The provision for Environmental Audit (Statement) as prescribed under the Environmental Protection Act for 1986 has great promise but has not been able to deliver. It was designed to be a tool through which corporates analyze their environmental performance in time and take suitable measures for improvement in resource consumption and waste management. Being linked to regulations, it made industry apprehensive, apprehensive of the fact that non compliance could be used to their legal disadvantage by the regulator. This introduced some amount of misreporting in order to make the report acceptable to regulatory agencies rather than helping the industry to introspect and improve. Voluntary approaches therefore, delinked to regulation therefore are assumed to play a more important role. Public disclosures of performance indicators provide powerful financial, social and reputational incentives for reducing negative externalities. It can also induce improvements from bad performers (which may otherwise require costly litigation) and introduce a system where corporate internalize reputation effects and perform better. The PROPER PROKASIH, Indonesia’s public disclosure program has been very successful in awarding good performers and calling public attention to polluters who are not in compliance with the regulations. (Regulation in the Information age-Indonesian Public Information Program in www. performeks.com/media/downloads/information_regulation.pdf) Philippines, Colombia, Mexico and Brazil have also undertaken identical programmes.

Here at home the Centre for Science and Environment has attempted a green rating of the Paper, Automobile and Chloralkali sector (The Greenest Paper Mill in India, July, 18, 1999, cseindia.org; Who is India’s Worst Paper Maker, Down to Earth, October 15, 2004 and Environmental Rating of Indian Caustic Chlorine Sector, Chandra Bhushan and Sunita Narain, C.S.E.) and ranked the major players on environmental performance . Another study done by the same organization for the cement industry pointed out that where economic logic met environmental objectives, the industry did well like in energy use and utilization of wastes but where investments did not yield short terms results the industry failed to meet expectations like in mine management, emission control and regulating livelihoods. Societally the industry was found to be dismal. (Cement: Not As Bad As We Thought, Down to Earth, December 31, 2005). Most of these studies point out that the major factors wrong with these industries is an inefficient use of resources and a poor technology base. (The Greenest Paper Mill in India, July 18, 1999, cseindia.org/node/441)

A pilot programme for environmental performance rating and public disclosure for industries was also initiated as part of a World Bank Programme and implemented collectively through the C.I.I., World Bank and the Uttar Pradesh Pollution Control Board. Both the authors to the present study were part of the study initiated in May 2001 which was coordinated from the World Bank by Mr. Carter Brandon, Dr. Smita Misra, Dr. Sushmita Dasgupta. (Also covered in Dr. Yashpal Singh, Environmental Performance Rating of Distilleries.www.oecd.org/data oecd) The programme covered 33 industries of different sizes and sectors at Ghaziabad and Noida. Industries were classified as Black and Red (implying lack of compliance) and Blue, Green and Gold (different levels of achieving compliance). Out of the 33 participating industries 6 were rated as Gold and Green, 16 rated Blue and 11 rated Black. This was a location specific compliance rating programme including small and medium enterprise also. It was not designed to be an environmental performance rating.

The Charter on Corporate Responsibility for Environmental Protection,2003 introduced through the efforts of the MoEF, the Pollution Control Boards and Industry Associations has seen a major break through in voluntary environmental performance.

In spite of the immense advantages that voluntary disclosure systems have, environmental performance rating exercises have been attempted but at a few places in India.

A pilot programme was commissioned by the U.P. Pollution Control Board in 2000 to evaluate and rate the environmental performance of the units in the Alcohol Industry. (Y. Singh, 2004, Environmental Performance Rating of Distilleries.www.oecd.org/data oecd) The study involved identification of the environmental indicators associated with the various activities in Alcohol production, understanding their environmental impacts and rating the environmental performance for intra industry comparisons by working out appropriate weightage systems for these indicators. The highlight of the study was the analysis of resource utilization efficiency of the units and its impact on environmental performance as well as profitability. The results of the study along with the names of the top 5 and bottom five performers were presented in an ‘open house’ where representatives from most of the participating distilleries were present. The report had concluded that in the case of Uttar Pradesh, the environmental performance of distilleries in western and Central Uttar Pradesh is better. Semi urban distilleries have a better performance as compared to rural based ones. Remarkably the study also revealed that improved environmental performance leads to better profitability. The industry was however observed to   exhibit insensitiveness to the use of raw materials, water, fuel, and power which results in enormous cost escalations. It was estimated that the sector could save more than Rs 100 crores per year it only the bad performers could come to the level of the best performers. The recommendations of the study were circulated and discussed in another open house. The participating distilleries had assured that they would take necessary action and improve their environmental performance.

