Overseas Training Programme on “Eco-Industrial Estate Development and Transformation”

ASEM Programme: Pilot Project on Developing Eco-Industrial Estates in Andhra Pradesh (EP-EIE-6)

Report on the Coaching of Key Personnel and Overseas Training Programme on “Eco-Industrial Estate Development and Transformation”

November 26th to December 5th, 2006

Coaching of Key Personnel and Overseas Training Programme on Eco-Industrial Development and Transformation – India/Germany

Contents

1 BACKGROUND, OBJECTIVES AND EXPECTED RESULTS...... 1 2 VISITED INSTITUTIONS AND ITINERARY...... 3 3 PARTICIPANTS ...... 4 4 OUTCOMES...... 5 5 SUMMARIES OF THE VISITS ...... 7 6 CONSOLIDATED SUMMARY OF THE EVALUATION...... 26

I Coaching of Key Personnel and Overseas Training Programme on Eco-Industrial Development and Transformation – India/Germany

1 Background, Objectives and expected Results

The Coaching of Key Personnel and Overseas Training Programme on Eco-Industrial Development and Transformation is part of the Human Resource Development Programme on Environment jointly implemented by Minsitry of Environment and Forests, GoI, InWEnt and GTZ-ASEM. InWEnt was responsible for concept development and coaching, whilst GTZ-ASEM was responsible for overall co-ordination, organisation, logistics and linking of the activity to the ASEM Programme “Pilot Project on Developing Eco-Industrial Estates in Andhra Pradesh”. Senior level key personnel for industrial estate development and transformation were identified as target group of the measure. Target organisations were the Andhra Pradesh Industrial Infrastructure Corporation (APIIC), AP State Pollution Control Board, Central Pollution Control Board, and the Ministry of Environment and Forests, GoI.

Based on preceeding activities like a rapid Training Needs Assessment in AP and previously gained lessons learnt, the following objectives and expected results had been agreed upon: Objectives 1. APIIC’s capacity to successful develop, market and manage (eco)-industrial estates is strengthened. 2. SPCB’s capacity to support the respective planning and transformation processes is strengthened. Expected Results 1. Participants have a sound understanding of the eco-industrial approach and its potential for sustainable development in India. 2. Participants are familiar with the required planning and clearance processes (internal and external, spatial planning dimension), and infrastructure and service elements in (eco)-industrial estates based on best practices in Germany and can transfer these to the Indian background. 3. A list of further capacity building requirements regarding (eco)-industrial estate planning, marketing and management is compiled.

In detail the measure aimed to strengthen awareness, knowledge and skills of the participants in the following fields: Awareness • To be aware of the concepts of eco industrial estates and sustainable industrial estate development - different types of emergence and organisation are possible to initiate/transform EIE; • To be aware of global trends in (eco)-industrial estate development and environmental management; • To be aware of the spatial standards, environmental standards etc., norms and guidelines for estate development; Knowledge • Knowledge of a tool box for planning and marketing of (eco)-industrial estates Site master planning, EIA for industrial estates Infrastructure planning & design Estate management including:

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→ Organisational structures → Industrial estate information management → Emergency and environmental management → Common services and modes of delivery of facilities and services → Funds and financial management • Marketing – prior marketing analysis, site marketing Skills • Transformation of international best practices to the Indian context • Methods and strategies for EIE presentation and dissemination of results to other result users

The following table shows the contents / topics being focussed during the training: Content Related topics 1. Integrated planning of (eco)-industrial • Legal framework estates • Identification of suitable sites • Needs analysis • Market analysis • Planning process • Cooperative solutions – processes, problems, strategies • Spatial planning 2. Management of (eco)-industrial estates • Pollution control including organisation and delivery of • Resource efficiency central services, risk assessment and emergency response • Outsourcing of services • Facility management • Internal and external coordination mechanisms • Logistics 3. Eco-industrial estates approach • Policy issues • Public support (incentives etc.) • Specification of the eco-industrial approach 4. Marketing of (eco)-industrial estates; • Market analysis appraisal of added value of eco-industrial • Marketing tools and strategies sites compared to common ones • Added value of eco-industrial measures

