yard. On an average 200 ships are scrapped down every year, churning out 2.6 million tonne of scrap steel and large quantity of other waste in terms of broken wood, rubber, insulation materials, paper, metals, glass, ceramics, plastics, leather, paints, thermocol, sponge, ash etc. (NIO, 2011). There are currently 169 plots (after merging to form larger plots), which have been developed along the coast out of which 132 plots are working. These plots possess valid Authorization and Approved RFMP plan for ship recycling (GPCB, 2012). Ship breaking represents an important source of raw material supply and provides jobs to tens of thousands of people. The practice is inherently sustainable, given that over 95 per cent of a ship can be recycled: steel is re-rolled and used in construction; machinery and equipment are reused; and oils and fuels are reused or recycled. In principle the recycling of vessels constitutes the best option for ships that have reached the end of their operating life. (UN, 2010) The ship breaking activities are carried out by engaging large number of contracted labour/workers who are specialized in job like oil removal, insulating material 28

26 removals etc. For dismantling of one ship, around workers are required (National Institute of Oceanography, 2011). According to figures provided by GMB, 5,052 vessels have been dismantled by the year 2010 in Alang since Some 60,000 workers are employed in the yards when the industry works at full force. In addition, over 500,000 workers are employed in associated downstream industries, such as rerolling mills, foundries, scrap-handling yards, local goods stores and other small businesses. (UN, 2010) Details of number of ships recycled and total tonnage is given in Table 2.6. Table 2-6 No of Ships dismantled every year at Alang Ship Breaking Yard Year No. of Ships LDT 10000MT Source: Gujarat Maritime Board (December 2011) obtained from GPCB

27 The Gujarat Maritime Board (GMB)is the main nodal agency of the shipbreaking yards of Alang/Sosiya. GMB presently grants permission for utilizing ship recycling plots as per the provisions of The Gujarat Maritime Board (Conditions and Procedures for Granting Permission for Utilising Ship Recycling Plots) Regulation, 2006 and amendments therein made in June2008. As a nodal agency, GMB provides links between central and local government agencies, such as the Gujarat Pollution Control Board (GPCB), the Custom Department, and the Directorate of Industrial Safety and Health (DISH), and the ship breaking industry. Industrial pressure in Coastal Regions Groups of chemical, petrochemicals, drugs and pharmaceuticals and textile industries are concentrated on the coastal districts of Bharuch and Surat. These industries contribute significantly towards water pollution causing environmental pressure on marine and coastal ecosystem. The world s largest ship recycling yard at Alang, in Bhavnagar is located in Gulf of Khambhat coast. Engine oil and other non-degradable toxic compounds flow into the protected waters of the Gulf of Kachch from where tides wash them into neighbouring creeks and mangrove swamps. Consequently, mangroves in the region are so degraded that they cannot be regenerated (Gadhvi, 2010). As per the report published by GEC, 2004, the following summary explains the status of coastal pollution in Gujarat due to industrial and human activities in the hinterland. A recent measure of setting up common effluent treatment plants (CETP) for the industrial units is an emerging threat. CETP s cannot treat certain types of pollutants like heavy metals, mercury and POPs. The disposal of hazardous waste and technical capability to measure the emission level need urgent attention. The coastal waters of Gujarat can be expected to receive 606 Mm3 domestic sewage and 215 Mm3 industrial effluents every year. In addition, about tonnes of domestic solid wastes are dumped into the sea. Coastal industries generate five million tonnes of solid wastes. There are no estimates made for agricultural runoff into the sea with increasing levels of pesticides and fertilizers from the districts of Kutch, Kheda, Surat and Valsad that are likely to contribute excess nutrient. Pollution of estuaries and downstream rivers has affected the livelihood of the local fishermen. 30

28 3. Polluting Industries in Gujarat Environmental contamination and pollution emanating from the polluting industries in Gujarat have been in the news in recent time as many critically polluting industrial estates /areas have attracted the attention of regulatory body and government together. CPCB has identified 2301 medium and large-scale polluting units under 17 highly polluting industrial categories in India. Out of these, 283 units are located in Gujarat. The state stands second in the position amongst the other states in India having most polluting industrial units in 2004 (see Annexure V). However, 273 industries have complied with the CPCB guidelines for reducing the potential pollution and 10 units has been closed down. Taking clue from the above scenario, an analysis of the distribution of Red, Orange and Green industries in Gujarat has been done with help of last five years data from 2007 to 2012 provided by the GPCB. In addition to this, the study tried to capture the status of waste generation and its possible impacts across various regions in Gujarat for the same period. This has helped in understanding the overall industrial pressure on environment across different regions and districts in Gujarat. Table 3.1 shows the categories of industries in Red, Orange and Green based on the total quantity and characteristics of different types of hazardous wastes generated, and type of production in industrial units. These are the followings Red- highly polluting industries Orange- moderately polluting industries Green non polluting industries Out of the total industries registered during under GPCB, more than 60 percent of industries fall under Red Category, while Orange and Green Category industrial units accounts for 23 and 17 percent respectively during the same period (see Table 3.1). 31

29 There are 16,770 (Red Category) industrial units registered under highly polluting industry category in Gujarat, which has increased by more than three times during 2006 and 2012 (see Table 3.1). Similarly the Orange category industrial units have also increased three fold during the same period. However, one observes that it is the Green Category industrial units that have registered much faster growth. It has increased from merely 828 units in to 4654 units in indicating more than five times increase in a period of five years duration (see Table 3.1). This indicates a positive sign towards having green industrial development in the state. Table 3-1 : Categorization of units in terms of Red, Orange and Green, In Gujarat to Year Red Orange Green Total Source: Gujarat pollution control board report 2011 and, Hazardous waste inventory,2007, GPCB 3.1. Regional Distribution of Red, Orange and Green Units: Almost 74 percent of the total Red Category units are located in Saurastra and Central Gujarat region in The remaining is distributed among South Gujarat (18 percent), North Gujarat (5percent) and Kutch (3percent). Saurastra has registered a significant increase in the Red Category industries during last 5 years (see Figure 3-1) Figure 3-1 Region Wise Percent Share of Red Industries Figure 3-2 Concentration of Red Industrial Based on the Percent Distribution 32

30 Source: Gujarat pollution control board repoer 2011 and, Hazardous waste inventory,2007, GPCB There are 6468 industrial units in the Orange Category in Almost 65 percent of Orange Category industry falls in Central Gujarat and Saurastra. Figure 3.4 shows that apart from Saurastra and North Gujarat all the other regions have shown declined in percentage share of Orange Category industries during 2007 and Figure 3-3 Region Wise Percent Share of Green Industries Figure 3-4 : Region Wise Percent Share of Orange Industries Source: Gujarat pollution control board repoer 2011 and, Hazardous waste inventory,2007, GPCB Same trend has been observed in the percentage share of Green Category industry across the regions. This indicates a clear shift in the location of Red Category industries toward Saurashtra particularly in Rajkot and Jamnagar districts. In terms of Green Category industry, Central Gujarat had 60 per cent of the total registered Green industries in Gujarat in the year 2007 however, it has declined to 46 per cent in the year Critical districts A district level analysis of share of Red Category industrial units during 2007 and 2012 indicates that the relative share of polluting industries (Red Category) are reducing in the so called Golden Corridor comprising of Ahmedabad, Bharuch, Surat and Vasad districts, except for the Vadodara district where the share has increase in 2012 compared to 2007 period (see Figure 3.1). However, Rajkot, Jamnagar, Mehsana and Gandhinagar districts have registered increasing share of Red Category industries during the same period. This does not mean that the relative number of Red Category 33

31 industries in the Goldern Corridor districts is less compared to other districts in In a nutshell, it indicates that Saurashtra and North Gujarat are the new destinations for the Red Category (Polluting) industrial units in the state in recent times. These two regions are ecologically fragile in terms of prevailing arid conditions and unique biodiversity and will have more deleterious impact on the environment due to polluting industries compared to other regions. Figure 3-5 District Wise Percent share of Red Industries Source: Gujarat pollution control board repoer 2011 and, Hazardous waste inventory,2007, GPCB The sudden jump in the share of Red Category industries in Rajkot, Vadodara and Jamnagar from 2007 to 2012 is a point to ponder as far as sustainable industries development in state is concerned. In terms of actual pressure on environment due to the industrial pollution loads, the study attempted to make an assessment of industrial waste generations and its management at regional level. 34

32 4. Industrial Pressure and Impact While increasing industrialization has lead to increase in waste generation, environmental pressures and impacts are observed in different magnitudes across the state. Hence this section presents the status and resulting pressure caused by industrial hazardous and liquid waste along different key components of waste value chain namely generation/capture, collection (storage and transport), treatment and disposal. The responses have been discussed in terms of institutional, financial, technology and promotion/awareness measures undertaken by different stakeholders in the next section Industrial Hazardous Waste Generation and Management According to Hazardous Waste (Management and Handling) Rules 1989 under the Environment (Protection) Act 1986: Hazardous Waste is defined in the Rule as any waste which by reason of any of its physical, chemical, reactive, toxic, flammable, explosive or corrosive characteristics, causes danger or is likely to cause danger to health or environment, whether alone or when in contact with other wastes or substances. Hazardous waste residue of production process may cause significant damage to environment and human health and / or environment unless handled, stored, transported, treated and disposed off scientifically using environmentally sound technologies Inventory: As per the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, every person engaged in generation, processing, treatment, package, storage, transportation, use, collection, destruction, offering for sale, transfer of the 1 These rules supersede. The Hazardous Waste (Management and Handling) Rules, 1989 and amendments therein. 35

