Eco Industrial Development in Andhra Pradesh

CO2/CO2 eq. Missions – baseline and saving potentials estimated: A first time effort was made to undertake baseline studies for estimating CO2/CO2 eq. Emissions from industries and industrial parks. Due to data constraints, though accurate results could not be achieved, the studies are a first towards finding potentials for future actions. The baseline studies conducted in four existing industrial parks show release of approx. 2.1 – 3.5 million tons of CO2 eq. and in the case of two new industrial parks it varied from 5.3 to 12.3 million tons of CO2eq. It was seen that the potentials of GHG emission reductions are considerable. If all the calculated potentials of the planned activities under the Project are fully tapped, CO2 equivalents of 3,844,193 CO2eq tons per year can be reduced.

Reduction of specific usage of natural resources (energy, raw materials, water) in production processes demonstrated: Through the usage of “Ecoprofit” tool was implemented in 14 SMEs on demonstration basis focusing on ‘energy’, ‘waste’ and ‘water’. Significant savings were achieved within the project implementation period.

The reduction of specific usage of natural resources (energy, raw materials, water) in production processes was successfully demonstrated. In the case of individual industries, resource efficiency has been successfully demonstrated with savings of materials and energy employing ‘EcoProfit’ tool. In the 14 industries covered in Hyderabad region alone, savings include electricity of 836 MWh/yr, coal of 2.8 t/yr, furnace oil of 1.1 t/yr, water of 1.8 mio ltr/yr, material savings of 300 t/yr and aggregated financial savings of over Rs 2 crore. Through environmental and energy audits demonstrated in 10 industries in Hyderabad, identified potential annual savings of 34,85,760 KWH of energy and 3,421 Tonnes of fuel, ≈ Rs. 27 mio annually.

One of the participating companies was the Times of India, which is a leading newspaper company in India. In this company, through optimization of air washer power consumption, the savings achieved are 44,000 kwh/yr, and through optimization of power consumption at centralised air conditioning system, the savings achieved are 22,400 kWh/yr.

The Environmental Audits were undertaken up in 10 identified industries on demonstration basis and the suggestions were made for improvement of pollution control systems with reference to air quality/ emissions, wastewater collection and treatment as well as solid waste disposal. As an immediate measure, a dairy unit has started construction of a new effluent treatment plant. Further, the Energy Audits undertaken in these industries (pharma, dairy and biomass power plant) on demonstration basis show that GHG emissions reduction potentials are to the tune of 9,884 tonnes of CO2e per annum and the estimated total cost savings are about Rs. 26.8 mio (€ 412,308) annually by way of energy savings with a onetime investment of Rs. 23.4 mio (€ 360,000).

Usage of renewable energy in industrial parks commenced: A proposal for installing solar panels at four zonal offices of the Andhra Pradesh industrial infrastructure Corporation Ltd. (APIIC) was prepared. The buildings are located in the industrial parks in Shamshabad, Moula Ali, Pashamylaram and Patancheru. The proposal provides technical information about the equipment to be installed and cost estimates. With this initiation, APIIC has already set up a few solar street lights in the industrial park at Nacharma/Mallapur/Maula Ali and is planning to introduce them in phased manner in all the 7 industrial parks under its Moula Ali zone.

Sustainability concepts planned in new Industrial Parks: For demonstrating systematic and comprehensive planning of new industrial parks, the case of multi-product Andhra Pradesh Special Economic Zone at Visakhapatnam having an area of 5,683 acres (2,300 hectares) was taken up. The environmental impact assessment (EIA) taken up included study of baseline environmental conditions, meteorology, ambient air quality, inland water quality, ground water quality, surface water quality, soil quality, flora and fauna, marine environment, socio-economic conditions, risk analysis and disaster management planning, traffic studies and transportation management.

Based on the EIA studies, Site Master Planning was taken up comprehensively. The plan includes special elements such as transport network, storm water drainage system, cogeneration plant, common waste water treatment and disposal, treatment of sewage and reuse, waste management, green belt and provisions for disaster risk management. This is the first time such as systematic planning process was taken up for an industrial park and hence was not fully optimal. However, the beginning of a process has been made. Concepts have been developed for replication in other new industrial parks and the approach showcased to the stakeholders through discussions, workshops and exhibitions. There is now a demand coming up application of the concepts for new parks with added elements of energy efficiency, renewable energy, and addressing environment and climate change issues.