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2 Visited Institutions and Itinerary

The following table gives an overview on the visited institutions and the itinerary of the travel. Addresses, contact persons of the institutions, core issues of the visits, an overview of the discussions and a list of the presentations and relevant secondary documents and information are given in chapter 5 Summaries of the Visits. The list of presentations and secondary documents is directly linked to the related files.

Day Location Visit at Organisation Model, Branches, Issues Sun Arrival (26.11)

Mon Frankfurt LUFTHANSA Technical Tasks of the unit and training approaches for (27.11) Training Unit maintenance, repair and operation of aircrafts site visit Nuernberg Municipal Planning Role of municipalities in the planning process for Authority Industrial Estates

Tue Nuernberg Industrial Estate Organisational Model, decision making, marketing, (28.11.) Nuernberg-Feucht- tasks (local administration and authority), central Wendelstein services Rudolstadt INTROTEC ltd. Central services: operation and management of an Industrial Site Schwarza industrial effluent treatment plant, hazardous waste management and deposition

Wed Rudolstadt State Development State Development Agency Thuringia responsible for (29.11.) Agency Thuringia conversion of industrial sites; remediation of Industriepark Rudolstadt- contaminated sites; process of conversion, Schwarza cooperation with authorities, clearances, infrastructure development; industrial development strategies in the context of “Regional Development”; soft and hard factors for the siting of industry and commerce; Zweckverband Central Services: construction, operation and Abfallwirtschaft Saale- management of a waste incineration plant; Orla EMS – Energie- und Central Services: operation and management of Medienversorgung energy and media supply; Schwarza Engineering and Planning process for industrial sites; Progetmanagement Consulting ltd.

Thu Eschborn GTZ Workshop on EID: “Site planning and risk and (30.11.) emergency concepts”

Fri (01.12.) Hoechst Industrial Park Hoechst Former Hoechst AG estate, conversion to an estate comprising a great variety of companies; Operating company for the site, logistics, services;

Sat Leverkusen Day off - (02.12.)

Sun Ruhrgebiet Guided Tour Conversion of former industrial and minig areas; (03.12) spatial planning, recycling of former industrial areas

Mon Leverkusen BAYER Chemical Park Chemical industries, BAYER special branch (04.12.) Leverkusen companies, electronics, coating industries; Operating company: BAYER Industry Services; great variety of central services

Tue Frankfurt Travel to India (05.12.)

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3 Participants

Participant Institution Function

Mr. D. Chandrasekhar APIIC General manager (EMP) Mr. B.R.K. Sarma APIIC, Head Office General Manager (Projects) Mr. Ch.S.S. Prasad APIIC Deputy General Manager (Engineering) Mr. M. Madhusudhan CPCB, Zonal Office Bangalore Scientist “C” Dr. Jag Ram Ministry of Environment & Forests, GoI Director, Mr. P. Bank Chief trainer ifanos concept & planning, Mr. F. Brunken Driver and guide ifanos concept & planning, Mr. G. Werner trainer ifanos concept & planning,

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4 Outcomes

In general the participants of the programme were very well aware, that a mere duplication of the highly differentiated German concepts would not meet the requirements in the Indian context. Thus the following proceeding was discussed and agreed upon by the participants:

• Analysis of the current status of environmental management systems in existing and planned industrial estates in India (based on the information and material provided during the programme); • Comparative case study on the enforcement of environmental laws in India and Germany, taking also into account the varoius levels of the legal system in Germany (EU, federal, state and local level); Î Identification of the most critical issues from the Indian point of view; Î Priotities of steps and measures for sustainable improvement of the situation in Indian industries (objectives, tasks, timeframe, organisational requirements etc.); Î Compilation of an operational plan; Î Identification of required services and inputs (from industries, research & development, donors (GTZ, InWEnt etc.)); Î Identification of required capacity building and human resource development measures; Î Implementation of the operational plan with support from and in cooperation with competent German partners (InWEnt, GTZ, Bayer IS etc.); Î Initiation and establishment of continuous cooperations.

