Sustainability is a key focus area at Indorama India Private Limited (IIPL). Several measures have been undertaken at both of our plants to reduce our carbon footprint, effectively manage waste, recycle plastic, mitigate pollution, and conserve water. We have diligently established all the necessary systems to ensure strict adherence to ESG norms, especially those laid down by the Ministry of Environment, Forest, and Climate Change under the Government of India.
Energy efficiency and conservation
- At the Haldia plant, an 8.3 MW steam turbogenerater has been installed to harness the waste heat generated by the sulphuric acid plant, significantly decreasing our reliance on grid power and reducing the carbon footprint of our manufacturing process. Our efforts have led to a 31% reduction in greenhouse gas emissions, dropping from 0.036 CO2 per tonne of production in 2020 to 0.0247 CO2 per tonne of production in 2021.
- Both Haldia and Jagdishpur plants have replaced conventional lighting with LED lights to improve energy efficiency.
- All fertiliser plants at Haldia employ renewable energy sources and carbon-neutral fuels, such as biomass briquettes, in lieu of fossil fuels like furnace oil. A new biomass briquette-based hot air generator was installed at the DAP-2 plant in December 2020.
- Taking a significant stride towards decarbonisation, both plants are transitioning to solar power. The Haldia plant is currently in the process of setting up a 500 kWp solar power plant, while the Jagdishpur plant has a solar power capacity of 130 kW.
- An upgraded Advanced Process Controller (APC) was installed at Jagdishpur’s ammonia and urea plant, leading to a reduction in specific energy consumption by 0.012 Gcal per MT of urea.
Water conservation and effluent recycling
- In July 2022, a 40m3/hr effluent recycling plant was successfully commissioned to achieve zero effluent discharge. This plant comprises a High Rate Solid Contact Clarifier (HRSCC) as well as Ultrafiltration (UF) and RO systems. As a result, there is no longer any effluent discharge into the green belt canal, leading to a substantial decrease in freshwater consumption.
- The Haldia plant boasts an impressive rainwater storage capacity of 7000 m3. Rainwater is utilised in the manufacturing process, further reducing our need for freshwater consumption. The Jagdishpur plant has also developed and commissioned a rooftop rainwater harvesting system and a groundwater recharge pond.
- Effluents and wastewater generated at the Jagdishpur plant are treated in effluent treatment plants before being supplied to the irrigation network within the factory and township.
- A total of 39,93,924 m3 of water was conserved through the recycling of condensate and boiler blowdown at Jagdishpur.
Green belt development
- Both the Jagdishpur and Haldia plants boast lush green belts that cover 33% of their respective premises, demonstrating their strong commitment to environmental preservation. This helps mitigate the impact of pollutants from their manufacturing processes.
- During the monsoon season of 2022, the Haldia unit collaborated closely with the local municipality to plant over 5,000 trees at strategic locations within the city. This initiative was aimed at promoting ecological sustainability in Haldia.
- The Jagdishpur team frequently organises training programmes and poster-making competitions to raise awareness about environmental protection among employees and contractors.
Waste utilisation
The Haldia plant implemented an innovative solution to eliminate SO2 and acid mist generated by the sulphuric acid plant. Through the application of ammonia scrubbing technology, the plant generates ammonium sulphate which is then used in the DAP plant as a nutrient carrier. This ensures the release of clean gas into the atmosphere. The technology behind this process was officially granted a patent in January 2023.
Plastic waste collection and recycling
Both the Haldia and Jagdishpur plants have adopted responsible manufacturing practices in alignment with the Plastic Waste Management Rules, 2016. Plastic waste is collected and recycled through a contract waste management agency.
Pollution control
- To ensure that emissions remain within the ‘consent to operate’ limits, the DAP, NPK, and SSP plants at Haldia are equipped with cyclones and multistage scrubbing systems, while the sulphuric acid plant employs an alkali scrubbing system. Online analysers are in place at all plant stacks to monitor emissions of PM, NH3, fluoride, SO2, and HF. This real-time data is linked to the CPCB server.
- The Haldia plant also features a robust effluent treatment and recycling plant with a 40 m3/hr capacity, in addition to a sewage treatment plant with a capacity of 160m3/day. Industrial effluent undergoes physicochemical treatment, while domestic effluent is treated using an activated sludge process. The treated effluent is further utilised in the manufacturing process.
- The Haldia plant has initiated a daily practice of water sprinkling during the winter season to mitigate air pollution, following the guidance of the WB Pollution Control Board and Haldia Development Authority.
Soil health testing
Soil testing plays a critical role in understanding the existing nutrient composition of the soil and identifying any nutrient deficiencies. This practice helps provide farmers with tailored fertiliser recommendations that, in turn, improve soil health and lead to higher crop yields. In FY23, IIPL conducted 27,146 soil sample tests across all operational zones.
