EXECUTIVE SUMMARY/PREAMBLE

Indian Rayon (A Unit of Aditya Birla Nuvo Ltd.)

EXECUTIVE SUMMARY/PREAMBLE

M/s. Indian Rayon (A Unit of Aditya Birla Nuvo Ltd.) is a multi-product

industrial conglomerate, a part of Birla Industrial House. The organisation

has a long, illustrious and magnificent legacy. The organisation has

consolidated its position under the dynamic Chairmanship of Shri Kumar

Mangalam Birla in the footsteps of late Shri G.D. Birla and Shri Aditya

Birla.

The plant site is located at Veraval, District: Gir-Somnath in

Gujarat state and at the intersection of longitude 70° 21.037' E and

latitude 20° 55.062' N. The site is well connected by Road, Rail and Air. It

can be approached from NH-8B and also through rail. The nearest railway

station is Veraval. The nearest Air Port is at Keshod and Diu at a distance

of about 45 km & 90 km respectively. The land area existing with Indian

Rayon at Veraval is 176 Acre.

There is no Ecological Sensitive Area such as National Park, Marine Park,

Sanctuaries, Reserve forest, Mangrove and Corals within 10 km radius

of the project site.

Unit has installed all the necessary equipments and Pollution Control

systems to maintain the quality of Environment, Health and Safety and

latest manufacturing facility for the production of Viscose Filament Yarn,

Sulfuric Acid, Carbon Di-Sulphide, Sodium Sulphate, Sodium Sulphide,

Caustic Soda Lye, Liquid Chlorine, Sodium Hypochlorite, Hydrochloric Acid

and Compressed Hydrogen Gas.

M/s. Indian Rayon (A unit of Aditya Birla Nuvo Ltd.) is operating under

statutory consents and clearances from Gujarat Pollution Control Board

(GPCB) and Ministry of Environment & Forest (MoEF) respectively.


Indian Rayon has obtained Environmental Clearance from MoEF to

enhance production capacity of Viscose Filament Yarn from 1300 MTPM

to 1650 MTPM through modification in spinning machinery of VFY Plant

& New Superior Spool technology is adopted to produce Viscose

Filament Yarn without any changes in production capacity limiting to 1650

MTPM and Caustic Soda Plant from 200 MTPM to 400 MTPM by the

installation of three electrolysers in the plant premises at Veraval, District

Gir-Somnath (Gujarat).

EC is issued subject to some Specific Conditions and General Conditions.

As per the EC conditions, the industry has to submit Conditions

Compliance Report every six months to MoEF. The industry has so far

submitted six monthly reports regularly to the office of MoEF at Bhopal

with a copy to the regional office GPCB.

This report has been prepared with a view to give complete information

regarding compliance of all conditions laid down in EC issuance letters No:

F. No.J-1011/4445 /2008 – I A II (I), Dated: 18th July, 2008 Corrigendum

dated 30th July, 2008 and 2nd August, 2011 by MoEF. Industry has

obtained renewed Consolidated Consent & Authorization No.

GPCB/CCA/JNG-1 (18)/ ID-17239/149692 from GPCB, Gandhinagar on

28.05.2013 which is valid up to 20.02.2018.

The Ministry of Environment & Forests (Government of India), has given

accolades to Indian Rayon, Veraval (A division of Aditya Birla Nuvo) for its

unrelenting endeavors towards environmental conservation and

development of clean technologies. Following are some of the

achievements in the field of Environment Management till date:

� Indian Rayon is selected for the prestigious 14th Annual Greentech

Environment Award-2013 in Platinum Category in Chemical Sector


� The Ministry chose Indian Rayon, for the coveted National Award

for Prevention of Pollution titled - The Rajiv Gandhi Environment

Award for Prevention of Pollution 2008-2009

� Indian Rayon has received Gold Award in Chemical Sector for

outstanding achievement in Environmental Management, Safety

Management and Corporate Social Responsibility for the year 2012

from Greentech Foundation, New Delhi

� Indian Rayon is continuously being awarded Greentech

Environment Excellence Gold Award since 2007 in Chemical Sector

for outstanding achievement in Environment Management

� Under the Chicago Climate Exchange’s (CCX) Carbon Offset

Program to reduce Green House Gas Emission as a proactive step,

Indian Rayon for the 1st time attempted potential area where

Company has taken measures in Energy Conservation. Indian

Rayon project activity has been registered with CCX and has been

issued 55,700t Co2e Green House Gas (GHG) in the Year 2010.