During the site visits and discussions capacity building / training needs have been identified by the participants in the following fields: Waste Water Treatment Plants (Common and Industrial) • Planning, dimensioning (including sewage system), construction, operation and maintenance; • Separation of storm and waste water; water resources management in gerneral and with respect to industrial activities; • Service contracts with industrial customers (amount of wastewater, loads, information on system failures and shockloads, (self)-monitoring of industries); • Self-monitoring of WWTP; • Human Resource Development; Ecological Compensation • Principles, instruments and legal framework; • Public participation and negotiation strategies; Legal framework • The Federal Immission Control Act and its Ordinances (as central legal instrument for approval and control of industries); • Enforcement of the relevant acts and ordinances (instruments, procedures etc.); • Monitoring and control;

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Disaster Risk Management and Safety • On- and off-site emergency plans particularly for small and medium industries and existing industrial estates with SMEs, enforcement and supporting measures to be taken by the IALAs; • Chemical Safety Management for SMEs; • Work place safety, occupational health and safety;

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5 Summaries of the Visits

Visit LUFTHANSA Technical Training (LTT) Theme Tasks of the unit and training approaches for • maintenance, repair and operation of aircrafts; • other capacity building products; • worldwide locations, Explore the possibilities to set up a Lufthansa Technik facility at new Hyderabad airport. Company Lufthansa Technical Training abstract is an internationally leading training organisation for all staff in aircraft maintenance operations – the Maintenance, Repair and Overhaul organisations (MRO). From basic technical training and type-related further training to management training LTT offers all areas of training which are important for an airline company. In 1999 Lufthansa Technical Training was the world’s first company to be certified under JAR 147 for basic and type training. In addition to technical courses, management courses qualify managers and executives for the growing non-technical requirements. In management training courses expert knowledge in compact form is imparted, for example about the new statutory regulations or stricter quality assurance, as well as team leadership skills and time management. Lufthansa Technical Training adapts all training programmes in the framework of the official requirements precisely to the client’s specifications and needs. Contact Mr. Schmidt-Klyk Address Lufthansa Technical Training Unterschweinstiege 12 60549 Frankfurt T: +49 (0)69 69 64 178 www.ltt.de Main issues Central issue of the visit was to start communication between APIIC and addressed Lufthansa Technik in order to explore further development options regarding the new international Airport in Hyderabad, AP. Lufthansa Technical Training is member of Lufthansa Technik AG which comprises 28 companies worldwide with a total staff of 25-28 thousand. Lufthansa Technik is member of Lufthansa Group. Lufthansa Technik maintains a world wide network of locations, which are sometimes specialised in particular products / aircraft types (e.g. Lufthansa Technik Philippines is specialised exclusively in C- and D-checks for Airbusses A330 and A340). Lufthansa Technik locations always require training provided by LTT to build the high-level technical capacities and competencies being crucial for Lufthansa Technik’s business. LTT usually cooperates with specialised local training institutions (e.g. in Beijing, PRC, LTT cooperates with AMECO Aviation College and GTZ; the German vocational training concept has been introduced into the Chinese system there.). The existence and accessibility of such resources is a main deciding factor for new locations. In general Lufthansa is looking for further development potentials. Air transport sector is generally expanding. Based on the development figures, lack of MRO