33 hazardous waste or occupier of the facility shall get authorization from the State Pollution Control Board. A record of Authorization granted by the Gujarat Pollution Control Board over the Years is given in Table 4.1. Table 4-1 : Authorization Granted under Hazardous Waste Regulations as Amended from time to time SR. No. Year Authorization Granted (including renewals) * * ** 635* ** ** ** ** 593 Source: Hazardous Waste Inventory as on Gujarat State by GPCB NOTE: * From the year , GPCB introduced the system of consolidated consents and authorization system (CCA) which provided the facility of application, processing and clearance of the consents under Water Act, Air Act and Authorization under Hazardous Waste Rules in one go granted for a period of 5 years and the same is reflected in sudden increase in number of authorizations granted ** Source: GPCB Annual Reports 36

34 Looking at distribution of the industrial units producing hazardous wastes in Gujarat, 72 percent of the total industrial units contributing to hazardous wastes come from 5 districts, Ahmedabad (24 percent), Surat (16 percent), Valsad (13 percent), Bharuch (10 percent) and Vadodara (7 percent). These districts also house about 80 percent of the Red Category units in the state. For district wise details refer Annexure VI. Figure 4-1: District wise Hazardous waste generating units 2007 Source: Hazardous Waste Inventory as on Gujarat State by GPCB Generation Hazardous waste can be broadly classified into three categories, Incinerable, Recyclable and Landfillabe. Table 4-2 shows that as in 2007 total Hazardous Waste generated in the State of Gujarat amounts to Million Metric Tonne/Annum. Out of which 64 percent of waste was landfillable, 30 percent was recyclable and meager 6 percent was incinerable. Table 4-2 : Total Hazardous Waste Generated in Gujarat No. of units generating HW 5739 Total HW generation in MMTPA Incinerable in MMTPA (9per cent) (6per cent) Recyclable in MMTPA (29per cent) (30per cent) Landfillable in MMTPA (62per cent) (64per cent) Source: Hazardous Waste Inventory as on Gujarat State by GPCB 37

35 District wise figures of hazardous waste generation suggest that for the year 2007, out of total hazardous waste generated, 70 percent was contributed by four districts, Bharuch (26 percent), Ahmedabad (19 percent), Kutch (15 percent) and Vadodara (10per cent). Figure 4-2 : Average waste Composition of Hazardous Waste Source: Hazardous Waste Inventory as on Gujarat State by GPCB Region wise analysis shows that Central Gujarat contributes maximum to the extent of 62 percent of total hazardous waste generated for the year 2007, followed by Kutch and Saurashtra with 15 percent and 14 percent share respectively. Saurashtra and North Gujarat have insignificant share of 5 percent and 4 percent of contribution respectively. For the details of total hazardous waste generated in different districts of Gujarat see Annexure VII. 38

36 Figure 4-3 : Total Hazardous Waste Generated in MMTPA for year 2007 Source: Hazardous Waste Inventory as on Gujarat State by GPCB Looking at the district wise & category wise generation, it becomes clear that districts located in the golden corridor (Ahmedabad to Valsad) having maximum industrial activities have much higher waste generation than other districts (see Figure 4.3). For district wise details of category of hazardous waste generation in Gujarat (see Annexure VIII). Figure 4-4 : District wise Generation of Hazardous Waste as on 2007 Source: Hazardous Waste Inventory as on Gujarat State by GPCB 39

37 Waste generated in Central Gujarat South Gujarat and Kutch is mainly landfillable in nature, whereas Saurashtra and North Gujarat have higher proportion of recyclable waste. Table 4-3 : Category wise Hazardous Waste (MTAP) Generated in different Regions of Gujarat (2007), Region Landfillable Recyclable Incinerable TOTAL Central Gujarat (57) (35) (8) Kutch (97) (2) (1) North Gujarat (44) (53) (3) Saurashtra (32) (64) (4) South Gujarat (77) (20) (3) Total (64) (30) (6) Source: Hazardous Waste Inventory as on Gujarat State by GPCB Note: Figures in parenthesis are percentage to total in each region Figure 4-5 : Composition of Hazardous Waste Generated in Gujarat Source: Hazardous Waste Inventory as on Gujarat State by GPCB Sector Wise Contribution in the Generation of Hazardous Waste: About one third of the hazardous waste generated in the State comes from miscellaneous sources and cannot be classified by industrial sector. However Dye, Dye Intermediate and Pigment is the single sector that contributes most in terms of generation i.e. 26 percent, followed by Engineering and Metallurgical sector which 40

38 contributes almost 8 percent. Other significant contributors are Pesticides, Textiles, Solvents, Petrochemicals and Oil Refineries. Table 4-4 : Sector Wise Contribution in Generation of Hazardous Waste in Gujarat (2007) Sr No Sector Hazardous Waste Generation MTPA, Miscellaneous Dyes / Dye- Intermediates & Pigment Engineering & Metallurgical Drugs / Pharmaceuticals Pesticides Textile Production / use of solvents Petrochemicals / Oil refining / Processing Metal Surface Treatment Glues / Resins/ Paints / Plastic Chlor Alkalies Pulp & Paper Acid Production Fertilizer Asbestos or ACM Electronics Industries Leather tanneries* Phenol per cent Hazardous Waste Generation MTPA, 2007 Total Source: Hazardous Waste Inventory as on Gujarat State by GPCB *As in 2012 there are no functional leather tanneries in Gujarat Treatment and Disposal Options Recycling, Treatment and/or Disposal of Hazardous Waste can be broadly classified into four categories as depicted in figure 4-6. The description of each category is as follows: 41

39 Figure 4-6 Treatment and Disposal Options of Hazardous Waste In House recycling/ recycling by Registered Recyclers: If an industrial unit plans to recycle the hazardous waste either in house or as a recycler, as per the Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008 items listed in schedule IV are allowed to be recycled. Every person desirous of recycling or reprocessing the hazardous waste specified in Schedule IV should make an application in the Form V accompanied with Consent to Establish by GPCB, Certificate of registration issued by District Industries Center or any other Government agency authorised, proof of installed capacity of the plant and machinery issued by district industries center, and in case of renewal, certificate of compliance of effluent from the GPCB or Zonal office of CPCB. The authorization granted is valid up to five years. The details of registered recyclers are presented in following sections. Co-processing: It is a concept in which hazardous waste generator / Facility operator and Cement/Steel Industry can use waste as an alternative fuel/raw material in environmentally sound manner. In recent years there have been efforts of co-processing in cement industries and substantial increase is seen in quantity of waste being co-processed. Figure 4-7: Hazardous Waste Co-Processed in various Cement Plants in Gujarat Source: Gujarat Pollution Control Board, 2012 Recycling by registered recyclers: 42

40 As on March, 2012 a total number of 117 recycling units were granted authorization under the Hazardous Waste (Handling, Management & Transboundary) Rules, 2008 in the state of Gujarat. Out of total units, 62 per cent units are recyclers of non-ferrous hazardous waste, 26 percent are of waste/used oil and rest units are recycling lead based wastes. Table 4-5 : Details of registered recyclers and Installed Capacity (2012) Sr.No. Type of waste recycled Total Number of Authorized Units Installed Treatment Capacity 1 Non Ferrous (MTPA) Waste/Used Oil (KLA) Lead based (MTPA) Total 117 Source: Gujarat Pollution Control Board, 2012 Figure 4-8 : Authorized Recycling units and installed Capacity in Gujarat (2012) Source: Gujarat Pollution Control Board, 2012 Looking at non-ferrous recycling units, Jamnagar district has maximum registered recyclers (28 units) which accounts for 25 per cent of total recycling capacity for nonferrous hazardous waste in the state. (see Figure 4-9) 43

41 Figure:4-9 - Number of Recycling Units and Installed Capacity of recyclers of Non- Ferrous Hazardous Waste (2012) Source: Gujarat Pollution Control Board, 2012 For recycling of waste/used oil, total 30 units across the state are granted authorization with total installed capacity of 1.73 lack kilo liters per annum (KLA). Ahmedabad district houses 42 per cent of the total installed capacity with 17 units, followed by Bhavnagar district with 14 per cent and Vadodara district with 14 percent of total installed capacity. (see Figure 4-10) Figure: 4-10 Number of Recycling units & Installed Capacity of Recyclers of Waste/Used oil (2012) Source: Gujarat Pollution Control Board

42 While, in case of recycling of lead based hazardous waste, Vapi district has a major share of 37 percent of total installed recycling capacity followed by Rajkot (20 per cent), Jamnagar (14 per cent), and Surat (10 per cent). (see Figure 4-10) Figure: Number of Recycling Units & Installed Capacity of recyclers of Lead based Hazardous Waste (2012) Source: Gujarat Pollution Control Board, 2012 As per available details from the year 2008 to 2012, a total of 1.06 lakh tones of hazardous waste has been recycled. For the last year ( ) total waste recycled in different categories are: non-ferrous waste MT, lead based hazardous waste MT and around KL of waste/used oil. For details of installed capacity and waste recycled over the last four years, refer Annexure IX. Treatment storage and disposal facility As per the Section 18 of the Hazardous Waste (Management, Handling and Transboundary Movement) Rules, 2008, The State Government, Occupier, or Operator of a facility or association of occupiers shall identify sites for establishing the facility for treatment, storage, and disposal of hazardous wastes in the state. The operator of Treatment, Storage and Disposal Facility (TSDF) shall maintain the records of hazardous wastes handled by the facility the same is discussed in following sections. TSDF (Treatment Storage and Disposal Facility) is a centralized unit facilitating member units to dispose off their waste. While land filling is generally practiced at TSDFs, Incinerators are being used to treat the waste which is incinerable in nature. There are a 45