� Aditya Birla Group (ABG) has engaged Ernst & Young (EY) in the

Year 2012, a leading professional services firm to facilitate the

process of developing sustainability agendas for Chemical business

and sustainability vision and approach at the Group level

� Corporate Commitment to the Environment Protection by

adopting initiative through Sustainability Vision 2020 & DuPont

Safety System has been adopted in the Year 2011 for safety

cultural Transformation

� Indian Rayon, Jan Seva Trust is continuously receiving Certificate

from Social Forestry Department (Govt. of Gujarat) since 2007 to

actively participate in people awareness towards tree plantation

campaign taken by the Govt. at the Taluka Level


� Being a system oriented plant and certified for ISO 9001-2008, ISO

14001-2004, OHSAS 18001-2007, SA 8000-2008

� Division is committed to quality of products, quality of work life

and quality of streams. It strives to achieve excellence and to be a

world class manufacturing company (WCM).

Replies to all conditions were supported with either documentary

evidence and/or photographs.

High Lights of Compliance Report (Environmental Management, CSR,

Regulatory Clearances & Memberships)

� Industry has Corporate Environment Management Structure for the

Environment Protection which, reports to office of chairman,

Structured Environmental Monitoring, Integrated Management

Systems and Regular Audits ensure Compliance to all Environmental

Protection Laws.

� Industry has obtained approvals from Chief Inspectorate of

Factories, Gandhinagar, Chief Controller of Explosives, Nagpur and

Fire Safety Inspectorate.

� The policy of the company is that for any Environmental incidents

there are no budget restrictions. However, a minimum amount of

Rs.25 to 30 lacs earmarked on annual basis for environmental

activities

� A High-Powered Environment Health and Safety (EH&S) Committee

� Organizing scheduled visit of local community people and

demonstration of steps taken to protect Environment.


� Forming Eco Club in school and organizing competitions on various

celebration of Environment days

� To keep Employees updated on Environmental and Safety

measures, various training programs on Environment Management

Systems, in-house mock drills and Environmental monitoring are

conducted regularly

� Effluent generated from different processes in company is treated in

Effluent Treatment Plant to meet stipulated standards before

discharge from factory outlet through Marine Pipeline with diffuser

system with sufficient dilution into deep sea since 2009.

� Industry has Installed Sewage Treatment Plant capacity of 500

M3/day in the Year 2011. Treated water is reused as make-up Water

for cooling Towers & Plantation.

� Industry is regularly Analyzing the treated effluent water samples for

the Bio Assay Test for maintain Marine Ecology

� Adoption of Continuous Viscose Filters for Process viscose waste

minimization and implementation of water saving techniques

� Reuse of steam condensate.

� Industry has completed mangrove plantation in 50 ha of area in

Gujarat Coastal line near Kodinar through Gujarat Ecological

Commission; Gandhinagar in the Year 2012.

� Regular monitoring of Ambient air quality by recognized Third party

Auditor Ahmadabad Textile Industries Research Association

(ATIRA).

� Fugitive emissions at source are controlled by providing ESP , Bag

filters, Water Sprinkler System ,Dry Fog system & cyclone separators

at shop floor etc.


� Fogging Generating System ODC-50 is installed at CS2 plant for

neutralization of odor in and around the plant.

� Dust suppression system -Dry fog based Dust suppression system

(114 Nos Nozzles), Water Sprinklers & 10 Nos of Rain Guns are

installed in Coal Handling plant to control of sub micron particle of

dust

� Industry has taken Membership of M/s Saurashtra Enviro Private

Project Limited, Bhachau for Integrated Hazardous waste

management of Spent Catalyst, Resin, Sulphur Sludge, Cellulose

Waste and Oily Cotton Waste.

� Industry has taken Membership of M/s E-Coli Waste Management

Private Limited, Sabarkantha for Environmental Friendly disposal of

E-Waste.