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(maintenance, repais & overhaul) capacities may occur in a few years. Based on this development LT is increasing the number of its locations worldwide. One of the regional markets with highest growth rates is India. Main decision factors for a new location are: How many aircrafts have to be served? How many potential customers are within range of the location (regular destination, or close to another regular destination)? How many aircrafts can be checked / have to be checked simultaneously? Available work space. Availability of necessary resources for LTT (classrooms, workshop facility, an old aircraft for training, local partner)? Cost profiles of the various products in the MRO-business differ significantly. For certain products most of the costs are related to spare parts; for others the biggest part is personal costs. Particularly for these products India with its low labour costs would be an interesting location. Related Presentation given during the visit documents Information brochure on the CD Group foto Other www.ltt.aero Website on technical training, e.g. engine overhaul relevant www.ltthf.com Website on management training (HF = human factor) Websites www.lttal.com Website on aviation legislation (AL = aviation legislation)

Visit Municipal Planning Authority – City of Nuremberg Theme Role of municipalities in the planning process for Industrial Estates and Business Areas Institution The city of Nuremberg is located in the northern part of the federal state of abstract Bavaria. It is the second largest town of the state with approx. 500,000 inhabitants. Nuremberg is the centre of the newly created “Metropolregion Nuremberg”. A “Metropolregion” is a highly densified urban region with a high international importance. The map at the left shows Germany’s 11 “Metropolregions”. The “Metropolregion Nuremberg” has 3.5 million Inhabitants and a gross-domestic-product of approx. 100 bill. €/year. Nuremberg itself has approx. 350,000 Metropolregion Nuremberg working places, 23,000 companies and 40% of its products are exported. The main economic sectors are: mechanical engineering industry, electrical industry, automobile and transportation industry, IT and communication and several service sectors (insurances, marketing research, trade fairs etc.). Several universities and applied science universities are located in the region. The Municipal Planning Authority is closely collaborating with the Municipal Authority for Economic Development to provide the necessary spatial and infrastructure resources for further development. This is not only related to available space for new companies but also to the general quality of life in the city. The central instrument to provide these issues is land use planning.

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Contact Mrs. Elisabeth Meisel Address Stadtplanungsamt Nuernberg Lorenzer Platz 30 90402 Nürnberg T: +49 (0)911 / 231-4900 e-mail: [email protected] Main issues Spatial planning in Bavaria is organised at three levels: addressed • State development planning is performed at state level, the related plan is the state development program. • Bavaria is divided into 18 planning regions with related regional plans. The municipalities have the local planning power; municipal land-use planning has two columns: • the preparatory land-use plan as masterplan, which identifies and determines the development potentials and visions for the municipality for approx. 2 decades; • the legally binding land-use plan, which is a layout-plan for particular parts of the planning area. The land-use planning procedure ensures public and stakeholder participation and participation of public agencies at two stages of the process. The first draft and the draft of the preparatory land-use plan have to be approved by the city council; the final planning has to be approved by the higher authority (in Bavaria at district level). Although public, stakeholder and public agency participation at two stages of the process might result in a long duration of the planning, experience shows that participation is a precondition for trouble free implementation. The different interests can be duly weighed and balanced and conflicts and blockades can be minimised at an early stage. Public agencies who participated in the planning procedure, must adapt their planning to the masterplan to the extent that they have not objected to this plan. New commercial areas are only identified and determined in the preparatory land-use plan. It is local policy in Nuremberg that the municipality does not purchase these areas but only facilitates and moderates the process of realisation with the owners and potential investors. Other municipalities may purchase such areas and then sell the land directly to the investors. The preparatory land-use plan indentifies development potentials whilst the realisation of development projects is regulated by the lagally binding land-use plan, the layout plan. The layout plan defines the local building statutes including an environmental assessment and report. There are two types of layout plans: • The “qualified layout plan comprise and fix type and measurements of buildings as well as amount of sealed and traffic areas. • the “simplified layout plan” do not comprise these determinations. (please refer to Federal Building Code §30, 1 and ,3). In case of simplified layout plans the municipality can conclude a so called “Urban Development Contract” (please refer to Federal Building Code §11) with an investor to fix particular objectives which shall be reached by the particular planning process. The “Urban Development Contract” is a more flexible instrument than the layout plan and can help to gain very specific results, adjusted to a particular situation.