Personnel in authorities increased with environment/energy experts: Initially, the functioning of ‘Environment Management Cells’ were outsourced to private companies/institutions. The environmental monitoring and management activities were planned and reviewed from time to time. However, due to poor delivery of services, it was decided to internalise the environment management functions.

Accordingly, APIIC had increased personnel at its headquarters and a few Zonal Offices with environment/energy experts catering to improved management of industry parks. These six additional staff members were trained by the Project. These engineers have initiated various activities related to environment protection at the APIIC headquarters and within their respective zones.

The concept of “Environment Cell” set up at APIIC was replicated by the Department of Pharmaceuticals of the Ministry of Chemicals & Fertilizers of the Govt. of India which had set up a similar Environment Cell to deal with environmental initiatives catering to pharmaceuticals industries in India.

Reduction of negative environmental impacts from Industrial Parks demonstrated: With the increased environmental/energy personnel at APIIC and propagation of eco industry park concepts, a number of activities have been initiated for reduction of negative environmental impacts from industrial parks including stopping of illegal discharge of industrial effluents and wastes, initiation of actions against defaulting industries, plantation activities, identification of infrastructure requirements their augmentation, construction of a Common Effluent Treatment Plant (CETP) in one of the industrial parks (Vijayawada) catering to chemical industries and organising of awareness programmes including door-to-door visits. Also, significantly visible is the plantation taken up by APIIC for 40 industrial parks and planning to set up CETPs in various industrial parks.

Capacity building and training of personnel implemented: A number of capacity building and training measures were taken up. An overseas visit-cum-exposure was organised in Germany for 10 participants of the partner organization APIIC and the Indian Ministry of Environment and Forests (MoEF) to provide insight into planning, development and management of sustainable (eco) Industrial Parks and the participants had opportunity to contact corresponding German suppliers in the fields of energy, environment and climate. Also, APIIC participated in the overseas-visit-cum exposure to Germany on “Industrial Disaster Risk Management”.

The junior environment experts appointed by APIIC were trained by the project. The industry personnel from the selected industries were trained on achieving resource efficiency using results of “Ecoprofit” and “Environment/Energy Audit’.

Round Tables on "Eco Industrial Parks" were organised in Hyderabad (Andhra Pradesh) and Ahmedabad (Gujarat). Environmental awareness programmes were organised in industrial parks in Kakinada, Visakhapatnam, Tirupati, Nellore and Shamshabad coupled with tree plantation and in some places environmental rallies were taken up. Particularly on the occasion of the World Environment Day 2009, the theme of “Unite to Combat Climate Change” was propagated through a massive rally in Hyderabad and parallel events in several industrial parks.

Eco industry park concepts widely promoted: For promoting eco industry park concepts and sustainability concepts, a number of activities related to Counselling, Training, Workshops and Exhibitions were organised. To start with, activities to be implemented during 2009 to 2010 were identified through a Planning Workshop organized in December 2008 with APIIC officials (Project implementation partner), including their zone managers. A photo Photo Exhibition was held at Patancheru Industrial Park where the Hon’ble Minister for Industries of Government of Andhra Pradesh, in her speech on the occasion, commended the efforts and activities taken up and requested to expand the activities to all the Industrial Parks in the state. Similar Exhibition was held at Industrial Park in Cherlapally.

Support was provided to the workshop on “Eco Industrial Areas” organized by the Andhra Pradesh Pollution Control Board which had over 150 participants from industry, experts from the field of environment etc. The workshop helped in promoting the eco industrial park initiatives. An Awareness Workshop on “ECOPROFIT Programme” was held at Hyderabad on April 16, 2010 in cooperation with the Federation of Andhra Pradesh Chamber of Commerce & Industry (FAPCII) for the member industries of FAPCII.