� Industry has taken Membership of M/s Girnar Bio-Medical Waste

Services, Junagadh (approved by Gujarat Pollution Control Board)

for environment friendly disposal of Bio-Medical Waste

� Hydrogen Gas is used replacing Furnace Oil for making Caustic Soda

Flakes resulting reduction in Carbon Dioxide emission elimination

� Replacement of Ozone Depleting Refrigerant by lithium bromide

based 5 Nos of Vapor Absorption Machine

� Elimination of use of barium carbonate for treatment of brine

resulting in elimination, combustion of barytes with reduced Carbon

dioxide emission

Indian Rayon (A Unit of Aditya

Ach

14th Annual Gree

Categ

3rd Annual Greentech CSR A

f Aditya Birla Nuvo Ltd.)

Achievements 2012-2013

ual Greentech Environment Award-2013 in Platinum

Category in Chemical Sector

ch CSR Award-2013 in Silver Category in Chemical S

Platinum

emical Sector


Project Name:

Expansion of Production Capacity of Viscose Filament Rayon from 1300 MTPM

to 1650 MTPM & Caustic Soda Plant from 200 TPD to 400 TPD at Veraval, Dist-

Junagarh, Gujarat by M/s. Indian Rayon (A Unit of Aditya Birla Nuvo Ltd.)

Point wise Compliance Report of Environment Clearance vide MoEF

Letter No:

F. No.J-11011/4445/2008 – I A II (I), Dated: 18th July, 2008 & 2nd August, 2011

Corrigendum dated 30th July, 2008

MoeF letter No. J-11011/382/2008-1A II (I) dated 2nd August, 2011

S.

No.

Conditions Reply to stipulated conditions

A. Specific Conditions

i The effluent generation shall not

exceed 8540 m3/d. The effluent from

the caustic soda plant and viscose

filament rayon plant shall be treated in

the company’s own Common Effluent

Treatment Plant and the treated

effluent after conforming to the

industry specific discharge standards

shall be sent to sea creek. The

domestic effluent shall be disposed of

through septic tank soak pit

• The effluent generation is within 8540

m3/d.

• Treated effluent after conforming to the

Industry specific standards of GPCB is

discharged into deep sea through Marine

Pipeline with diffuser system.

• The domestic effluent generated is treated

in STP

• Monitoring results for Treated effluent

from ETP & STP with Photographs of ETP,

STP, Marine pumping station is enclosed as

Annexure -I.

ii Process emissions from the caustic

soda plant shall be scrubbed with alkali

scrubber with efficiency of 95% at each

• Process emissions from the caustic soda

plant are scrubbed in 4 Alkali scrubbers in

series with overall efficiency of 95%.


stage. Bubble cap tray followed by

packed bed scrubber with water as

scrubber media shall be installed to

control HCl emissions. Stack of

adequate height for caustic soda

plant and HCl synthesis unit shall be

provided for dispersion of emission

• Bubble cap tray followed by packed bed

scrubber with DM water as scrubber media

is installed to control HCl emissions.

• Stacks for different units are constructed in

accordance with GPCB standards

• Stacks of 34 m each are constructed for

Caustic Soda Plant and Hcl Plant

respectively.

• List showing all stacks constructed onsite

at Indian Rayon along with Photographs

are enclosed as Annexure – II

• Photographs showing Pollution control

equipments for Process, Cl, H2 & HCl

emissions are enclosed as Annexure – II

iii The vent gases from Sodium

hypochlorite plant and HCl acid plant

shall be controlled at source by

effective absorption system. Waste

Chlorine gas shall be used in

preparation of HCl. Bubble cap tray

followed by packed bed scrubber

with DM water shall be provided to

scrub HCl gas mist and vapor. The vent

gases shall be discharged from the

stacks of adequate height for

effective dispersion. On line chlorine

monitors with DCS within Caustic

Soda plant to monitor chlorine gas and

on line hydrogen monitors with DCS

• The vent gases from Sodium hypochlorite

plant and HCl acid plant is controlled by

effective Absorption system

• Stack of 34 m is constructed at HCl plant.