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Related Presentation documents Background data on Nuremberg (2006) on the CD Preparatory land use plan (in German) 11 Maps (not linked) Federal Building Code Urban Development and Urban Policy in Germany Spatial Development and Spatial Planning in Germany Environmental Protection and the Specific Role of Spatial Planning The Regional Planning Procedure Public participation Nuremberg soil conservation concept Soil functions protection Briefing on the economic region of Nuremberg/Central Franconia Other www.stadt-nuernberg.de Official website of Nuremberg, also available in English relevant www.economy.nuremberg.de facts and fugures on local economy, including an Websites industrial estate service portal.

Visit Industrial Estate Nuernberg-Feucht-Wendelstein Theme • Organisational Model: Special Purpose Corporation • Tasks (local administration and authority) • Central Services Institution The Industrial Estate Nuernberg-Feucht-Wendelstein is a joint undertaking of abstract the three communities in its name. It has been established as a conversion project on a former airfield used by the U.S. Army. After the “Wende” the Army withdraw and the area was sold to the three communities by the Federal Government. Due to its location within the borders of three communities the actors had to find a feasible solution to run the estate efficiently and to gain the highest possible advantages for their local development. Contact Mr. Norbert Eberhardt (Managing Director) Address Industrial Estate Nuernberg-Feucht-Wendelstein Am Tower 13-15 D - 90475 Nürnberg T: +49 (0)9128 / 72 42 72 - F: +49 (0)9128 / 72 41 048 E-mail: [email protected] www.gewerbepark-nuernberg-feucht.de (in German only) Main issues The Estate is organized as a Special Purpose Association (Zweckverband) addressed comprising the municipalities of Nuremberg, Feucht and Wendelstein. The Special Purpose Association is acting as local authority having ordinance sovereignty in the area. The tasks of the Association are: • Fulfil the Federal Buidling Code • Administrate procedures of landscape conservation and landscape development • Ensure the supply of electricity, gas, heat and water in the estate • Sewarage and waste water disposal • Infrastructure (streets, channels, etc)

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The Association shall be financed by profit gained from selling the land, which has been realised so far. Services have to be financed by fees) The partition of the communities regarding the area is 48% to Feucht, 32% to Wendelstein and 20% to Nuremberg. Based on the activities and inputs, benefits and charges are divided in 40% each to Feucht and Nuremberg and 20% to Wendelstein. The situation with one city of 500,000 inhabitants and two small communities cooperating in ine organisation has to be duly balanced. The decision making is allocated to the Association Board and the Association Committee. The Committee is running the operational business. Both bodies are manned equally between the partners. The Committee only consists of the three mayors. Decisions in this body can only be taken unanimously. The Chairman position is shifted every two years between the mayor of Nuremberg and Feucht. Unanimous decisions are very important to avoid conflicts of interest and to avoid a 2 against 1 situation. In fact there are several examples when the mayors had to decide against the particular interests of their community and for the interest of the joint estate. Thus the success of the undertaking is highly depending on the personality and the political will of the mayors. Local taxes (business tax and landownership tax) are fixed by the communities and are therefore different within the estate (highest in Nuremberg, lowest in Feucht). The taxes are paid to the respective community. 80% of the paid taxes remein with this commnunity. 20% are given to a joint pot and are re- distributed between the partners according to the 40:40:20 key. Services are organised as follows: • Wastewater is collected and piped to the municipal WWT Nuremberg • Rainwater is separately collected, transferred to rainwater treatment ponds and then discharged to a small creek. This system very cost effective and helps to reduce the fees. For example in Nuremberg all customers have to pay wastewater and rainwater fee, which is depending from the sealed surface area. • Residual waste collection and disposal is the legal duty of the counties and cities. In order to have a single system in the estate, the partners agreed to run the collection and disposal by the City of Nuremberg. Recyclable waste I collected by different service providers. • Energy and water supply are provided by an own company (Gewerbepark Nuernberg-Feucht Versorgungs- und Abwasserentsorgungs GmbH) founded and owned by the partners. Related Presentation documents Group foto on the CD German Taxes Taxes and the promotion of the environment German law on nature conservation German environmental laws

