1

Page 111/02/2014

Raghu Babu NukalaDeutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH

Layout Planning of

Chemical Industrial Parks

Page 2

Layout Planning of Chemical Industrial Parks: Some Core Issues

11/02/2014

» Improper siting of chemical industrial parks

» Unplanned development and haphazard land use changes

around Industrial Parks

» Disaster management aspects not integrated into Layout/Site

Master Plans of Industrial Parks

» Lack of guidelines, criteria etc. for planning of industrial parks

» Lack of capacities for proper layout/site master planning of

industrial parks

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Page 311/02/2014

Si te

Site Selection

Site Master Plan

Contents of the Presentation:

Layout/Site Master Planning• Existing standards/criteria/

guidelines for planning• Case examples• Some criteria for planning

Siting aspects• Industrialisation trends• Siting approaches• Siting criteria

Recommendations

Page 411/02/2014

Layout/Site Master Planning of Chemical Industrial Parks

S i t e

Site Selection

Site Master Plan

3

Page 511/02/2014

Industrial Park Level:

» Indian Green Building Council (IGBC) - Green

SEZ Rating System, Green Townships (India),

Green Landscape

» UN indicators for sustainable development

(UNDESA 2007)

» OECD Green Economy Indicators

» Chinese Eco-Industrial Park Standard

» Chinese ISC Guide for Low Carbon Industrial

Zones

» Indicators of Kaiserslautern University of

Technology

» Indian Green Building Council (IGBC): Green

SEZ Rating System

» DGNB (German Sustainable Building Council)

Some Reference Criteria

» Guidelines for Planning Mega

Project, Punjab

» Guidelines for Planning Industrial

Estates, 2011, Gujarat

» Industrial Policy 2007, Tamil Nadu

» Industrial Policy 2011, Haryana

» Master Plan for Delhi – 2021

Industry/Building Level:

» Green Star Rating (Green Building Council of

Australia)

» Energy Conservation Building Code (Ministry

of Power, India)

» Indian Green Building Council (IGBC): Green

Homes, Green Existing Buildings, Green

Factory Building, High-performance

commercial buildings (India)

» LEED (Leadership in Energy and

Environmental Design) Rating System, USA

Page 611/02/2014

» Site selection: site preservation & restoration

» Site planning & design: innovation & design, adaptability & future-

proof

» Resource efficiency (energy, water, materials) - renewable energy;

recycle/reuse of water, materials, energy etc.

» Minimise environmental impacts: wastes, waste water,

ecosystem

» Social infrastructure

» Improved business performance, staff productivity and well-being

» Buildings – materials used, energy efficiency etc.

» Quality site management and administration

Summary of Reference Criteria

Disaster aspects are not reflected in the available Industrial Park criteria/rating systems

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Page 711/02/2014

Green SEZ Rating System for Industrial Estates - IGBC

» Site preservation and restoration

» Reduced use of fossil fuels

» Energy efficiency

» Water efficiency

» Handling of solid waste

» Materials & Resources

» Innovation & Design Process

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» Site Selection and Planning

» Water Conservation

» Energy Conservation

» Material Conservation

» Indoor Environment Quality and

Occupational Health

» Innovation & Design Process

Green Factory Buildings (IGBC)

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Page 911/02/2014

» Environmental quality (effects on the global and local environment;

resource use; waste generation)

» Process quality (participatory planning, detailed and integrated

planning, planning process)

» Socio-cultural and functional quality (social quality; health, comfort

and user satisfaction; functionality; design quality

» Technical quality (technical infrastructure – energy, wastes, etc.;

technical quality – transportation system etc.)

» Economic quality (life-cycle costs of buildings, site development/plan

efficiency etc.)

DGNB Germany Criteria for Industrial Estate Sustainability Certification

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Disaster Management Provisions for Chemical Industrial Park Planning (Germany’s Major Accidents Ordinance

to Industrial Estates)

» “Closed” Industrial Estate: Industrial Estate with common fences,

shared emergency management and shared infrastructure

» Coordinated emergency response and integrated emergency

management

» Joint security service

» Joint emergency management for the whole Park

» Joint fire brigade organised by infrastructure operator

» Fence at the perimeter of the whole Park

» High risk/vulnerability areas may need additional security

Source; Guidance Application of the Major Accidents Ordinance to Industrial Estates (SFK-

GS-44), German Federal Ministry for Environment, Nature Conservation and Nuclear Safety

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Page 11

Case Example: Hoechst Chemical/Industrial Park (Germany)

» Infrastructure company (owned by major operators) responsible

for emergency management and fire brigade

» Joint Disaster Management Plan for the Park

» Joint command centre

» 24hrs/7 days service of “Emergency Managers” and medical

centre

» Senior managers from Park users act as Emergency Director in

case of major incidents

» Internal command with Park Fire Chief and Emergency Director.

