: P-7
SAFETY, HEALTH AND ENVIRONMENT: GRASIM PERSPECTIVE
by
S.S. Pipara
Sr.Vice President (Tech.)
Grasim Industries Limited
Birlagram Nagda (M.P.), 456 331, INDIA
Fax no.: (07366) 244114, 246024, e-mail: sspipara@adityabirla.com
ABSTRACT
Grasims prime concern has been to integrate Safety, Health and Environment in all its
industrial activities through i) Motivational and Promotional activities, ii) Training,
Education & Awareness Activities, iii) Inspection, Audit and Testing, iv) Investigation &
Analysis, and v) System Perfection. These activities form strong pillars of SHE management
across all levels in the organization.
As a part of Aditya Birla Group Company, we have adopted World Class Manufacturing
(WCM) concept in the year 1997 for all activities related to industrial production.
In the context of industrial activity, the company strategy is to maintain Economic Progress
with Sustainable Development through i) Resource saving in production process and ii)
Adequate treatment of discharge/ emissions to render them harmless.
These require careful selection of both Production and Waste Treatment Technologies. In
Production Technology, one has to look for Cleaner Technologies and practice in-plant
controls for effecting recovery & recycling, so that resource utilization is maximized.
Consequent reduction in influent load increases effectiveness of effluent treatment and
renders final discharge / emissions harmless to the ecology. These concepts have been
implemented in letter and spirit.
Grasim firmly believes that it is possible to enjoy the benefit of modern technology &
industrialization without damage to the ecology & environment of this country.
KEY WORDS : SHE Safety Health & Environment, VSF Viscose Staple Fibre, WCM
World Class Manufacturing.
COMPANY PROFILE
Grasims Staple Fibre Division Nagda, a Unit of Aditya Birla Group, has pioneered the
manufacture of Viscose Staple Fibre in India in 1954 & today it is the largest producer of
Viscose Staple Fibre with unique Spun Dyed and Speciality Fibre manufacturing capabilities
in Asia.
SHE APPROACH
This paper deals with progressive SHE management policies and objectives, which are
universally applicable for all industries in general and chemical process industries in
particular.
While dealing with SHE approach and deployment, we would like to highlight what is being
practiced at Grasim.
System Perfection
As a part of Aditya Birla Group Company, we have adopted World Class Manufacturing
(WCM) concept in the year 1997 encompassing full-fledged set-up covering all dimensions
related to:
Figure - 1
World Class Manufacturing Model
WCM Mission
Waste
Elimination
Information
Systems / BPR
Technology and
Cash Flow
Work
Environmen
t
(5S)
JIT / Supply
Chain
Management
Liaison,
Team
Force and Skill
Development
Equipment
Effectiveness/
TPM
Customer
Driven: Internal
and External
Quality First:
SQM and Best
Practices
Zero Accident
Zero Pollution
Zero Losses
Zero Breakdown
Zero Defect
Zero Customer
Complaints
Year
1994
1999
- Power Generation
OHSAS-18001 (Occupational Health & Safety Assessment System)
2001
Manufacture and Supply of Viscose Staple Fibre and Sodium Sulphate;
Energy Generation; Design, Development and Manufacturing of Plant
and Equipment for Man-made fibre
SA-8000 (Social Accountability)
Manufacture and Supply of Viscose Staple Fibre and Sodium Sulphate; 2004
Energy Generation; Design, Development and Manufacturing of Plant
and Equipment for Man-made fibre chemicals and Allied industry
Equipment (Safety Appliances) has helped in accident / incident prevention. This has resulted
in accidents reduction year after year. In short, there has been reduction in the no. of
accidents by 88% as compared to 1998.
Figure - 2
Nos
700
600
500
400
300
200
100
0
590
Base year 1998
211
1998
1999
88% % % %
117
78
93
69
2000
2001
2002
2003
Year
Employees active participation and sense of ownership have resulted in work place
reorganization, plant layout improvement, elimination of wasteful process / activities. This
has accelerated the process of SHE management and overall improvement in safe working
environment through reduction in operational hassles. This has also contributed in quantum
jump in productivity along with tearing down boundaries.