Dr. Pradeep Kumar the prime mover behind this programme had hoped that the study would lead to better control of industrial Pollution besides improving the efficiency of units. The report was also presented by Dr. Yashpal Singh before representatives from all over the world at an International Conference on Economic Instruments held at Paris in 2004.The World Bank recognized this report as an important study and published a poster acknowledging the utility of the study. The poster also recommended that the exercise should be repeated so as to assess benefits.

It is in this context that the Distillery sector has been revisited to evaluate the impacts of the previous study. It also intends to tell the industry where it can still improve in order to earn better profits and reputation. While the earlier study looked into the performance indicators for the years 1998-99 to 2000-2001, this study covered the year 2004-05 to 2006-07.

The present report presents a comparative study of both the assessments. The Distillery sector with an installed capacity to convert over 3 million tonnes of molasses annually in U.P. is one of the major industrial sectors with a constantly growing contribution to the state exchequer by way of excise duty (Rs. 2912.90 Crores in 2004-2005, Rs. 3114.3 Crores in 2005-2006 and Rs 3518.3 Crores in 2006-2007). It also provides employment to more than 10,000 persons in the state. The industry has grown considerably over years. While there were 37 operational distilleries in U.P. (35 molasses based and 2 broken grains and malt based) out of a total of 43 distilleries in 2000-2001, 59 distilleries have been reported for 2006-2007 (56 Molasses based and 3 grain based). All these distilleries were requested to participate in the study. Out of these, 36 distilleries   participated. 24 distilleries have participated in both the 2000-2001 and 2006-2007 evaluations.

Conclusions

The study for the period 2000-2001 had indicated the following:

1.         Distilleries in central and western U.P. are marginally better performers.

2.         The semi urban distilleries were observed to perform better than the urban and rural based units.

3.         57% distilleries are located in the Ganga catchment followed by Ghagra and Yamuna. 86% of the distilleries discharge their effluents into the rivers (Ghagra-5, Gomti-1, Ganga-18 and Yamuna-6)

4.         An improved environmental performance leads to better profitability.

5.         The sector is not sensitive to the efficient use of raw materials, water, fuel and power. Optimization in raw material consumption and judicious use of water and energy shall reduce the production cost and increase profitability. This will make the product more competitive in the Global market and help the industry to maximize the capacity utilization.

6.         If the bad performers evaluate the best performers, the sector is likely to save Rs. 105.81 Crores by optimizing resource utilization (Molasses Rs. 26.95 Crores, Water Rs. 12.04 Crores, Biogas Rs. 22.50 Crores, Total Energy Rs. 45.32 Crores)

The following recommendations were made and presented before an open house session with Industry representatives and the Pollution Control Board.

1.         Eighteen out of the 33 units studied have a very poor environmental performance.

2.         All plants should have facilities to monitor the amount of biogas generated. They must also ensure to utilize the gas in boilers to meet the energy requirements. Where the biogas generation is poor, industries should retrofit the inefficient plants.

3.         Those units which have not installed the second aerobic stage should do it at the earliest.

4.         There is immense scope for reducing water consumption. This should be implemented.

5.         Metering systems should be installed to monitor consumption of biogas, water and electricity.

6.         Wherever feasible effluents should be utilized in production of bio-manure or in the case of grain based distilleries as cattle feed. Use of treated effluents for irrigation should be encouraged.

7.         Energy audit and trainings should be utilized

8.         Best available technologies should be utilized.

9.         Distilleries should be encouraged to implement ISO 14001.

Against these findings and recommendations these has been a considerable improvement in environmental performance in 2006-2007. 24 distilleries were common to both the phases of the study, 22 of these have improved by way of total environmental performance, 12 in terms of capacity utilization, 18 in terms of molasses consumption, 17 in terms of average recovery of alcohol, 18 in terms of water consumption, 10 (out 0f 22) in terms of total energy consumption, 14 (out of 22) in terms of total renewable energy consumption, 17 (out of 22) in terms of spent wash generation, 13 (out of 19) in terms of biogas generation, 18 (out of 22) in terms of dilution ratio.(Tables 2 to 10.