43 few industrial units having captive hazardous waste treatment and disposal facility which consists either or both of the storage and disposal facility and incinerators. List of Common TSDFs with their capacity and type of waste received is given in Annexure X. Figure 4-12 : Hazardous Waste Treated & Disposed by TSDF over the Years Source: Gujarat Pollution Control Board, 2012 From to , a total of lakh Metric Tonnes of hazardous waste was treated/disposed out of which almost 92per cent was landfillable and 6.6per cent was incinerable, while 0.9per cent was landfillable after treatment and 0.6per cent was coprocessed. (GPCB, 2012). Besides co-processing at TSDFs, there is co-processing happening in cement industries. Chemical gypsum generated from neutralization process in chemical industries is widely used as raw material in cement industry which otherwise used to get landfillled in TSDFs. This gets reflected in stagnation in landfillable waste in last two years as shown in the Figure Figure 4-14 TSDF at Bharuch Figure 4-13 Common Incinerator at Kutch 46

44 Source: GPCB, 2012 Figure 4-15: Location of TSDFs in Gujarat as on March 2012 Source: Gujarat Pollution Control Board, 2012 Figure 4-16 : Hazardous Waste Treated in different Districts of Gujarat for the year (MTPA) Source: Gujarat Pollution Control Board,

45 As the Figures 4.16 shows that co-processing is done at the TSDF situated in Surat, which amounts to Metric Tonnes for the year , while in majority of TSDF, waste received and treated is of landfillable nature, and the same is reflected in time series data given in Annexure X. Table 4-6 District wise TSDF in Gujarat as of 2012 District No TSDFs of Capacity Incinerable Co - LAT* Processing Landfillable Ahmedabad Vadodara Bharuch Surat Vapi Bhavnagar ** Kutch Total Source: Gujarat Pollution Control Board, 2012 *=Landfillable After Treatment (Treatment = stabilization of the semi liquid hazardous waste into Solid ) **=TSDF at Bhavnagar does not have incinerator. It receives MTPA hazardous waste of incinerable nature and sends it to other incinerator for its treatment. All the 4 common incinerators available are located within TSDFs as listed below. Out of four common incinerators, one incinerator at Palsana is closed since year 2010 and stores the incinerable waste and treats some in co-processing units. For time series data of waste received & treated in common incinerators refer Annexure XI. Table 4-7 Common Hazardous Waste Incinerators in Gujarat (2012) Sr No. 48 Common Incinerator Name No of Members (Waste Received) Incinerable / Co-processing 1 Nandesari Environment Control Limited Bharuch Enviro Infrastructure ltd M/s. Gujarat Eco Textile Park, Palsana, / Surat Gujarat Enviro Protection & Infrastructure

46 Ltd. Gabheni, Surat, (at present Closed) 4 Saurashtra Enviro Projects Pvt. Ltd Total Source: Gujarat Pollution Control Board, 2012 Apart from Common TSDFs, there are total 16 Captive Hazardous Waste Treatment and Disposal Facilities and 72 Captive Incinerators in Gujarat. The breakup of captive incinerators is as under:- (1) Organic chemicals industries =45 (2) Pharmaceutical = 11 (3) Pesticides Sector=16.Groundwater Quality near Treatment Storage Disposal Facilities CPCB carried out ground water quality monitoring in and around two TSDF sites located in Gujarat in order to assess the status of groundwater quality. The groundwater quality studies at TSDF GEPIL, Surat reveals highest COD and TDS values as 164 mg/l and mg/l respectively. The groundwater quality at TSDF BEIL, Ankleshwar reflects maximum concentration of COD, TDS and hardness as 22 mg/l, 1910 mg/l and 523 mg/l respectively. The concentration of other parameters viz. TKN, NO3-N, and NH3-N were also found elevated in the ground water. The COD value measured in the leachate wells of BEIL TSDF, Ankleshwar was as high as mg/lit, however this leachate is being collected and treated at Common Effluent Treatment Plant. (CPCB, ) 4.2. Status of Effluent Treatment in Gujarat In view of the key role played by SSI units and the constraints in complying with pollution control norms individually by these units, the Ministry of Environment and Forests (MoEF), Govt. of India initiated a technical and financial support scheme to promote common facilities for treatment of effluents generated from SSI units located in industrial clusters (CPCB, 2005). Till 1990, only one CETP at Jeedimetla, Hyderabad was in operation. The report further elaborates that under the Common Effluent Treatment Plant (CETP) financial assistance scheme, 50per cent subsidy on project capital cost, 49

47 25per cent share each of Central and State Governments was provided. For the rest 50 percent, provision was made so as the units can raise loan up to 30 percent of the project cost and rest 20per cent of the project capital cost was borne by SMEs. As a result, 88 CETPs having total capacity of 560 MLD have been set up throughout India covering more than polluting industries. In the year of 2005 State of Gujarat had 16 numbers of CETPs amounting to 18.2per cent of total CETPs available in the country, where as combined capacity as percentage of total capacity amounted to 28.2 percent; which was highest in the country (CPCB, 2005). As per the latest figures available there are total 28 operational CETPs in Gujarat with total treatment capacity of MLD with 5636 member units 2. Treatment schemes of almost all the CETPs employ primary treatment, secondary treatment and tertiary (filter) system is also employed in most of the schemes. (CPCB, 2005) Figure 4-17 : CETP at Vatva (The Green Environment Services Co-op.Society Ltd.) Source: 2 The volume of wastewater generated and treated by industrial units which are not members of CETPs and the industrial units which have captive ETPs is not available. 50

48 Figure 4-18 : CETP at Odhav (Odhav Enviro Project Ltd.) Source : 51

49 Table 4-8 Status of CETPs in Gujarat (As on March 2012) Sr No District No of CETPs No of Members Total Installed Capacity (MLD) 1 Ahmedabad Daily Input (MLD) 2 Surat Rajkot Bharuch Mode of reception of effluent Network Of Pipeline (7), Tankers & Pipeline (2), Tankers (2) Network Of Pipeline (4), Tanker(1) Open Drains (2), Tankers (2) Tankers (2), Network of Pipeline (1) 5 Vadodara Tankers (2) Tankers 6 Gandhinagar Pipeline Network 7 Junagadh Pipeline Network 8 Valsad Pipeline Total Source: Gujarat Pollution Control Board, 2012 and of of Discharge Point River Sabarmati after mixing with sewage(6), Land (2), Reused(2), Evaporated (1) Kadodara Khadi, Bhedwad Khadi, Khadi, Estuary of River Mindhola (2) Land Deep Sea Estuary of River Mahi (2) Land Sea Creeks Estuary of River Damanganga

50 Discharge points of CETPs are river, estuary, deep sea, sea creeks and open land. It is observed that there is a gap between the total installed capacity of CETPs and daily input reaching the plants and thus CETPs are not fully utilized as per their installed capacity. This can be attributed to provision of higher designed capacity to accommodate future requirements. Member units are not operating at full capacity or member units are treating effluents within premises moreover few industries are having their captive effluent treatment plants. Figure 4-19: Location of Functioning CETPs in Gujarat (as on March 2012) Source: Gujarat Pollution Control Board, 2012 Note: Refer Annexure XII for Number & Address of CETPs Trend over last four years suggest that total numbers of CETPs, member units and treatment capacity has increased steadily (see Figure 4.19). In the year 2012 total capacity has increased to 1.5 times of that in year The increase in capacity can be attributed to addition of 3 new CETPs, 1 in Ahmedabad and 2 in Surat with total capacity of MLD. Whereas the increase in CETP capacity during 2008 to2011 was mainly due to augmentation or expansion of existing CETPs and marginally due to new CETPs.

51 Figure 4-20 : Number of CETPs and Member Units in Gujarat & Total Capacity of CETPs in Gujarat Source: GPCB, 2012 Regional analysis shows that almost 78 percent of total treatment capacity in year 2012 is located within South Gujarat, followed by 20 percent in Central Gujarat and 2 percent in the Saurashtra. Kutch and North Gujarat do not have any presence of CETPs. Figure 4-21: Total Treatment capacity & Total Members of CETPs in Gujarat (2012) Source: GPCB Annual Report Out of total 5636 units connected with all the 28 CETPs across Gujarat in the year 2012, majority of the units are from Central Gujarat, with a share of 55per cent, followed by Saurashtra with 25per cent share and South Gujarat with remaining 20per cent. This could be attributed to more than half of small scale industries of state located in central Gujarat. 54

52 Total inflow in the above CETPs amounts to MLD. Details of Discharge Locations of all the CETPs mentioned above are as follows: Table 4-9 Discharge of Treated effluent from CETP Discharge Locations Quantity (in MLD) Quantity in Percentage Discharge into Creek/Gulf /Estuary/ Sea Discharge in river after mixing with sewage* Discharge on Land Reuse/ Self Consumption Evaporated 0.17 Total Source: Gujarat Pollution Control Board, 2012 *Total discharge from CETPs along with effluent from industrial units in Narol which are not members of CETP amounting to around 100 MLD gets mixed with treated sewage of about 1075 MLD and after dilution, finally gets discharged into river Sabarmati, GPCB 2012 As shown in the Table 4.9, out of total discharge per cent is disposed into Creek/Gulf /Estuary/ Sea, almost 5.74 percent into River (after mixing with sewage) and 2.13 per cent on land. Evaporation and/or Self consumption as reuse constitutes insignificant amount of mere 0.19 per cent of total treated effluent discharged. Also, over last five years quantity of wastewater discharged into Creek/Gulf /Estuary/ Sea has doubled. Refer Annexure XII for details. About 80per cent of the total treated effluent is discharged from South Gujarat, followed by Central Gujarat (18 percent), and Saurashtra (2 percent). Details of the same are shown in Table Table 4-10 Discharge of Treated Effluents from Various Regions of Gujarat Region Creek/Gulf /Estuary/ Sea River Land Evaporated /Self Consumed Total Saurashtra Central Gujarat South Gujarat Total Source: Gujarat Pollution Control Board,