Figure 3
Training, Education and Awareness Activities
Base year 1998
222% % % %
3000
2549
2500
Nos.
2000
1554
1676
1999
2000
1500
1000
1364
1396
2001
2002
792
500
0
1998
2003
Year
Health
As a policy, we are exceeding the target set before us by statutory bodies for periodic health
check-up of all employees in the organization. Special care is being taken for employees
working in hazardous areas. Grasim Jana Kalyan Trust has got 123 beds Hospital with indoor
and outdoor facilities and medical check-up of all kinds including major operations. The
hospital facilities are also available for surrounding rural population. The 18 member
competent team of Doctors, Surgeons, Specialists are catering to the needs of all kinds of
patients round the clock. Facilities like ICU, Mobile Van and Visiting Specialists are taking
care of children and aged persons.
Health is Wealth and Service to Mankind is the best way of Worship This has been
motto of Grasim Jana Kalyan Trust. Under this, twice a week a team of Medical Officers
visits remote areas and renders free treatment for rural population. Serious cases are
immediately looked after and the patients are hospitalized for treatment.
Under Grasim Rural Community Development programme, Cataract eye operation, Polio
corrective surgery, ENT, Family planning and Tuberculosis camps are being regularly
organized at Indu Bhai Parekh Memorial Hospital of Grasim Jana Kalyan Trust, Birlagram
Nagda at free of cost for poor and needy people in and around the township.
Environment
Grasims prime concern has been to protect, preserve and improve the environment in and
around its industrial complexes. Grasim believes that it is possible to enjoy the benefits of
modern technology and industrialization without damage to the ecology and environment of
the country.
Our motto is to keep and maintain LAWN green in and around this industrial complex where
L stands for Land Pollution, A stands for Air Pollution, W stands for Water Pollution and N
stands for Noise Pollution.
Several innovative steps have been taken for recycling and utilizing waste water and for
improving the recovery of chemicals from effluent discharges and gaseous emissions. Treated
effluent from Staple Fibre plants has been successfully used for local irrigation. The Effluent
Treatment Plants are most modern and employing latest state of the art technology and
equipment design.
On-site and Classroom training on use of Safety Appliances and Fire Fighting
Equipment.
On-site Emergency Mock Drills at odd hours for emergency preparedness and
response.
Step - 2
Monitoring of SHE activities and feedback to Shop Floor employees on:
Accident Analysis.
Step - 3
Motivating shop floor employees
To improve SHE Work Culture through:
Celebration of National & Industrial Safety Day, Fire Service Week and World
Environment Day
Zincfree Process Technology was developed by Birla Research Institute, Nagda and
successfully implemented at Staple Fibre Division, Nagda for the First Time in the
World. Till date, this has been patented 15 countries including India, USA, Belgium,
Australia, UK, France, Sweden etc
Monitory impact of Raw Material input reduction is Rs. 19.06 Crores at actual
production level for the year 2003 04 (refer Table 1)
Man-Made Cellulosic Staple Fibre have been produced the world over, by the
conventional "Viscose" Process, right since the beginning of this century. Of late,
however, considerable R&D work is going on for producing the same by direct
dissolution of cellulose in a Solvent. This Solvent can be washed off from the spun fibre
and recycled back for dissolution. Thus the process becomes a "closed process" with
minimum possible waste generation and emission.
The direct production of Cellulosic Fibre, using Solvent Spinning Technology has some
commercial advantages over the Viscose route. There is much less chemical usage, fewer
process steps, no by-product formation. Eco-friendly. It is also simpler.
c. Utilization of Waste
Incineration of Effluent Treatment Plant (ETP) Sludge
With the plant scale successful implementation of Zinc-Free Process Technology, the
ETP Sludge has become non-hazardous in nature. We have developed suitable
technology for drying dewatered sludge taken out from Belt Presses. With this, the entire
sludge is being incinerated in existing coal fired Boilers.