Authority may take over in case of outside impact.

» Costs are shared according to risks

Page 1212

Case Example: Bayer Chemical Park, Leverkusen (Germany)

Compact; Well laid out road network; Well defined industrial

blocks/zones, Entry/exit points, Separate provisions for trucks and

passenger cars

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Page 13

Case Example: Shanghai Chemical Industrial Park (SCIP) (China)

11/02/2014

» Emergency Response Centre

» Fire fighting station

» Centralised Industrial Gases: CO2, H2, O2, N2,

Plant air, Instrumentation air

» Centralised Co-generation Plant: Electricity-

600,000kw; Steam：660t/h

» Centralised Incineration facility for hazardous

wastes

» Jetty ,Tank Form and Pipe Racks – for distribution

of chemicals etc.

Page 1411/02/2014

» Information collection and transmission

» Local safety monitoring

» Accident prevention, command and management.

» Public safety/security

» First aid

» Fire Fighting

» etc.

Case Example: Shanghai Chemical Industrial Park (SCIP), Shanghai, China

SCIP Emergency Response Center

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Page 15

1

Medium hazard industry

High hazard industry

Low hazardindustry

Low hazard activity at periphery

Green belt/buffer

Green belt/buffer

Green belt/buffer

Green belt/buffer

Green belt/buffer

Emergency exit

Emergency exit

Emergency exit Emergency

exit

Emergency exit

Fire station

Container terminal

Disaster management facility

Truck parking

Case Example: APSEZ Visakhapatnam

Page 16

Layout/Site Master Plans Provisions for Disaster Risk Management

11/02/2014

» Zoning of industries as per disaster risks

» Adequate entry/exits, emergency exits

» Proper road network (IRC standards) and circulation system, Access

controls

» Separate provisions for passenger and goods traffic, hierarchy of parking

– overnight stay, temporary parking, loading/unloading

» Buffer zones, green belts – industrial park level, zone level, plant level

» Fencing for the whole Park and for sub-zones (as per requt.)

» Emergency Response Centre

» Fire station

» Common infrastructure – tank forms, pipe racks, waste incinerator,

cogeneration plant etc.

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� Specify “disaster management” requirements for

Industrial Parks

� Develop Guidelines for integration of “disaster

management” aspects into Industrial Park Planning

� Develop criteria on “disaster management” for

integration into Industrial Park “Rating Systems”

� Undertake capacity building (organisational and

individual) on planning of industrial parks

Suggestions:

Page 1811/02/2014

Understanding

The Industrialisation Trends

S i t e

Site SelectionSite Master Plan

10

Page 1919

IndustrialClusters

(textiles, electroplating, tanneries etc.)

Special Investment

Regions (SIRs)

(> 100 sq.km)

PCPIRs (Petroleum,

Chemicals & Petrochemical

Investment Regions)

( ≈ 250 sq.km)

National

Investment and

Manufacturing

Zones INIMZs)

(≈ 5,000 Ha)

Industrial Corridors

(e.g., DMIC; BMIC etc.)

Types of Industrial Parks

Page 20

» DMIC: 1,483 km long, 300 km

wide

» Area under Influence: 14% &

Population: 17% of the country

» Total Population: 173.4 Million

» Total Workers: 68.36 Million

» Total 82 Districts of Six States

within the Influence Area

(excluding MP)

» 24 industrial nodes have been

proposed along the DMIC

Example: Delhi-Mumbai Industrial Corridor (DMIC)

Haryana

Rajasthan

Gujarat

Maharashtra

Madhya Pradesh

Uttar

Pradesh

Uttaranchal

Arabian Sea

Dadri

J.N.Port

End Terminals

DFC Alignment

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Page 21

AP PCPIRNational Highway 5Rail Network

SEZ

ONGC Refinery & Petrochemical Unit (1,200 acres)

Gangavaram Port

Visakhapatnam Port

Pharma City

(2120 acres)

Logistics Corridor

Coastal Pipeline Corridor

NTPC Thermal Power Plant

Visakhapatnam Airport

Hetro Drugs- USFDA Chemical Zone (400 acres)

SEZ

HPCL – Phase I & II

HPCL NapthaCracker & Aromatic Complex (3500 acres)

Example: Andhra Pradesh Petroleum, Chemicals and Petro Chemical Investment Region APPCPIR)