53 Looking at the receptors, South Gujarat as well as Central Gujarat discharge treated effluents into Creek/Gulf /Estuary/ Sea. South Gujarat discharges almost 70 percent of the total treated effluent from CETPs into Creek/Gulf /Estuary/ Sea, while Central Gujarat discharges almost 65 percent of the total treated effluents from CETPs into Creek/Gulf /Estuary/ Sea. A total of 8.27 MLD of treated effluents are discharged in open land, 85 percent of which are being discharged from CETPs of Saurashtra region and rest in Central Gujarat. Figure 4-22 : Treated Effluent Discharged into Sea Figure 4-23 : Treated Effluent Discharged into River Source: Gujarat Pollution Control Board, 2012 Apart from CETPs, there are significant numbers of industrial units having their own treatment facilities, i.e. Effluent Treatment Plants (ETPs). Recent figures suggest that the total number of effluent treatment plants installed and commissioned up to March 2012 is There has been an increasing trend in ETPs during 2008 and A total of 1240 ETPs have been installed in Gujarat within a span of five years (see Figure 4.24). It will be useful to maintain state level database of treatment capacity and treatment quality for these ETPs to get an idea about total wastewater generated and treated by the state. 56

54 Figure 4-24 : Total Numbers of ETPs in Gujarat Source: GPCB Annual Reports ( to ) Quality of Treated Effluent (CETPs): Part A of the Schedule VI of the Environment Protection Rules, 1986 laid down general standards for discharge of Effluents. Standards are laid down separately according to the receiving bodies like Inland Surface Water, Public Sewers, Land for Irrigation and Marine Coastal Environment. (see Annexure XIII for the standards). CPCB conducted a survey in 2005 for performance evaluation of all the CETPs across India, which covered 15 CETPs of Gujarat. Out of 15 CETPs none were able to meet the prescribed limits for general parameters of ph, BOD, COD, TSS & TDS, While 2 CETPs were found in compliance with ph, BOD, COD and TSS but not complying TDS Standards. (CPCB, 2005) The quality of the effluent discharged from various CETPs varies over a period of time. Six parameters namely, ph, TSS, TDS, COD, BOD & NH 3 are analysed over the period of past 3 years. Out of 28 functional CETPs, data regarding outlet effluent quality (yearly average of parameters) are available for 21 CETPs only. Out of these 21 CETPs, one CETP at Changodar has no discharge as they self consume the effluent and one at Pandesara, Surat has been operational since 2011 and the data trend is not available. Hence performance of 19 CETPs has been presented below. These CETPs are grouped according to their discharge points. They are further categorized into Green, Orange and 57

55 Red for analysis purpose. Green Category means value of parameter of treated effluent is maintained well within the prescribed limit for all the three consecutive years, while performance category Orange means, respective CETP has failed to maintain value of outlet parameters for 1 or 2 years out of three and performance category Red means, CETP has failed to maintain outlet standard for all the three consecutive years. CETPs Discharging into River Figure 4-25 : ph Level Treated Effluent of CETPs Discharging into River Figure 4-26 : ph Level of Outlet Discharge into River All the six CETPs discharging into river are maintaining ph of treated effluent well within the prescribed limits for last three years. CETP ID: 1. The Green Environment Services Co-op.Society Ltd , Phase II, GIDC Vatva Ahmedabad 58

56 2. Odhav Enviro Project Ltd.,25, GIDC Odhav, Ahmedabad 3. Gujarat Vepari Maha Mandal Sahkari Udhyogik Vasahat Ltd., 181, GVMMS Industrial Estate, Odhav, Ahmedabad 4. Odhav Green Enviro Project Association, 394, GIDC Odhav, Ahmedabad 5. Naroda Enviro Projects Ltd., , Phase I,GIDC Naroda,Ahmedabad 6. Narol Dyestuff Enviro Society, 1083 Near Vishal Textile Mill, B/h Narol-Court, Narol, Ahmedabad CETPs Discharging into River Figure 4-27 : BOD Level of Treated Effluent of CETPs Discharging into River Figure 4-28 : BOD (mg/l) Level of Outlet Discharge into River All the six CETPs discharging into river fall into performance category Red as far as BOD Levels of the treated effluent is concerned CETPs Discharging into River 59

57 Figure 4-29 : COD Level of Treated Effluent of CETPs Discharging into River Figure 4-30 : COD (mg/l) Level of Outlet Discharge into River COD levels in the treated effluent of all the six CETPs discharging into river fall into performance category Red. 60

58 CETPs Discharging into River Figure 4-31 : TSS level of Treated Effluent of CETPs Discharging into River Figure 4-32 : TSS (mg/l) Level of Outlet Discharge into River CETP 2 (Odhav Enviro Project ) falls in the Green category and CETP 6 (Narol Dyestuff Enviro Society )falls into Orange category as far as TSS levels in the treated effluent are concerned. Rest falls within the red category, indicating that they have failed to 61

59 maintain TSS levels in treated effluent within the prescribed limit for all the three consecutive years CETPs Discharging into River Figure 4-33 : TDS level of Treated Effluent of CETPs Discharging into River Figure 4-34 : TDS (mg/l) Level of Outlet Discharge Into River All the Six CETPs discharging into river fail to maintain TDS levels in the treated effluent within the prescribed limit for all the three consecutive years. 62

60 CETPs Discharging into River Figure 4-35 : NH-3 level of Treated Effluent of CETPs Discharging into River Figure 4-36 : NH-3 (mg/l) Level of Outlet Discharge into River Three out of six CETPs (2,4 and 6) discharging into river have maintained NH 3 -N level in the treated effluent well within the prescribed limit. 63

61 As discussed earlier the discharge from CETPs and other non member units from Narol is mixed with sewage before final discharge into river Sabarmati. Results of the samples taken from 100 meter downstream of the final discharge point in the river Sabarmati (at Miroli) indicates that concentration of BOD and COD has been considerably brought down from their earlier levels at final CETP outlet after dilution with 1075 MLD of sewage. Figure: 4-37 BOD Concentration in River Sabarmati near final discharge point Source: GPCB Annual Reports ( to ) Mixing with sewage ensured concentration level of BOD well within the limit (100 mg/l) except for the year 2009 as evident in figure Mixing with the sewage has helped achieve percent reduction of BOD levels to almost 90 per cent on an average. Figure: 4-38 COD Concentration in River Sabarmati near final discharge point A reduction of 91 per cent had been achieved over the years because of dilution with sewage, which ensured the COD concentration at final discharge point into river Sabarmati well within the prescribed limit of 250 mg/l. Source: GPCB Annual Reports ( to ) 64

62 CETPs Discharging on Land Figure 4-39 : ph level of Treated Effluent of CETPs Discharging on Land Figure 4-40 : ph Level of Outlet Discharge on Land All the three CETPs discharging on land are maintaining ph of treated effluent well within the limit. CETP ID: 7. Bavla Eco Project. Sr No: 1440/P,Opp : Ganpati Boil Centre Ta. Bavla,Ahmedabad. 8. Vinayak Jal Sudhikaran Co.op. Soc. Ltd. C/o. Tirupati Agro Ind. At Bavla, Ahmedabad. 9. Kalol GIDC Industries Association, 65/66, GIDC Estate Kalol, Gandhinagar 65

63 CETPs Discharging on Land Figure 4-41 : BOD level of Treated Effluent of CETPs Discharging on Land Figure 4-42 : BOD (mg/l) Level of Outlet Discharge on Land Out of three CETPs discharging on land, two are falling into performance category Green, and one in Kalol is falling in performance category Red, as far as BOD levels of treated effluent is concerned. 66

64 CETPs Discharging on Land Figure 4-43 : COD level of Treated Effluent of CETPs Discharging on Land Figure 4-44 : COD (mg/l) Level of Outlet Discharge on Land* * Discharge Standard not specified Though COD standards for discharge on Land for Irrigation/Plantation is not specified in the rules, but taking the COD discharge standard for river to compare the variation, COD levels in One CETP at Kalol falls into Red category. 67

65 CETPs Discharging on Land Figure 4-45 : TSS level of Treated Effluent of CETPs Discharging on Land Figure 4-46 : TSS (mg/l) Level of Outlet Discharge on Land All the three CETPs discharging their treated effluent on land are maintaining TSS limit well below the prescribed limit. 68

66 CETPs Discharging on Land Figure 4-47 : TDS level of Treated Effluent Of CETPs Discharging on Land Figure 4-48 : TDS (mg/l) Level of Outlet Discharge on Land None of the CETPs discharging on land are meeting the standards as prescribed as far as level of TDS in treated effluent is concerned and CETP No. 9 (Kalol) registers exceptionally high values for all the three years. 69

67 CETPs Discharging on Land Figure 4-49 : NH3 level of Treated Effluent of CETPs Discharging on Land Figure 4-50 : NH3 (mg/l) Level of Outlet Discharge on Land * Discharge Standard not specified As far as level of Ammoniacal Nitrogen in treated effluent is concerned, discharge standard of NH 3 -N for land are not prescribed but the figures show that it is well within the level prescribed for discharge into surface water. 70

