Resource detail

Challenge: The Hazira manufacturing unit of RIL (Reliance Industries Ltd) located in Gujarat produces polyester products worth annual turnover of Rs 175 billion. The manufacturing process generates huge amount of pollutants including ETP sludge, spent catalysts, PTA incinerator ash, coke, bottle waste, spent batteries as solid wastes. Large quantity of pollutants increase both air and water pollution level in the locality. A tested environment management system is necessary to abate increased pollution level in the plant.

Initiative: RIL is committed to the abatement of water and air pollution and also an effective hazardous waste management system in place. In the process RIL Hazira has commissioned world’s biggest polyester recycling facility. It also collects polyester and PET bottle waste of 40 more producers. The project implemented by RIL Hazira aimed not only at maximizing the recycling of polyester waste, but also at increasing the production capacity of fiberfill and reducing its production cost by minimizing the consumption of oligomer, toners, catalysts, and other high cost items. A four phase project was designed for the period of 2002-2007. The first phase revamped the PFF (polyester fiberfill) project and resulted in an increase of production capacity upto 82 MTD. The Phase -2 was the commissioning of post-consumer use PET bottles recycling system. The Third phase entailed the increase in water recycling quantity with a corresponding decrease in virgin through a Six Sigma project. The final phase was used for maximization of waste recycling in all forms. At present, plans are in place to further decrease the 25% virgin oligomer component in production process while increasing production volumes.

Outcome/Benefits: The major benefits from the project include value addition to potential pollutants, environment protection, additional employment generation, and improvement in the living standards of ragpickers. In addition, sizeable monetary benefits in terms of cost saving and higher production were also achieved.

Commercially tested: Yes