• Waste Chlorine gas is used in preparation

of HCl

• Bubble cap tray followed by packed bed

scrubber with DM water as scrubber media

is installed to control HCl emissions

• 26 No’s Online chlorine monitors with DCS

installed onsite at chlorine handling area

• 2 No’s Online hydrogen monitoring is with

DCS installed onsite at hydrogen handling

area of caustic soda plant

• Refer for Photographs Annexure - II


shall be installed

iv Particulate emissions from the

captive power plant and coal fired

boiler shall be controlled by

electrostatic precipitator and bag

filters and emissions shall be

dispersed through stack of adequate

height. Particulate emissions shall

conform to the prescribed

standards. For dispersion of

emissions from the DG set, stack height

as per CPCB standards shall be

provided. Emissions from the DG Sets

shall conform to the standards

prescribed by the CPCB. The DG sets

will be provided with the acoustic

enclosures to mitigate the noise.

• 3 ESP has been installed onsite the plant.

• The DG sets are provided with the acoustic

enclosures to mitigate the noise.

• Particulate emissions conform to GPCB

standards

• Stacks for different units are in accordance

with GPCB standards

• Stack Height for D.G Sets installed onsite as

per GPCB Standards are:

� 6 nos of D.G Sets (2279 KVA) 40 m

each

� 2 nos of D.G Sets 1450KVA 11m

each

� 1 No of D.G set 1500 KVA 30 m

• Particulate emissions monitoring results as

per GPCB standards & Photographs ESP,

Bag Filters, Acoustic enclosure are

enclosed as Annexure – III

v Dykes of adequate height shall be

provided around the HCl acid tanks to

collect the acid within the dyke walls in

the event of catastrophic failure of the

tank

• Dykes of adequate height is provided

around the HCl acid tanks.

• Photographs are enclosed as Annexure –

IV

vi The gaseous emissions from the

carbon di sulphide plant in the form of

CS2 and H2S shall be recovered by

condensers and H2S shall be scrubbed

• The gaseous emissions from the carbon di

sulphide plant in the form of CS2 are

recovered by Condensers

• H2S is scrubbed with caustic soda in 2-


with caustic soda and 2-stage

absorption system to recover sodium

sulphide.

stage Absorption system to recover sodium

sulphide.

• Photographs are enclosed as Annexure – V

vii The adequate measures shall be

taken to prevent the fire hazards

and accidental release of cl2

• Inventory of 70 tons bullet for Chlorine gas

storage is eliminated by resorting to store

directly in 900 kg cylinders using liquid

chlorine pump. This reduces the risk of

accidental release of Cl2 to 900 kgs only.

• Preventive measures and recommendation

of Environmental Impact & Risk

Assessment study carried out by National

Environmental Engineering Research

Institute,(NEERI), Nagpur are being

implemented.

• Recommendations of Fire study & Risk

Assessment are being implemented to

prevent fire hazards.

• Routine Assessment are being done with

implementation of Preventive measures

and recommendations of the study


VI

viii The project authorities shall comply

with the recommendations made in the

EIA/EMP report.

Complied.

ix Green belt shall be developed in 12 ha

of plant area to mitigate the effects of

fugitive emissions all around the plant.

The development of green belt shall be

• Green belt area of about 24 ha has been

developed in the plant area with various

scientific measures as per CPCB guidelines.

List of type of Plantation given in


as per the Central Pollution Control

Board guidelines.

Environmental Impact & Risk Assessment

study by National Environmental

Engineering Research Institute,(NEERI),

Nagpur & Photographs are enclosed in

Annexure – VII

• All around the plant area viz. Rayon, Power

Plant and Caustic Soda Plant is surrounded

with the Green belt by planting 55,000

trees. Besides above 1.147 acre area is

used/developed with lawn (Hariyali). Total

10.3 Km length of hedges are planted and

maintained. Work Order to Gujarat

Ecological Commission, Gandhinagar was

given for mangrove plantation in 50 ha of

area in Gujarat Coastal line near Kodinar

and Plantation has been completed in the

month of January 2012.

• Plant Area breakup:

� Plant Boundary: 176.26 acre

� Green Belt Area: 59.31 acre (24 ha)

� Open Area: 114.18 acre

x Rainwater harvesting measures shall be

undertaken to recharge the ground

water.