Hence, ETP Sludge is fully utilized and disposal problem is completely eliminated. In
economic terms, saving equivalent of about 8 T/ day of Coal achieved.
Effluent Load:
RESOURCE CONSERVATION
Water Conservation
Over the years, various innovative measures have been taken for conservation of water.
Broadly, various water conservation measures can be categorized as under:
Figure 4
275
300
250
Water Conservation
200
200
125
150
M3/T Fibre
100
80
60
50
41
42
49
0
1980-81 1982-83 1992-93
1999-00 2000-01
Recycling of various effluent streams within the plant to the maximum possible extent.
Figure - 5
Graph Showing Progressive Reduction in Specific Chemical & Specific Power
Consumption
200
Percentage
160
Fibre Production
120
100%
Sp. Chem. Cons.
80
Sp. Power Cons.
40
0
8081
8283
8485
8687
8889
9091
9293
9495
Year
ENERGY CONSERVATION
Rayon plants require considerable quantities of process steam and power. Rather than
generating them separately, properly designed co-generation plants can meet the process
steam and power requirement, economically and with lower emissions.
Steam
Steam consumption has been reduced by more than 38% by introduction of Multi-Stage
Flash Evaporators (MSFEs), Acid Absorption Crystallizers, Multi-effect Anhydrous
Evaporators and by using of steam in lieu of water in Cutter Venturies.
Figure 6
Steam Consumption
14
13.5
12
9.17
T/T Fibre
10
7.94
7.51
7.68
8.31
8.29
8
6
4
2
0
1980 - 1981 1998 - 1999 1999 - 2000 2000 - 2001
2001-2002
2002-2003
2003-04
Present steam consumption level is 8.29 T/T of Fibre against the one-time 13.5 T/T of
Fibre. This has resulted in steam saving equivalent to 1792 TPD for 344 TPD Fibre
Production.
Power Conservation
Power consumption level at Nagda have reduced from 1750 kwh/T of Fibre to 1144 kwh/T
of Fibre over the years thereby saving 8.69 MW of power for a production level of 344
TPD fibre.
Through continuous efforts, specific consumption of chemicals as well as energy in the
production process have continuously reduced.
Figure 7
Power Consumption
1900
1700
1500
1300
1100
900
700
500
300
100
1750
1362
1980 1981
1998 1999
1254
1999 2000
1107
1108
1098
1144
2000 2001
20012002
20022003
20032004
Installation of :
Twin Roll Presses in place of Conventional Sieve Band Presses for Viscose
making.
Bigger size Mixing Condenser (1400 mm diameter) in all Multi Stage Flash
Evaporators.
Additional Multi Stage Flash Evaporator and idling down non-economical Double
/ Triple Effect Evaporators.
Counter flow Cooling Towers with RCC structure in Sulfuric Acid Plant.
Figure - 8
Graph Showing Progressive Reduction in Pollution Load
Percentage
200
Fibre
Production
150
100 %
100
Flow Rate
50
SS
BOD
Zinc
Year
SHE ACHIEVEMENTS
The company is accredited for IS/ISO 9001:2000, 14001, OHSAS-18001 and SA-8000.
First company in the World to have pioneered and implemented an innovative Zinc-Free
Process Technology for Viscose Manufacturing, thus eliminating Heavy Metal from
product and environment. No other VSF producer in the world has been able to do so.
This has been patented in 15 countries.
Viscose Staple Fibre, product, is Certified by BTTG Manchester, UK for free from
harmful substances under Oeko-Tex Standard 100 certification.
Innovative methods adopted looking to 50 years old Industrial Set-up to create Safety
Awareness in different section of the plant Photographs on Unsafe and Safe way of
doing things displayed
On-site Emergency Plan approved by The Director (Industrial Health & Safety)
On-site Emergency Mock-drill being conducted without specifying date, time and
location in the Organization and response is found Excellent in 98% of the cases.