The repeat study has also reiterated the findings of the earlier study that an improved environmental performance leads to better profitability. There has been a considerable improvement in per capita use of resources although there is still scope for improvement. Two industries have adopted technologies based on concentration of spent wash and burning the same in better to generate steam and power for the process. These units show improved performance on all the energy indicators and have no effluent issues. Some new units installed in 2006-2007 or later are based on this technology.

Download the full document here : Distillery_Rating_UP

The Fly-ash mission was commissioned in 1994 with the Department of Science and Technology as the nodal agency and the Technology Information and Assessment Council (TIFAC) as the implementing agency. The Ministry of Environment and Forests, Govt. of India, Ministry of Power, Thermal Power stations, R&D Institutions and Industry together have launched a Technology Project in Mission Mode (TPMM). Their focus is on the demonstration of coal ash related technologies for infusing confidence and thus ensuring large scale adoption.

Fly ash utilization has great potential to lower green house gas emissions by decreased mining activities and reducing Carbon dioxide production during manufacture of materials that can be substituted by fly ash.

Fly ash can substitute up to 66% of cement in the construction of dams. It is also used as a pozollanic substitute for cement in Roller Compacted Concrete dams-an innovative dam technology developed as a result of efforts to design more economical concrete dams that could be constructed rapidly with designed performance. Fly ash in R.C.C. is used not only for saving cement cost but also for enhancing strength and durability. Replacement levels of fly ash primarily Class f, range from 30-75% of total cement material. Fly ash can also be used in Portland cement concrete to enhance the performance of the concrete. Portland cement is manufactured with Calcium oxide, some of which is released in a free state during hydration. As much as 20 pounds of free lime is released during the hydration of 100 pounds of cement. This liberated lime forms the necessary ingredients for reaction with fly ash silicates to form strong and durable cementing compounds thus improving many of the properties of concrete. Typically 15-30% of the Portland cement is replaced with fly ash. This results in net reduction in energy use and green house gas and other emissions.

Fly ash from coal fired Thermal power plants is an excellent material for the manufacture of other construction materials like fly ash bricks, mosaic tiles and hollow blocks. The manufacture of conventional clay bricks requires the consumption of large amounts of clay. This depletes top soil and leads to degradation of land.

Except for Fly ash-clay fired bricks, fly ash bricks do not require clay and serve the dual purpose of conserving top soil and the constructive utilization of fly ash. Technologies are also on verge of entering the markets for manufacture of cementing material as well as fly ash bricks with fly ash content as high as 90%.Orissa Government in India has banned the use of soil for the manufacture of bricks up to 20 km. of a thermal power station. In the case of fly ash-clay fired bricks, a mixture of clay and fly ash is fired. The unburnt carbon of the fly ash serves as fuel for burning. Approximately20-30% energy can be reduced by adding25-40% flyash.

The World Bank has cautioned India that by 2015 disposal of coal ash would require 1000 square km. or one meter square of land per person.

Some of the high volume applications of fly ash are for use in paving, building embankments and mine fills. Utilizing fly ash in roads saves top soil, avoids creation of low lying areas, does not deprive the nation of the productivity of top soil and reduces the demand of land for fly ash disposal.

The use of fly ash in the Nizamuddin bridge road embankment at Delhi, India for about 2 Kms. and a height of 8 meters in a flood zone has demonstrated the use of fly-ash in adverse conditions. This has not only saved the top soil and used fly ash which was otherwise a waste but also saved Rs. 1.4 crores in a total project of Rs. 10 crores.