All efforts for rain water harvesting are being

taken. Due to high water table in area further

recharging is not possible. However separate

storm water drains are provided to prevent

flooding by discharging into Devaka River.

B. General Conditions

i. The project authorities shall strictly • Noted.


adhere to the stipulations made by the

Gujarat State Pollution Control

Board (GPCB)

• Indian Rayon is regularly submitting

Compliance status of all stipulated

conditions given in Consolidated Consent

& Authorization (CC&A) of Gujarat State

Pollution Control Board (GPCB)

ii. No further expansion or

modifications in the plant shall be

carried out without prior approval of

the Ministry of Environment & Forests.

In case of deviations or alterations in

the project proposal from those

submitted to this Ministry for

clearance, a fresh reference should be

made to the Ministry to assess the

adequacy of conditions imposed and to

add additional environmental

protection measures required, if any.

• Noted.

• With reference EC issued by MoEF letter

no. F. No. J-11011/445/2008-IA 11(I)

dated 18th July, 2008, 3 Electrolysers are

installed in caustic soda plant.

• With reference to EC issued by MoEF letter

no. F. No. J-11011/445/2008-IA 11(I)

dated 18th July, 2008, modification in

spinning machinery of VFY Plant is carried

out. New Superior Spool technology is

adopted to produce Viscose Filament Yarn

without any changes in production

capacity limiting to 1650 MTPM.

• Photographs have been enclosed as

Annexure – VIII

iii. The project authorities shall strictly

comply with the rules and regulations

under Manufacture, Storage and Import

of Hazardous chemicals Rules, 1989 as

amended in October, 1994 and January,

2000. Prior approvals from Chief

Inspectorate of Factories, Chief

Controller of Explosives, Fire Safety

Inspectorate etc. must be obtained.

• Factory license of Chief Inspectorate of

Factories is enclosed as Annexure -IX

• Permission letter of Chief Controller of

Explosives is enclosed as Annexure - X

• Executive summary of fire study & Risk

Assessment is enclosed as Annexure – XI

• Indian Rayon is complying with the rules

and regulations under Manufacture, Storage

and Import of Hazardous chemicals Rules,


1989 as amended in October, 1994 and

January, 2000.

iv. The project authorities shall strictly

comply with the rules and regulations

with regard to handling and disposal of

hazardous wastes in accordance with

the Hazardous Wastes (Management

and Handling) Rules, 2003.

Authorization from the State Pollution

Control Board must be obtained for

collections/treatment/storage/disposal

of hazardous wastes.

• Noted and Complied in reference to rules

and regulations with regard to handling and

disposal of hazardous wastes in accordance

with the Hazardous Wastes (Management

and Handling & Transboundary Movement)

Rules, 2008.

• Authorization from the Gujarat State

Pollution Control Board is obtained for

collections/treatment/storage/disposal of

hazardous wastes in Consolidated Consent

& Authorization (CC&A) valid up to 20th

feb,2018

CC&A Letter No. GPCB/CCA/JNG-

1(18)/ID-17239/149692 dated 7th June,

2013

v. The overall noise levels in and around

the plant area shall be kept well within

the standards (85 dBA) by providing

noise control measures including

acoustic hoods, silencers, enclosures

etc. on all sources of noise generation.

The ambient noise levels shall conform

to the standards prescribed under EPA

Rules, 1989 viz. 75 dBA (day time) and

70 (dBA (night time).

• Noise Monitoring was conducted by ATIRA,

Ahmadabad in the month of October 2013 ,

showing results within Noise GPCB limits

for the stated categories.

• Noise Monitoring Results & Photographs of

Acoustic enclosure and Silencer are

enclosed as Annexure – XII

vi. Occupational health surveillance

programmme shall be undertaken as

regular exercise for all the employees,

• Occupational health surveillance

programmme are undertaken as regular


specifically for those engaged in

handling hazardous substances. The

first aid facilities in the occupational

health centre should be strengthened

and the medical records of each

employee should be maintained

separately

exercise for all the employees, specifically

for those engaged in handling hazardous

substances.