A three day International Conference on "Eco Industrial Parks" was organised during July 6-8, 2009 at Hyderabad. The Conference had about 100 participants from India, Germany, Philippines, Tunisia, Bangladesh and Indonesia. The following themes were covered:

• climate change and industrial disaster risk management concepts
• legal issues and policies/strategies
• site master planning, development and management of eco-industrial parks
• instruments, technologies & services for planning, development and management of eco-industrial parks

Eco Industrial Park concepts expanded with climate-relevance: The relevant tools viz. Ecoprofit, Environmental Audit and Energy Audit, were demonstrated in industries with content-inclusion of climate-relevant measures, which specifically aim at energy and resource efficiency. Also, the originally conceived concepts of Eco Industrial Parks were expanded while targeting expansion of the concepts to other parts of India. For example, for expansion to the pharmaceuticals sector in India and for eco industrial development in the state of Gujarat, the focus had been provide for infrastructure strengthening including on renewable energy and on resource/energy efficiency in individual industries. This was also positively received by the partners in DoP and Government of Gujarat.

Multiple impacts - Replication of Eco-Industrial Park concepts started in Andhra Pradesh and other parts of India: The Project succeeded in replication of the Eco-Industrial Park concepts within Andhra Pradesh and beyond. APIIC had scaled up the application of the concepts from the two industrial parks that were taken up initially to 32 industrial parks. The results are more forthcoming in 15 industrial parks. In the state of Gujarat, the activities were initiated for transformation process of two existing industrial parks at Naroda and Vatva near Gandhinagar, the state’s capital. Also, activities for promoting eco industry park concepts in pharmaceuticals sector have been initiated in cooperation with the Department of Pharmaceuticals (DoP) of the Indian Ministry of Chemicals and Fertilizers. The focus is in five states having significant presence of pharma industries and these are Andhra Pradesh, Gujarat, Maharashtra, West Bengal and Tamil Nadu.

Further, for the Government of Orissa, a proposal was developed for planning and development of 450 acre ‘Solar Technology Park’ through the Industrial Promotion and Infrastructure Corporation Ltd. (IPICOL).

A cooperation agreement was made with the Engineering Staff College of India (ESCI) in Hyderabad, with the Centre for Climate Change taking lead in implementing Ecoprofit and other training measures for pharmaceuticals industries.

Documentation, Tool Box etc.:

• Documentation for the 'pilot effort to eco industrial park in Andhra Pradesh' for two of the existing APIIC parks was completed to serve as a guide for the strengthening and spread the use. Also, detailed documentation of the eco industrial park efforts so far in Andhra Pradesh had been completed.

• Another significant accomplishment had been development of a Version 01 of Tool Box on ‘Eco Industrial Development’ based on the experiences from India, Thailand, China, the Philippines and Tunisia.

• Lack of information has often been a problem for planning measures for addressing environment and climate issues. As a first time measure, preparation of 1st version of the “Environmental Information” reports was completed for 8 existing industrial parks of APIIC. These reports developed as an example will help eventfully develop a geographic information system (GIS) based Industrial Parks Information System.

• A content management system (CMS) based website has been developed on "Eco industrial Development in Andhra Pradesh” [www.ecoindustrialparks.net]. The website is under up gradation with an improved and new look [www.hrdp-net.in/e18092/] as well for expanded outreach beyond Andhra Pradesh catering to Eco Industrial Development in India.
• Environmental Cell of GIZ was set up at APIIC to support in planning, coordination, monitoring and documentation of various interventions of the current project in Andhra Pradesh.

Implementation of principles of eco industrial parks: Implementation of principles of eco industrial parks has been extended to over 30 existing Industrial Parks in Andhra Pradesh that were developed more than decade back and lacked the basic environmental infrastructure. In these parks, environmental infrastructure is being strengthened with drainage systems, sewerage systems, common effluent treatment plants, plantation, solar street lamps etc. Measures related to environment-friendly and resource efficient management are implemented partially in over 10 industrial clusters. Environmental staff have been appointed in APIIC. Measures for increasing environmental awareness and control of illegal dumping of wastes and effluents are being implemented.

Common Effluent Treatment Plants (CETP): Work has been initiated to restructure the business model/structure of an existing CETP located at Industrial Park Nacharam/Mallapur to make it financially viable and operational. Also, planning process has started for setting up of a modern CETP at a Special Economic Zone.

 

• Eco Industrial Development in Andhra Pradesh
• Eco Industrial Development in Gujarat
• Hazardous Waste Management in Karnataka
• Eco Electroplaters Park in Tamil Nadu
• Capacity Development
• Feedback from Stakeholders