Page 22

Kutch

Jamnagar

Porbandar

JunagadhAmreli

Bhavnagar

Rajkot

Surendranagar

Banaskantha

Patan

MehsanaHimmatnagar

Kheda Panchmahal

Dahod

Vadodara

BharuchNarmada

Surat

Navsari

Valsad

Anand

Gandhinagar

Ahmedabad

Knowledge corridor

Chemicals, petrochem. pharma, textiles and engineering

Industrial corridor(DMIC)

Gujarat International Finance-Tec City

Bio-Tech cluster

Soda ash and salt-based industries, cement and steel pipes

182 industrial estates across Gujarat

Soda ash and salt based

Engineering and ceramics

18 Captive Ports along 1600 km coastline across Gujarat

Special Investment Region (SIR)

Petroleum and brass parts

Savli Biotech Park

60 special economic zones (SEZs) across Gujarat

Example: Industrial Areas in Gujarat

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Page 2311.02.2014Example: Industrial Areas in Gujarat in DMIC

Page 2411/02/2014

� New industrial areas need land use planning (Site Master Plans,

Development Plans/Regional Plans) integrating “disaster

management” aspects

� Existing industrial areas too need retrofitting integrating

“disaster management” aspects

(over 2,000 industrial estates exist in the country)

Suggestions:

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S i t e

Site SelectionSite Master Plan

Understanding

Siting Aspects

Page 26

Human habitat

Ecosystem service areas: Forests

Ground water

Surface water bodies

Public water supply areas

Eco sensitive zones –national parks, wildlife sanctuaries etc.

Monuments, historic places

Scenic areas, nature conservation areas

Atmospheric emissions

Water pollution

Solid/haz. wastes

Disaster risks

Resource consumption

Source Receiver

Energy consumption

Impact

Potential

Agri. Lands

Proper site selection is important to minimise disaster risks

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Associated Activities/Land Uses with Industrial Parks and Investment Zones

Industrial

Industrial

Industrial

Industrial

Industrial

Industrial

There is need for planning and regulating land uses around industrial areas for minimising disaster risks

Page 28

Land Use Planning of Industrial Areas

11/02/2014

The state / local level authorities such as:

» industrial Development Corporations

» infrastructure Development Boards

are identifying locations for:

» industrial estates,

» investment zones / regions, and

» industrial corridors, and

preparing development / master plans. (e.g.

Dholera Special Investment region of DMIC by

the Gujarat Infrastructure Development Board)

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Page 29

Example: Dholera SIR (Gujarat)

Source; Presentation on “Industrial Park Development In the State of Gujarat”, by Gujarat Infrastructure

Development Board, Oct 2013

Total Area

(including 22

villages)

90,370 ha

Total Jobs 827,000

Industrial, Tourism &

other Jobs

343,000

Support Jobs 484,000

Supported population 2.5 million

Population living in

DSIR2.0 million

Page 3011/02/2014

» There are 1,666 MAH units in India.

» Out** of 602 districts in India, 263 districts have MAH units.

» 170 districts have clusters of more than 5 MAH units

(hazardous/industrial pockets).

** Source: Dr. Anil K. Gupta, Associate Professor, Sreeja S. Nair, Assistant Professor, NIDM, New Delhi;

Presentation on “Siting of Industries in a Multi-hazard Environment- Risk Mapping and Knowledge

Management’”,

Declare Major Hazard Vulnerable Areas and set timeframe for preparation of Land Use Plans by state agencies� Areas with “Major Accident Hazard” industries � Areas with major accident hazard activities, other than industries: include areas

with gas/chemical pipelines, ports/harbours, storages of chemicals etc.� Areas prone to natural disasters

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Page 31

� All forests

� National parks,

Sanctuaries and other

critically ecologically

sensitive areas

� Monuments

� Tourist sites

� High land capability areas

� High physiography areas

� Organised bathing places

� Flood prone areas etc.

Site Selection Approach: Example of Zoning Atlas of CPCB

Step 1: Elimination approach - Mapping of areas to be avoided

Page 3211.02.2014

LegendLowHighMedium

Land Use Sensitivity

High

Medium

Low

Dispersion Sensitivity

L e

Disp.

Land Use

High Med Low

High High High High

Medium High Med Med

Low High Med LowL e g en d

L o wHi g hM e d iu mS en s i t i v e Zo n e s

Air Pollution Sensitivity

Risks due siting of air polluting industries

Overlay Matrix

Step 2: Risk assessment

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Page 3311.02.2014

Leg end

All a ir po llu ting indu stries

Me dium air po lluting in du stries

Se ns it ive zo ne s

All w ater p ollu ting indu strie s

All w ater a nd a ir po llutin g ind ustries

All w ater p ollu ting a nd m ediu m air p o llu tin g ind ustrie s

Me dium wa ter po llutin g indu stries

All a ir and me dium w ater po llu ting indu strie s

Me dium air and w ater pollu tin g ind ustrie s

Mo derate w ater p ollu ting ind ustrie s

All a ir po llu ting and m ode rate w ate r po llu ting in dustries

Mo detate w a te r and m e dium air pollu ting in dustries

Step 3: Site suitability assessment for industries

Page 3411/02/2014

Step 1: Exclusion Analysis: Conservation areas; Historical and

archeological sites; Wetlands; Landslide prone areas; Federal lands; Natural reserves; Soils of agricultural significance; Coastal barriers; Schools etc.