• The first aid facilities in the occupational

health centre are strengthened and the

medical records of each employee have

been maintained separately.


XIII

vii. The project proponent shall also

comply with all the environmental

protection measures and safeguards

recommended in the EIA and Risk

analysis. Report. The Company must

also undertake social

welfare/community development

measures in the surrounding villages,

such as health care, education and

drinking water supply facilities

• Executive summary of Environmental

Impact & Risk Assessment study was

conducted by NEERI in April,2013 details

are enclosed as Annexure – XIV

• Executive summary HAZOP study as well

as Safety Audit by M/s. Prosafe

Engineering Pvt Ltd was conducted for

Indian Rayon. Details are enclosed as

Annexure – XV. Environmental Protection

measures and Safeguards have been

adopted in the plant.

• The plant is OHSAS 18001:2007, ISO

14000:2004, ISO 9001:2008 and SA 8000 :

2008 certified system. certificates are

enclosed as Annexure – XVI

• The company is engaged in various CSR

activities in the Area including Heath care,

education, women empowerment etc.

Details are enclosed as Annexure – XVII

viii. A separate Environmental Management

Cell equipped with full fledged

• Organizational Chart of Environmental

Management Cell is enclosed as Annexure –


laboratory facilities shall be set up to

carry out the Environmental

Management and monitoring functions.

XVIII

• Photographs of laboratory facilities are

enclosed as Annexure – XIX

ix. The project authorities shall provide

adequate funds both recurring and non-

recurring to implement the conditions

stipulated by the Ministry of

Environment & Forests as well as the

State Government along with the

implementation schedule for all the

conditions stipulated herein. The funds

so provided should not be diverted for

any other purpose.

• The policy of the company for any

environmental incidents is with no budget

restrictions. However minimum amount of

Rs 25 to 30 Lacs are earmarked on annual

basis for Environmental activities. Details

on recent recurring & non recurring cost

budget for the year 2012-2013 have been

enclosed as Annexure – XX

• Photographs showing Pollution control

system at Indian Rayon are enclosed as

Annexure - XXI

x. The implementation of the project vis-

à-vis environmental action plans will be

monitored by Ministry`s regional office

at Bhopal/State Pollution Control

Board /Central Pollution Control Board.

A six monthly compliance status report

should be submitted to monitoring

agencies.

Receipts of six monthly compliance status

report submission are enclosed as Annexure –

XXII

xi. The Project Proponent shall inform the

public that the project has been

accorded environmental clearance by

the Ministry and copies of the

clearance letter are available with the

State Pollution Control Board/

Committee and may also be seen at

Complied details are submitted with earlier

compliance reports.


Website of the Ministry of Environment

and Forests at http:/envfor.nic.in. This

should be advertised within seven days

from the date of issue of the clearance

letter, at least in two local newspapers

that are widely circulated in the region

of which one shall be in the vernacular

language of the locality concerned and a

copy of the same should be forwarded

to the Regional office.

xii. The Project Authorities shall inform

the Regional Office as well as the

Ministry, the date of financial closure

and final approval of the project by the

concerned authorities and

the date of commencing the land

development work, if any.

Not Applicable.

8. The Ministry may revoke or suspend

the clearance, if implementation of any

of the above conditions is not

satisfactory.

Noted.

9. The Ministry reserves the right to

stipulate additional conditions, if found

necessary. The company in a time

bound manner shall implement these

conditions.

Noted.

10. Any appeal against this environmental

clearance shall lie with the National

Environment Appellate Authority, if

Complied and final decision copy is attached

with Compliance report submitted dated

14.01.2009.


preferred within a period of 30 days as

prescribed under Section 11 of the

National Environment Appellate

Authority Act, 1997

11. The above conditions will be enforced,

inter-alia under the provisions of the

Water (Prevention & Control of

Pollution) Act, 1974, Air (Prevention &

Control of Pollution) Act, 1981, the

Environment (Protection) Act, 1986,

Hazardous Wastes (Management and

Handling) Rules, 2003 and the Public

Liability Insurance Act, 1991 along with

their amendments and rules.

Noted.

















EXECUTIVE SUMMARY/PREAMBLE

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