Fly ash-Lime-Gypsum bricks are manufactured using the properties of the mixture as an ‘Hydraulic Cement’ meaning thereby that it sets and hardens in the presence of moisture and on the lines of Portland cement, gets stronger with age but unlike clay bricks does not need sintering. Nearly 200 tonnes of coal are needed to sinter one million clay bricks, a process that liberates over 180 tonnes of Carbon dioxide. The production process of fly ash lime gypsum bricks eliminates this process and has the potential to earn carbon credits in return. Air-water cured bricks are of similar qualities as clay fired bricks and 20 to 25 paise cheaper. Steam cured bricks are of much superior quality as compared to wire cut clay bricks and cheaper by 25 to 50 paise than wire cut bricks.

Cellular light weight concrete blocks are used as a substitute to bricks and conventional concrete blocks. This is a foaming agent based technology from Germany using Fly-ash (to the extent of1/3rd to 1/4th of the total materials constitution), sand, water and foam manufactured from biodegradable foaming agents. Foaming agent and foam generator if used for the production of Cellular light weight concrete blocks with more than 25% content of fly ash is eligible for concession in import duty by the Government of India. The blocks have a better strength to weight ratio and reduce dead load resulting in a saving of steel and cement costs and in reduction in foundation size. It has better acoustics and thermal insulation (Air conditioning requirements are considerably reduced). There is a saving in mortar and it has a higher fire rating.

Fly ash based polymer products are also being used as wood substitutes. They have been developed by using fly ash as the matrix and jute cloth as the reinforcement. The Jute cloth is laminated by passing through a polymer fly ash matrix and then cured. The number of Laminates is increased to get the desired thickness. The product can be use in many applications like door shutters, partition panels, flooring tiles, wall paneling and ceiling. The developed material is stronger more durable, resistant to corrosion and cost effective as compared to wood. This technology has been developed by the Regional Research Laboratory, Bhopal in collaboration with Building Materials and Technology Promotion Council (B.M.T.P.C) and TIFAC. One commercial plant has been set up based on this technology near Chennai, India.

Sources:

www.dst.gov.in/whats_new/what_new08/fly-ash.pdf

www.parisaramahiti.kar.nic.in

www.tribuneindia.com/2000/20000217/science.htm

www.icrindia.org/?p=180

www.bmtpc.org/pubs/papers/paper4.htm

www.icjonline.com/may2007.htm

Damle Anand, 2003: Use of Fly Ash in Burnt Clay manufacturing, Cleaner Technology, Impacts/12/2003-2004, MOEF-CPCB, Govt. of India, 2003 pages11-21

Kumar Vimal and Mathur Mukesh,2003 :Clean environment through fly as utilization. Cleaner Technology, Impacts/12/2003-2004, MOEF-CPCB, Govt. of India, 2003 pages235-255

TIFAC, 1995: Techno market survey on fly ash bricks

ENERGY SAVINGS AND ENVIRONMENTAL BENEFITS
Most of the developing countries face energy scarcity and huge housing and other infrastructure shortage. Ideally in these countries materials for habitat and other construction activities should be energy efficient (having low energy demand). The following table shows some examples of energy savings achieved through the use of Fly Ash in the manufacture of conventional building materials. It should be noted that use of Fly Ash also improves the properties of building material, as mentioned above:

Source: Building Materials in India: 50 Years – A Commemorative Volume, Building Materials & Technology Promotion Council, New Delhi, India, 1998

Conversion of fly ash into wealth generator

(Excerpt from President A P J Abdul Kalam’s
address to the nation on the eve of the country’s
56th Republic Day):

“As you are aware, the use of coal for power generation results in an increased quantum of fly ash production, which has reached about 100 million tonnes per year. All out efforts are needed to utilize this fly ash not only from environmental considerations, but also to avoid land usage for fly ash dumping. Though there has been a steady progress in fly ash utilization from 1990, we have a long way to go to reach the target of 100 per cent fly ash utilization. It is reported that the agricultural increase of grains is around 15 per cent, green vegetables 35 per cent and root vegetables 50 per cent, when fly ash is mixed with soil. Toxicity tests have proved that there is no toxic element due to fly ash. But it has higher nutrients due to increased availability of iron and calcium. Fly ash can become a wealth generator by making use of it for producing ‘green building’ materials, roads, agriculture etc. Full utilization of the generating stock will provide employment potential for three hundred thousand people and result in a business volume of over Rs.4,000 crore.”