68 CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-51 : ph level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-52 : ph Level of Outlet Discharge into Creek/Gulf/Estuary/ Sea All the ten CETPs discharging into Creek/Gulf /Estuary/ Sea are maintaining ph of treated effluent well within the limit. CETP ID: 10. Globe Enviro Care Ltd. [chemical units], PP 1, Off road no. 2, B/h Kay Tex Mills, GIDC Estate, Sachin, Surat 11. Sachin Enviro Infra Ltd., [process houses] P/2, GIDC Sachin, Surat 12. Palsana Enviro Protection Ltd., Kadodara, Surat 13. Enviro Infrastructure Co. Ltd. ECP Canal road, Umraya, Ta. Padra, Vadodara 14. Nandesari Environment Control Ltd., 519/P, GIDC Nandesari, Vadodara 15. Panoli Enviro Technology Ltd. 619, GIDC Estate, Panoli, Bharuch 16. Bharuch Eco-Aqua Infrastructure Ltd., (BEAIL), Ankleshwar 17. Enviro Technology Ltd., 2413/2414, GIDC Estate, Ankleshwar, Bharuch 18. Vapi Waste & Effluent Management Co. Ltd., 4807, Phase IV, GIDC Vapi, Valsad 19. Gujarat Eco textile park Pvt ltd, S.No 479,480, village Baleshwar, Ta. Palsana, Surat 71

69 CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-53 : BOD level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-54 : BOD (mg/l) Level of Outlet Discharge into Creek/Gulf/Estuary/ Sea Out of ten CETPs discharging into Creek/Gulf /Estuary/ Sea, two (No. 10 and 11) are falling into performance category Orange, four are falling into performance category Red (15,16,17 &18) and rest four ( 12,13,14,19) CETPs are in Green category, as far as BOD levels in the treated effluent is concerned. 72

70 CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-55 : COD level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-56 : COD (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea 73

71 As far as the level of COD in treated effluent is concerned, all the CETPs discharging into Sea fail to maintain the level except CETP No. 14 (Nandesari Environment Control). Other CETPs are in Orange or Red categories as can be seen from the Figure

72 CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-57 : TSS level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-58 : TSS (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea 75

73 As far as the level of TSS in treated effluent is concerned, out of ten CETPs discharging into Creek/Gulf /Estuary/ Sea, one CETP No. 14 (Nandesari Environment Control) had maintained TSS level well within the prescribed limit for all the three consecutive years. Other CETPs are in red or orange category as can be seen from the Figure CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-59 : TDS level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea Figure 4-60 : TDS (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea* * Discharge Standard not specified; Standard for surface water discharge is taken. 76

74 Except for CETP No. 12 (Palsana Enviro Protection) and 19(Gujarat Eco-Textile) all units have TDS values far above the prescribed discharge standards. CETPs Discharging into Creek/Gulf /Estuary/ Sea Figure 4-61 : NH3 level of Treated Effluent of CETPs Discharging into Creek/Gulf/Estuary/ Sea 77

75 Figure 4-62 : NH3 (mg/l) Level of Outlet Discharge Creek/Gulf/Estuary/ Sea As far as level of Ammoniacal Nitrogen in treated effluent is concerned, four out of ten CETPs discharging into Sea fail to achieve proper discharge standard while CETP with No. 10 (Globe Enviro Care) falls into orange category and two CETPs 14 (Nandesari Environment Control) and 13 (Enviro Infrastructure) maintain NH3-N level well within the prescribed limit. For rest of the CETPS, it is either not applicable due to absence of Ammoniacal source or data is not available. For Gujarat which is one of the most industrialized states with leading position in waste generation and treatment infrastructure it is imperative to look at quality of water with respect to other states. At a National level, Gujarat shows lower percentage of violations with respect to parameters for water quality of Aquatic Resources i.e. rivers, lakes, ponds, tanks and ground water. The monitoring results obtained during 2010 for all States and Union Territories were published by the Central Pollution Control Board in its report Status of water quality in India The analysis given in the above report in terms of violation (state with highest violation has ranked one and so on) suggests that: For the parameter Dissolved Oxygen (DO) in surface water, the position of Gujarat is at number 13 with 6 per cent violation and for rivers Gujarat ranks 14 th with per cent violation of

76 With respect to the parameter ph, Gujarat is at the top along with other eleven states with 0% violation in surface water and 1.2 % violation in rivers, indicating that the critical parameter of ph is maintained throughout though there are large numbers of complex chemical manufacturing clusters. For the parameter BOD Gujarat stands at 16 th position in surface water and 18 th position in Rivers with per cent violation of 25 and 19 respectively. In the case of fecal coliforms and total coliforms state scores 9 th with per cent violation of 11 and 19 respectively for surface water. Same is the case with rivers. As far as water quality of the lakes is concerned, for the parameter Dissolved Oxygen and ph Gujarat stands at number 10 with per cent violation of only 4, and 7 respectively. For parameter of BOD also, Gujarat ranks 10 th with per cent violation of 24 per cent. For Fecal coliform and Total coliform, Gujarat scores 6 th and 5 th place with 4 percent and 5 percent violation respectively Waste Management at Alang When the ship comes to Alang for demolition purpose, no hazardous materials in loose form are allowed on-board, recyclable and hazardous wastes are expected to be generated while dismantling. For the temporary storage of solid wastes (Hazardous./Non-Hazardous.), separate storage rooms are provided at ship recycling yard /plot. The recyclable wastes are sold out by the ship breaking units to the registered recyclers while non-recyclable and hazardous wastes are disposed into TSDF of G.M.B. at Alang which is currently operated by GEPIL. Similarly, the bilge water waste is disposed at the GEPIL TSDF at Alang which in turn is transported to GEPL facility at Surat for final treatment of the same. Upgradation of existing Infrastructure is ongoing for (1) Expansion and up gradation of existing TSDF facility (2) New Incineration plant with capacity of 5 MT/Day (3) New Bilge Water Treatment Plant with capacity of 10 KLPD. 79

77 Figure 4-63 Hazardous waste generated at Alang Infrastructure: Waste Management Sent to Surat MT BILGE WATER OILY RAGS PAINT SLUDGE PAINT CHIPS RUBBER THERMOCOL Upto Dec- 11 Waste Disposal MT SLF Disposal Solidification/ Stabilisation Sent to Surat Source: Gujarat Maritime Board (December 2011), Obtained from GPCB, 2012 Due to hazardous health effects of Asbestos its management is outsourced to Industrial Hygiene Services (IHS), Baroda which is carrying Asbestos handling as per National and International Guidelines. Since June-2010, IHS is anchoring and managing asbestos containing material removal, handling, scrapping and packing jobs for ships which are dismantled at Alang Ship Breaking Yard. The oil removal process and its recovery and recycling is done by registered recyclers with GPCB Critically Polluted Industrial Clusters/Areas- The Case Studies Ministry of Environment and Forest in 2010 has adopted a Comprehensive Environmental Pollution Index (CEPI) system evolved by the CPCB, for carrying out and environmental assessment of 88 Industrial Clusters. The clusters are characterized by the environmental quality at a given location following the algorithm of source, pathway and receptor and aggregated CEPI. The CEPI indicates severe adverse effects on environment and is also an indication of large percent of population experiencing health hazards. On the CEPI scale, 43 such industrial clusters, having CEPI greater than 70 on a scale of zero to 100, have been identified as critically polluted based on the parameters related to incidence of pollution in 80

78 water, land, ground water, and air. Among these 43 industrial clusters there are 6 industrial clusters which belong to Gujarat, in which Ankleshwer in Bharuch district is most polluted industrial cluster among 88 industrial clusters which has been assessed by CPCB (see Table 4.11). Table 4-11 The CEPI Scores for Critically Polluted Industrial Areas / Clusters in Gujarat AIR WATER LAND CEPI Ankleshwar Vapi Ahmedabad Vatva Bhavnagar Junagarh Source: Annual report, MoEF and CPCB, 2010 Two case studies namely Ankleswar and Vapi Industrial Estate has been presented in the BOX- 1 & 2 respectively in order to understand the state of industrial environment in terms of pressure, status, impacts and response of all the stakeholders in improving the environmental quality of these clusters in recent times. 81

79 Box 1 A case study of Ankleshwar Industrial Estate (AIE) Ankleshwar Industrial Estate (AIE) is the largest chemical estate in Asia, covering an area of 16 square kilometers and housing nearly 700 units of industries manufacturing chemicals, pesticides, pharmaceuticals, bulk drugs, petroleum products, textiles, plastics, etc. It is situated on the Bombay-Delhi rail-road links taking full advantage of industrial infrastructure in terms of accessibility to market and raw materials. Status Out of 671 industrial units in AIE more than 98 percent are SSIs, and remaining are medium and large units(see Table 1). The plants in Ankleshwar process large quantities of basic chemicals, solvents, acids, and fuels to manufacture more than 25percent of Gujarat s (5percent of India s) output of pharmaceuticals, chemicals, pesticides, dyes, and intermediaries. Assuming the share of pollution is commensurate, AIE may be producing 5percent of India s total chemical pollution in just 16 square kilometers (Vinish Kathuria and Thomas Sterner, 2005). Table 1:Distribution of Industries in Ankleshwar Industrial Estate (AIE) Large Medium Small Total Source: Comprehensive Environmental Pollution Abatement Action Plan, GPCB, 2010 Pressure: According to latest report of CPCB(MoEF ), Ankleshwar has categorized as most polluted industrial cluster in Gujarat as well as in India (See Table 2). Among total industries 42 percent units are in highly polluting category and 68percent units fall under Red Category. Table 2: Highly Polluting Industries in Ankleshwar Industrial Estate (AIE) (17 Most Polluting Industrial Categories) Sector Large Medium Small Total Total Source: Comprehensive Environmental Pollution Abatement Action Plan, GPCB, 2010 AIE has estimated that its members generate 45 MLD of liquid waste and 42,500 tonnes per annum of solid waste respectively (Jani, 2001). According to Comprehensive Environmental Pollution Abatement Action Plan, GPCB, 2010 initial treatment capacity of CETP in AIE was 1 MLD of raw effluent, and the current capacity of this CETP is 1.8MLD (in 2010). Table 3: Red Category Industries Ankleshwar Industrial Estate (AIE) (54 Red Categories) Category Large Medium Small Total Red Source: Comprehensive Environmental Pollution Abatement Action Plan, GPCB, 2010 Even if we take effluent generation estimation of 2001(Jani, 2001) and capacity of CEPT in 2010 (GPCB, 2010), it is much lesser then needed. This shows urgent action on expansion and up - gradation of existing CETP. The immediate response of all the stakeholders is to augment the effluent treatment capacity in AIE. 82