Periodic Audit carried out for all lifting equipment to check conditions and design
aspects.
Most Modern Effluent Treatment Plants for Industrial and Domestic Effluents. 100%
Survival of Fish in 100% Effluent confirms excellent quality of Treated Waste Water
More than 80% utilization of Power Plant Fly Ash for manufacture of Bricks etc. year
after year. Grasim is the only company in India utilizing fly ash of this order and far
superior than the world average of 32%.
39%
35%
100%
10%
Pulp
10 %
H2SO4 7 %
Caustic Soda
8%
Actual results of Air, Water and Hazardous Waste are far superior then the limits
prescribed by Pollution Control Authorities.
Ecological Indicators
Quality of Air, Water, Soil, Crop and Plant Response, Bio-mass Production and Bio-diversity
is better or comparable at Nagda than surrounding villages.
Socio-Economic Indicators
Population Growth, Health Care and Educational Facilities, Individual Income/ Savings and
Revenue Collection are better at Nagda as compared to surrounding villages.
AWARDS
2004- The 2004 Stockholm Industry Water Award.
2003- Greentech Gold Award for Environment Excellence.
2003- PCRA Award for Energy Conservation from Ministry of Petroleum and Natural
Gas, Govt. of India.
2002- Rajiv Gandhi National Quality Award- Commendation Certificate.
2002- AVB Group Chaimans Silver Award for Manufacturing Excellence.
2002- ICMA.Award for Excellence in Management of Health/ Safety/ Environment for
the year 2001-02.
2002- ICMA Acharya P C Ray Award for Development of Indigenous Technology for
the year 2001-02
2002- Greentech Industrial Safety Platinum Award.
2002- Golden Peacock Environment Management Award from World Environment
Foundation.
2002-CII-Inter Industry Competition on Industrial Safety, Health and Environment
Management Award, Western Region.
2002-Indira Gandhi Memorial National Award for Best Environmental and
Ecological Implementation.
2001-Indo-German Greentech Environment Excellence Award.
2001-National Energy Conservation Award from Ministry of Power, Government of
India.
2001-Oil Conservation Award from The Ministry of Petroleum & Natural Gas,
Government of India.
2000 -M.P. State Level Award for Best Performance in the field of Pollution Control
and Protection of Environment.
LOOKING AHEAD
The green productivity management policies and practices adopted by Grasim have paid rich
dividends. However, what is more important is that it has infused an across-the-board culture
whereby the rank and file of the organization has become aware of the potential and
importance of involving human resources & innovative upgradation of technology for
management of environment to achieve Sustainable Development.
And the journey continues
Table 1
Raw Material Savings
Particulars
1996-98
Kg/ T F
Rayon Grade Pulp
Zinc
Caustic Soda
Sulphuric Acid
Carbon Disulphide
Lime
Avg.
1042
2
567
767
175
65
2003 -04
1010
0.0
551
744
162
56
Reduction
Impact
36
2
16
23
13
9
Rs./T F
968
106
176
43
205
16
Table-2
Fly Ash Utilisation
Fin. Year
Generation
Utilization
Utilization
1994 - 95
1995 - 96
1996 - 97
1997 - 98
1998 - 99
1999 - 00
2000 - 01
2001 - 02
2002 - 03
2003 - 04
(MT)
131627
127368
150858
150020
145321
181069
212640
234086
`201806
224913
(MT)
124336
112856
144388
126567
137702
180300
171333
200229
169323
194273
%
95
89
96
84
95
99
81 *
86 *
84 *
86 *
Table-3
Water Conservation
Year
1980 - 81
1999 - 00
2000 - 01
2001 - 02
2002 - 03
2003 - 04
M3/T Fibre
275.0
80.1
59.6
41.1
42.3
48.8
Vitae