Step 2: Inclusion Analysis: Flat land (<21% slope), Process water supply -

less than 3 miles; Proximity to major Highway Network – less than 3 miles; Accessibility to a 115KV or 230kv sub-station for power production – less than 2 km; Proximity to sanitary sewer line – less than 3 miles; Wastewater treatment plant –less than 3 miles etc.

Step 3: Suitability Analysis (weightage)

Step 4: Comparative Assessment of Sites

Step 5: Site selection

Site Selection Approach: Example of Renewable Power Generation and Resources

Recovery Facility, Puerto Rico

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Page 352/11/2014

Source: Presentation on “SITING OF INDUSTRIES IN A MULTI-HAZARD ENVIRONMENT- Risk Mapping and Knowledge

Management’”, Dr. Anil K. Gupta, Associate Professor, Sreeja S. Nair, Assistant Professor, NIDM, New Delhi

Site Selection Approach: Methodology from NIDM, New Delhi

Page 36

Hazard IdentificationAll hazards have to be identified comprehensively and systematically ...

• eg. „classical“ EHS-hazards, loss of production, ... Operation

hazards

Network

hazards

Environmental

hazards

• eg. failure of utilities, supplies, transportation ...

• eg. natural hazards, adjacent plants and traffic ways, ...

• eg. densely populated areas/buildings, natural reserves, ...Environmental

vulnerability

• eg. plant vulnerability, neighbourhood/environment sensitivity, company image, ...

Terrorist threats

36Source: Presentation on “European Best Practice for industrial Disaster Risk Management (iDRM)”, Dr. Christian

Jochum, InWEnt Senior Advisor (www.inwent.org), Director of Centre, European Process Safety Centre ,

Chairman, German Commission on Process Safety

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Page 37

DGNB Germany Criteria for Industrial Locations

11/02/2014

» Life Cycle Assessment (resource consumption and emissions)

» Water and Soil Protection

» Changing Urban Microclimate

» Biodiversity

» Environmental Risks [Indicators: earthquake; avalanches; storm; flood;

landslide, soil subsidence]

» Land Use [Indicators: proportion of fallow land; area integration; area

pollution]

» Total Primary Energy Demand

» Resource-efficient infrastructure

» Drinking Water Demand and Waste Water Volume

Page 38

Safety distances –

mandated in line with

Germany’s major

accidents law under

Federal Pollution

Control Acts

(based on long term

operating experience

and analysis of major

accidents)

www.kas-bmu.de

Safety DistancesCommission on Process Safety (German Federal Ministry for Environment

- BMU)

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Page 3911/02/2014

1. Undertake district-wise risk assessments and identify areas to

be avoided for MAH Units.

2. Develop siting criteria for MAH Industries and other

installations.

3. Notify Safety Distances.

4. Identify “Major Hazard Vulnerable Areas” and direct state

agencies to prepare Land Use Plans (development

plans/regional plans/master plans).

5. Specify “disaster management” requirements for integration

into Industrial Parks.

Recommendations:

Page 4011/02/2014

Recommendations:

5. Develop Guidelines for integration of “disaster management”

aspects into Industrial Park Layout/Site Master Planning.

6. Develop Criteria on “disaster management” for integrating into

Industrial Park rating systems.

7. Apply for all new industrial areas and investment regions,

8. Retrofit existing/old industrial areas.

9. Undertake capacity building (organisational and individual) on

planning of industrial parks.

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Page 41

Thank You

11/02/2014

Raghu Babu Nukala

Indo German Environment Partnership (IGEP) Programme

Senior Technical Advisor & Programme Coordinator

Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH

3rd Floor, B5/2 Safdarjung Enclave

New Delhi 110 029T +91 11 49495353, Ext: 2358

F +91 11 49495391

E: nukala.raghu@giz.de

I: www.giz.de; www.ecoindustrialparks.net

Page 4211/02/2014

Ongoing Site Master Planning Activities with GIZ Support

Women entrepreneurs

industrial park (AP)

APSEZ (AP)

Green Industrial park AP)

Multi-product

SEZ (AP)