80 Impact: The impact of industrial pollution in AIE has been reported in a study of Centre for Science and Environment, New Delhi and published in the Down to Earth edition of May 31, According to this report: Groundwater in AIE is highly contaminated. The contamination is a result of more than 3,000 industrial units in the estate. Around 270 million liters of liquid waste and 50,000 tonnes of solid waste are generated annually. This often becomes a problem for people living in villages around the industrial estate because they depend on groundwater to meet their daily needs. Even crops growing on contaminated soil absorb the pollutants. The highest concentration of molybdenum was found 2,760 (ppb), whereas the WHO standard is 70 ppb. High concentration of chromium was linked to the pigment and pharmaceutical industry; lead was linked to fertilizer and paint industry and the highway (NH-8). Amla Khadi was among the major sources of the heavy metals. Other sources included effluent-laden channels, oil field areas and highways. Response: There have been a lot of initiatives undertaken by state government and industrial association for creating better environmental infrastructure and educational facilities including the awareness programme in AIE in recent times. Following are some of the examples of such response so far in AIE: Enviro Technology Limited a CETP was established in 1986 having 1.8 MLD capacities and EC is obtained to increase the capacity to 3.5 MLD. According to Business Standards, Ahemdabad 8 August addition: the Carbon Oxygen Demand (COD) has been brought down significantly from 500 COD to the permissible limit of 250 COD. Common incinerator of 2.5 MT/Hr capacity was erected in 2004 near TSDF site. Closed pipeline conveyance from FETP to deep sea was completed in The capacity of FETP is of 60 MLD. Disaster Prevention Management Centre (DPMC) which does many activities including running of prescribed courses of Industrial Safety and Environment Protection was established. Ankleshwar Research & Analytical Infrastructure Limited was established in AEPS ecology centre was established in Library at United Phosphours Limited provides valuable research facilities and educational materials for industrial research and actions. Conclusion: State of environmental affairs is at cross road in the Ankeleshwar Industrial Estate in Gujarat. The environmental pollution into air, water and land has reached beyond critical limits and has impacted the natural resource base and human health negatively, as reported above. The small scale units are huge in number with potentially polluting industries. They are unable to take care of industrial pollution coming out of their respective units due to lack of financial and technical knowledge individually. However, there have been a few initiatives towards improving the environmental condition at AIE through active participation of industrial association of AIE, government agencies and other inter-governmental bodies. The AIE association can take a lead in mobilizing the resources and support system with the help of the other stakeholders. The Eco-city initiative of Kawasaki Industrial Estate in Japan is an example of environmental improvement in 1970s. One can adopt the similar process and proceed towards achieving the goals of eco-city and industrial symbiosis in this coastal city of Gujatrat. 83

81 BOX -2 A case study of Vapi Industrial Estate (VIE) Vapi Industries Estate came into existence in There are around 759 industrial units covering an area of 1140 hectares. About 70 per cent of the industries are manufacturing chemicals such as dyes and dyes intermediates, pigments, pesticides, fine chemicals, and pharmaceuticals. The remaining 30 per cent are paper mills, packaging, engineering, plastic, textiles, food processing, printing ink and many other products s manufacturing units. Industrial Break-up: Type Red Orange Green Large Medium Small-scale Total Grand Total 759 Source: Comprehensive Environmental Pollution Abatement Action Plan, GPCB, 2010 About 75% industries are falling under Red Category (high pollution potential) and 15% industries under Orange Category (moderately polluted). Most of these industries are chemical and dyes and dyes intermediates small scale units. Impact In 2007 Blacksmith Institute s report declared Vapi as one of the most polluted industrial places in the world. According to this report more than 50 industrial estates discharge heavy metals, pesticides, and chemical waste. Mercury in the groundwater is 96 times higher than WHO standards. Very high incidences of cancer and birth complications have been reported in the area. According to a report published in Down to Earth (2012), wherein CPCB in its interim assessment report 2012 has prepared CEPI for 82 industrial clusters in the country. CEPI of Vapi industrial estate has increased from in 2009 to in The CEPI levels of ambient air and water quality in Vapi industrial cluster have also increased. The CEPI level of ambient air has increased from 74 in 2009 to in 2012 while that of water has increased from in 2009 to in However, the CEPI score for land has improved from in 2009 to in This is mainly because of the clearance of illegal dumps of solid hazardous waste by Vapi Waste Effluent Management Corporation Limited. Response A technical committee has been formed by GPCB that constitutes Board members and outside experts to discuss and decide upon the cases of the change of product mix and some typical applications from critically polluted areas. For vigorous and surprise monitoring, a specific vigilance teams has been formed under the leadership of senior officer of GPCB. 84

82 Industrial units are directed to set up multi effect evaporator for their concentrated waste water. Third Party monitoring of the entire industrial estate and CETP. Board of Vapi Waste and Effluent Management Co Limited (VWEMCL) is taken over by the State Government (GIDC). Professional chief executive officer is appointed for VWEMCL. VWEMCL has constituted a technical, disciplinary and audit committees for day to day functioning. Trial run for technological innovations at CETP to meet with discharge norms are going on. Treatment units at CETP are upgraded. Largest community waste exchange facility for segregation and collection of spent acid supply as raw material to different industries has been set up where Saleable Gypsum production on neutralization 300 tonnes/day is produced. FACCO technology is adopted for treating majority of refractive COD molecules. FACCO plant of 300 KL/day capacity is commissioned at CETP in January VWEMCL approached Environmental Genomics Division of NEERI, Nagpur for availability of bacterial cultures capable of improving the assimilatory capacity. And NEERI pilot plant is aimed to degrade the nonbiodegradable COD and ammonical nitrogen through using NEERI - EGU consortia. Conclusion: It is evident from above discussion that though Vapi has figured in one of the most polluting industrial estate in India, along with Ankeleshwar, its recent effort has resulted in reducing land pollution. With the support of GCPC and other stakeholders working as network, it is likely that other environmental parameters would improve in due course of time. The various responses towards the environmental protection listed above are note worthy and will ensure better industrial environment in and around the estate. 85

83 5. Gujarat State s Response to Industrial Environment The state of industrial environment in Gujarat has critically been perceived by the scientific community, regulatory body and civil society members including community at local, national and international level in recent times. This is because of rapid industrialization policy adopted by the state in order to sustain high economic growth of double digit and attracting foreign direct investment. Rapid industrialization has also provided employment to large section of the society thereby helped the state in reducing poverty to some extent in recent time. However, it has also resulted in environmental pollution in certain critical locations which needs immediate attentions of policy maker and planner to take corrective measures. The previous section on industrial waste management has elaborately dealt with the various environmental implications of hazards waste and industrial effluent due to industrial activities. The recent trends of industrial investment leading to overall growth of the sector, has also helped in taking certain industrial environmental protections measures, however, there is a tremendous need and requirement of industrial environment facilities and proper management control from all the concerned stakeholders in the state. Few such initiatives towards industrial environmental improvement adopted and initiated by the industries groups with the help of Government of Gujarat and other bilateral agencies, have been taken up in the state Industrial Environmental Management Initiatives in Gujarat The Government of Gujarat has started promoting sustanaible environment condition by reforming industrial policies. During 1980s and 1990s in order to accelerate the industrial growth, industries availed with sales tax benefits under various fiscal incentives. Pioneer units in the backward area were given capital investment subsidy particularly to small and tiny industries, which has promoted the 86

84 growth of SSI units in state. Some of the crucial things were added in subsequent industrial policy, where technology up gradation and environment prevention were promoted. Promotion of specific industries though private players for establishment of industrial parks were given priority. Industrial Policy, 2009 has put more emphasis on improving environmental infrastructure, promoting holistic development, responding to changing domestic and global environment, which added complete new dimension in sustainable industrial development in the state in recent time State level environmental initiatives: Policy, Planning and Management initiatives by GIDC Besides policy reforms the state government has undertaken planning and management initiatives in industrial estates in the following ways. General development control regulation has been developed specially for SIR regions, along with the detailed master plan. Regional development authority has been established in each SIR to look after the physical planning and environmental issues through master plan and zoning regulation. Common facilities to be provided in each industrial estate with separate parking facility in up to 10 percent of the total area of GIDC estates. Environment Impact Assessment is made compulsory for upcoming industrial estate. Tree plantation has been made compulsory for upcoming GIDC industrial estates Recycle of waste for large industries is now mandatory Initiatives like road expansion, utility corridors improvement, provision of drainage system have been taken for infrastructure improvement in old GIDC estates. Initiatives for environment management improvement by increasing green belt, providing solar systems in old GIDC has been undertaken. 87

85 5.2.2 Institutional Building Gujarat Cleaner Production Board (GCPB) GCPB was established by Gujarat Industrial Development Corporation (GIDC) in association with National Cleaner Production Center (NCPC) in Also, Government took lead in setting up local Cleaner Production centre by CETP companies, which would be networking with GCPC. Such centers are already established at Naroda, Vapi and Vatva, and others are being considered to cater to the need of their member units with respect to dissemination of information. Industrial Policy, 2009 announces financial assistance scheme for implementing cleaner production measures. CP award has been instituted to encourage, appreciate and motivate industries. GCPC is also functioning as Environment Information System on the subject area of CP and industrial technology under World Bank assisted Environment Management Capacity Building Technical Assistance project. Other environment benefits were also achieved though CP implementation like water and energy, reduction in gaseous emission, elimination in generation of spent acid, elimination of hazardous waste generation, substitution of hazardous material into non hazardous material, improvement in the working environment.(jain B., 2009) Department of Climate Change Government of Gujarat Gujarat has established a separate Department for Climate Change in year 2009 which is directly governed by the Chief Ministers Office. It is the 4th State Province in the World to have a Department for Climate Change. This is a pioneering initiative by Government of Gujarat that reflects that the issues of climate change are at the forefront of governmental agenda. The department initiated preparation of a comprehensive State Action Plan for Climate Change, under the National Action Plan on Climate Change (NAPCC). Main objective of this initiatives is to give a human face to environmental issues; empower people to become active agents of sustainable development; promote an understanding that communities are pivotal to changing 88

86 attitudes towards environmental issues; and advocate partnership, which will ensure all citizens and people in Gujarat to enjoy a safer and more prosperous future. Gujarat Energy Research & Management Institute (GERMI) Gujarat Energy Research & Management Institute was established in The objective is to carry research in the field of renewable energy and environment and it also has an excellence in industrial learning. The institute has set up to develop human resource assets to cater the petroleum sector, allied energy sectors as well as other industry sector. It also aims to improve the knowledge base of policy makers and technologists by offering intense research in various environment and energy sector. Centre for Industrial Area Planning & Management In view of the rapid industrialization in the state, CEPT University in the year 2008, with the support from Gujarat Industrial Development Corporation (GIDC), established a Centre for Industrial Area Planning & Management (CIAPM). The center facilitates in imparting academic knowledge and skill development in the area of industrial development, planning and management. The Centre is envisioned to act as an important player/ stakeholder in the development of industrial areas of Gujarat to ensure proper planning with requisite infrastructure along with appropriate industrial environmental management. It shall also function as a think tank to carry out research and documentation, impart education and training and act as a consultative group so as to become state Resource Centre in Industrial Development for Gujarat Performance Monitoring by Regulatory Body Industrial environmental regulation and monitoring is carried out primarily by GPCP along with the support of CPCB and other research organization established by MoEF. However, due to huge industrial pressure monitoring to each and every individual unit in the state becomes difficult as the numbers of industrial units registered to GPCB are very large. A study conducted by CSE, 2009 reports that an average number of inspections to industrial units carried by the technical staff in 89

87 Gujarat is during 2001 and The report further elaborates that the average inspection per year per industry in Gujarat works out to be only two while average inspection per technical staff per year is reported to 380. This performance itself indicates a heavy work load on the technical staff of the GPCP as compared to other state pollution boards such as KSPCB, MPCB, OSPCB and CECB, as reported in the above mentioned study. Regarding the inspection schedule provided by the CPCB, the report further reveals that state boards have either an unrealistic or too lenient inspection schedule, for example the Red category industries are inspected once in a month in Gujarat and Tamil Nadu while it is once in two years in West Bengal and Andhra Pradesh. Action against illegal dumping of hazardous waste As reported in State of Annual Report, 2005, GPCB identified 22 illegal hazardous waste dumping sites and had shifted 34, MT of hazardous waste lying on those sites to various TSDFs. The only dumpsite which remains to be remediated i.e. Hema Chemicals in Vadodara city wherein chromium residue is accumulated/dumped adjacent to the plant premises. However, at present due to rapid urbanization numbers of resident colonies and commercial complexes are coming up in and around those areas. GPCB has issued closure directives under section -5 of EPA-1986 for the closure of the unit and sealed the premises. There have been 96 notices and 157 closure directions issued between 2008 and 2012 to defaulter industrial units under Environment Protection Act, 1986 by GPCB. As per report published in Times of India, Ahmedabad edition dated 17 th May, as many as 1680 industrial units have been served closure notices while 2118 industrial units have been given show cause notices for violation of Air, Water & Environment Protection Acts in the state till date. Among these both closure and show because notices issued, maximum number of show cause and closure notices were served to the industries located in Ahmedabad Industry level initiatives: Industrial groups and major players have been able to initiate many industrial environmental protection measures towards ensuring the cleaner production and 90

88 sustainable industrial development in the state. The Table 5-2 summarises all such initiatives undertaken by industrial units, with support from state government and other bi-lateral agencies in the state. However these are not exhaustive list, there are many examples of such industrial responses to pollution control measure undertaken by various stakeholders, which might not yet documented or are not available with the authors at the time of writing this report. Table 5-1 Industry level initiatives Initiatives Areas Waste minimization waste management Project Details Tracking Hazadous waste through XGN Waste minimization at through co processing Waste minimization Ambuja Nagar: Salient Features Module has developed IN extented Green node(xgn) regarding sysmtum though on line data. List of registered industry and daily quantity by all TSDF being generated though XGN CPCB has developed guidelines 2010 for co processing of hazards waste in cement kilns. During approximately MT of waste has been co processed in the cement industries. A liquid AFR handing, storage and feeding system has planted in Ambuja nagar, at Kodinar. Helps various type of liquid waste in cement kiln and substitute the consumption of fossil fuel. Initiatives Vatva at Establishment of CETP with capacity of MLD, with biological process supplemented by electro- oxidation. Establishment of common secure landfill facility, capacity of MT which is certified for ISO 9001:2008, 14001:2004 Waste water conveyance- ECP-first facility in India Establishment of Effluent Channel with of conveying capacity of 90,000 M3/day of treated water over distance of 55 Km in Gulf of Cambay. Vapitowards strides better The anaerobic treatment system has been commissioned, 91

89 environment implement the pipeline project on treated effluent discharge divert domestic effluent from Bil Khadi to CETP for further treatment Achieving excellence in textile effluent treatment A power co-generation plant generating 35 MW power and stream for processing using Naphtha as fuel is set up. Objective of this setup is to minimizing water consumption by recycling almost entire effluent. Utilization of Ammonium Carbonate (Scrubber effluent) from CPC Blue Industry in MgCO 3 Manufacturing Industry Initially, 17 CPC Blue manufacturing unit located at Vapi, Ankleshwar and Vatva cluster are consider for case-study. Scrubbed Effluent generated i.e Ammonium Carbonate solution in this 17 units MTA & it is required to be treated separately by them conventionally. Magnesium Carbonate manufacturing unit are using Spent Ammonia as raw material and there are 30 nos of Magnesium Carbonate Manufacturing Units situated in Chitra cluster of Bhavnagar. The Ammonium Chloride generated by MgCO3 manufacturing industry at Chitra Cluster is utilized by Soda Ash Industries for the recovery of Ammonia. Approximately to nm3 /day Bio-gas(containing % Methane) is produced daily. Waste-to- Energy power Generation project, Kanoria Chemicals Industries Ltd, Ankleshwar Waste Heat Recovery System ( W.H.R.U.) has also been installed and about1700 Kg/hr (at 10Kg/Cm2 pressure ) steam generation takes place daily. The Power plant is working since on average 68.5 to 72.3 PLF having average monthly generation of units. Technology process & Hazardous Waste Management at Alang Sosia Ship Breaking Yard Integrated APCM for Cupla GMB created a Treatment, Storage and Disposal Facility (TSDF) particularly for ship breaking sites, which is authorized by the Gujarat Pollution Control Board under the Hazardous Waste( Management & Handling) Rules. Air Pollution Control System has been installed in 150 foundries of Ahmedabad. 92

90 innovation and technology up gradation Monitoring management planning base Foundries 3Xtended Green Node supporting E governance 81-90per cent reduction in particular matter concentration per cent reduction in the temperature of flue gas 12-15per cent energy saving Timely acceptance & disposal of industries & hospitals application Monitoring and online live tracking of transportation of hazards waste. AhmedabadTex tile processors association working towards a better tomorrow Ahmedabad textile processors association (ATPA) has drawn out plans to check air and water pollution. installation of bag filters in textile units and air pollution control measures and Effluent Treatment Plants(ESPs) Environment management (Environmental Conservations & green initiatives) Bio remediation of oily sludge by ONGC Mehsana: Remediation of 1500 tonnes of oil contaminated soil. After competition of the project hydrocarbon content in soil and other heavy metal content was in permissible limit. Reforestation and plantation practices at Kovaya limestone mine: Out of total mining area of 953 hectares, 104 hectares is covered under plantation and other 20 hectares has been rehabilited through water storage. About 12 Lac CUM of rain water has been collected and utilized for dust suppression on haul roads & for plantation inside the mines. 93

91 Sustainable environment management The BEAIL story: Greening efforts at reliance industries, Jamnagar: Paryavaran Mandir, Naroda Gas distribution project The pipeline assisted environmentally safe disposal of treated water deep into sea keeping Narmada Astuarine zone and nearby area free of pollution. About 2200 acres of total area has been covered by tree plantation. On average 2595 trees per hectare has planted against the statutory requirement of 1500 to 2000 trees per hectare. A waste Museum a first kind in the country has also been established, which encourage industrial symbiosis to reduce dumping of waste. Reduction of 23,165,722 tco2 emission by reducing fossil fuels through use of 57 MMSCMD gas in industrial sector(as on 2009) Training and Awareness Awareness Programme on Environment & Hazard Management in Pharmaceutical s & Bulk Drug Industry To bring in awareness and sensitize the pharmaceuticals sector on various aspects of environment, hazard management and technical know-how to the pharmaceuticals & bulk drug industry in identifying problems and gaps leading to a way forward in terms of implementation of solutions to reduce the associated environmental risks GPCB Bulletin Awareness Programmes on Energy Efficiency. GPCB -Bulletin (Gujarat Pollution Control Board) Quarterly bulletin in Gujarati and English on pollution prevention and control To update industries with new technologies and services relevant to Energy Efficiency. Knowledge about new funding mechanisms, financing structures and how to develop bankable energy efficiency projects is also given. 94 Training Integration Environment on of FICCI and disaster management institute of Bhopal. Occurrence of chemical accidents and probability of their manifesting in a chemical

92 Planning with Chemical Disaster Risk Reduction & Preparedness disaster remains a cause of concern. Unlike emergencies caused due to natural disasters, which are difficult to prevent, chemical accidents can be prevented and their impacts minimized by better planning, preparedness and response. Safety and Training Institute being run in Alang by GMB Safety Training and Labour Welfare Institute has set by GMB at Alang in 2003, which has so far trained more than 15,000 labour involved in all profiles of jobs in ship recycling. The training, undertaken by experts, covers firefighting, handling hazardous wastes and asbestos wastes, use and wearing of personal protective equipment (PPE) and others. Source: Adopted form GOG, (2011) and Modi, (2007) 5.4. Initiatives Taken for Cleaner Production Energy Conservation Awareness Programmes Energy Conservation Awareness Program have been conducted by GCPC at industrial estates namely in Ahmedabad, Ankleshwar, Vapi, Rajkot and Surat. GCPC was supported by Indian Renewable Energy Development Agency (IREDA) and Energy Development Authority (GEDA) for this programme. A three day training program was conducted at above industrial region, where industries were introduced to the details of policies and tools for energy conservation and energy audit. An understanding of scope of utilizing renewable energy was also identified during the training programme. Cluster Project GCPC has helped Dyes and Dye-intermediate cluster of Naroda GIDC in applying certain cleaner production options under the Scheme for Assistance to Cluster Development. The results of this program are as follow. Technology up-gradation options for filteration, drying, sulphonation, and reduction in COD. Fluid coupling to improve energy efficiency in industrial motors. Rainwater harvesting has been installed in several industrial units. 95

93 Common facility for cluster has been provided, which include spent sulfuric acid concentration and reuse, gypsum recovery, common drying, R&D and laboratory facility and electric workshop for cluster. CP Demonstration Project GCPC has carried out cleaner production demonstration projects for Pulp and Paper industry, Electroplating, Hospital and Hotel. Under this program various CP options are being suggested to industries. The implementation of CP solution resulted in both financial and environmental benefits. Details of these benefits are given in Table 5.2. Table 5-2 Benefits to industrial units after CP demonstration Type Of Industry Proposed Financial Benefits Pulp & Paper Investment(One time): Rs. Sector 5.38 crores Electroplating Sector Hospital Sector 96 Saving: Rs.1.22 crores year Investment (One time) : Rs lakh Saving: Rs lakh /year Investment(One time) : Rs.1.1 crores Saving: Rs.56 lakh /year Environmental Benefits Reduction in wastage of final product, which will be benefited in conservation of water, raw material, energy, time etc. Reduction in BOD, TSS & toxicity of wastewater, which reduces treatment costs. Reduction in quantity of effluent and so the cost of treatment. Plastic waste can be sold for recycling. Reduction in pollution load, which reduces treatment costs. Reduction in ETP load, which reduces treatment costs. Recycle/Reuse of treated water in the process areas. Improvement in working environment. Reduces energy, water, & waste disposal costs. Reduction in air emissions which results in air quality improvement. Reduction in pollution and ETP load which reduces treatment costs. Improved health and safety. Hotel Sector Investment: Rs. 94 lakh Quality of water improves. Elimination of CO2, avoids

94 Saving: Rs.55 lakh /year stringent law implications. Reduces disposal problems of food waste. Co-Processing of Waste Gujarat Pollution Control Board (GPCB) has granted Authorization / Permission to M/s Ambuja Cement, M/s Ultratech Cement, M/s Sanghi Cement Ltd. and M/s. Lafarge India (P) limited Chhattisgarh for co-processing of different type of Hazardous Wastes in line with regular permission accorded by CPCB. Approximately up to March 2012, MT of Hazardous and Non Hazardous waste have been co-processed in the cement Industries. Sr No Waste Co-processed in Various Name of Cement Plant Cement Plants in Metric Tons Ambuja Cement Limited Kodinar Junagadh Ultratech Cement Limited - Kovaya Ultratech Cement limited Narmada - Jafrabad Gujarat Sidhee Cement Limited Total Besides, GPCB has also accorded Interstate NOC for Co-processing of Hazardous Waste at Lafarge Cement Limited Chhatishgarh from M/s. Gujarat Narmada valley Fertilizers Corporation Limited, Bharuch and M/s. Gujarat Enviro Projects Infrastructures Limited, Surat for which regular permission is accorded by CPCB and about MT of waste is Co-Processed in the Cement Plant. 97

95 Utilization of Ammonium Carbonate (Scrubber effluent) from CPC Blue Industry in MgCO 3 Manufacturing Industry 17 CPC Blue manufacturing unit located at Vapi, Ankleshwar and Vatva cluster were taken up for pilot. Scrubbed Effluent ( Ammonium Carbonate solution) generated in this 17 units MTA & it is required to be treated separately by them conventionally. Magnesium Carbonate manufacturing unit use Spent Ammonia as raw material and there are 30 Magnesium Carbonate Manufacturing units situated in Chitra cluster of Bhavnagar. The Ammonium Chloride generated by MgCO3 manufacturing industry at Chitra Cluster is utilized by Soda Ash Industries for the recovery of Ammonia. Effluent Treatment Plant CPC Blue Industry (Ammonium Carbonate) Scrubbed solution Ammonium Chloride Effluent Treatment Plant MgCO 3 Manufacturing Industry (Raw material) replacement of Sea - Beasten Ammonium Chloride Soda Ash Industry Recovery of Liquor Ammonia Triple stage Effluent Recycling System Recycling System of CPC Blue, MgCO 3 and Soda-Ash Industry Source: GPCB,

96 Spent Acid Bank and Gypsum washery Project at a Glance M/s. Novel Spent Acid Management Vatva, Ahmedabad Innovative concept of waste exchange. Comprehensive treatment of residual Effluent and generation of Gypsum Treatment of spent acid 1500 m 3 per day for the cluster of Ahmedabad Region. Treated Spent Acid is sold to end users; more than 20per cent acid is being sold to the chemical industries, like H-Acid, FC-Acid and other Industries for reuse in productions and in textile industries leading to saving on the virgin acid. Segregation of saleable gypsum is sold to the Cement Industry and thereby illegal Disposal /movement of Spent acid is avoided. Source: Gujarat Pollution Control Board,

97 5.5. Initiatives at Alang Comprehensive waste management plan is not prepared till now however, individual plot holders have to statutorily submit Recycling Facility Management Plan (RFMP) which includes management of waste disposal method to protect the environment and safety measures for the workers prior to issue of Consolidated Consent and Authorization. Details of number of authorization granted to individual plot holders and number of RFMP sanctioned by GPCB are as follows: Table 5-3 : Authorization Granted & RFMP Sanctioned at Alang over the years Particulars Total No. of units Granted Authorization. No. of units Granted RFMP Source: Gujarat Pollution Control Board, 2012 It is expected that the ship breaking activities would cause environmental impacts, the intensity of which would vary depending on several factors such as the quality and quantity of wastes, the digestive capacity of receiving near shore seawater and degree of ecological sensitivity of marine area. In response to that GPCB carried out a study entitled Impact of Ship Breaking Activities on Marine Ecology of the Coastal Water of Alang in May, 2011 with technical assistance from National Institute of Oceanography, Goa. The objectives of the study were to assess prevailing status of water quality; sediment quality and flora and fauna of project area; to assess the impact of pollution due to ship breaking activities on the coastal ecology of Alang; and to estimate bioaccumulation of selected trace metals in the tissues of fishes prevailing in the region. 100

98 Figure 5-1 Water Sampling Stations at Alang for the Study Source: (National Institute of Oceanography, 2011) The coastal water of Alang was monitored in the pre-decided grid covering an area of about 200 km 2 at 25 stations including 3 stations for temporal assessment (12 hours) and water samples were obtained from the surface as well as bottom, for depth exceeding 3m, to analyze parameters like temperature, salinity, suspended solids (SS), dissolved oxygen (DO), BOD, nitrate, ammonia, phosphate, petroleum hydrocarbons (PHc) and phenols. Apart from water sampling, sediment quality, flora and fauna and bioaccumulation of heavy metals in the tissues of fishes and prawns prevailing in the region were studied. The study concluded that in general the ecology of coastal water of Alang is seen similar to that of surrounding area of Bhavnagar and Dahej. The adverse impact of ship breaking activities on water quality, sediment quality and biological characteristics was not significant except a certain intertidal region showing high concentration of PHc and some metals. The results of bioaccumulation suggest that the concentration of Hg was well below the permissible level. To confirm the impact of ship breaking activities on the ecology of Alang, a long term monitoring is essential. For details refer report number NIO/SP-41/2010 (SSP 2007) by National Institute of Oceanography Goa. 101