Visit INTROTEC ltd. - Industrial Site Schwarza Theme • Central Services: Operation and Management • Effluent Treatment Plant • Hazardous Waste Management and Deposition Company Introtec Schwarza GmbH is in charge of disposing wastewaters at the

11 Coaching of Key Personnel and Overseas Training Programme on Eco-Industrial Development and Transformation – India/Germany abstract Industrial Park Rudolstadt-Schwarza. Core activities on site include polymer and chemical fibre production as well as the production of unprocessed corrugated cardboard from recycled paper. As main partner, the Veolia Water Germany subsidiary OTWA Ostthüringer Wasser und Abwasser GmbH, has been operating the WWTP since February 2006. Five employees guarantee 24/7 service for currently 17 indirect dischargers. The scope of services comprises technical and commercial operational management of the surface water drainage sewers, a vacuum drainage system, a WWTP with two technically separate treatment lanes, a wastewater sludge landfill, an emergency tank and various runoff structures to discharge purified wastewater into Saale River. The overall treatment capacity is approx. 8,500 cbm/d for an organic load of 400,000 PE. Contact Mr. Gameh (Managing Director) Adress INTROTEC Schwarza GmbH Fritz-Bolland-Straße 6 07407 Rudolstadt Fon:+49 (0)3672 355944 - Fax:+49 (0)3672 355945 e-Mail:[email protected] www.veoliawasser.de/en/ Main issues Ownership and Operation addressed The plant is owned by LEG (Landesentwicklungsgesellschaft Thuringia), which is the owner of the estate at Schwarza. The owner is responsible for renewal activities and other investments. The plant is operated by INTROTEC, which has a 30 years operation contract with LEG and pays a yearly rent. INTROTEC has service contracts with the local companies fixing amaounts and composition of wastewaters, necessary interfaces, fees and payment conditions. These are also 30 years contracts. The customers are obliged to announce new processes, new pollutants or operational disturbances to INTROTEC. Pollution control and monitoring • INTROTEC has to keep the limits given in the operating licence. The required parameters have to be monitored by INTROTEC. BOD and COD have to be checked by INTROTEC in 24h-samples; the daily records have to be kept. • The controling authority undertakes 5-6 unanounced control visits per year measuring an own set of samples. 4 out of 5 samples have to meet the required values. • Ruling acts and ordinances are: The Federal Wastewater Charges Act and Ordinance and the Federal Water Act. • The clients are obliged to report in time on system failures and shockloads; in most cases this system works. In case of not reporting failures, some of the clients might be identified by the specific pollutants emitted by them.

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Related Presentation documents Brochure Veolia Water on the CD Brochure WABAG Trends in water treatment technologies EU Waterframework Directive EU List of prioritary substances German water conservation policy Federal Water Act Wastewater Charges Act Introduction to Federal Wastewater Charges Act Wasterwater Ordinance Federal Flood Control Act Water Resources Management in Germany Part 1 and Part 2 Federal Soil Protection Act Federal Soil Protection and Contaminated Sites Ordinance Threshold Values from Soil Protection Ordinance German Report on Soil Protection Other www.hach-lange.de – analytical test sets, chemicals, measuring devices relevant Websites

Visit State Development Agency Thuringia Industriepark Rudolstadt-Schwarza Theme Conversion of the site by State Development Agency Thuringia: • remediation of contaminated sites; • process of conversion, • cooperation with authorities, clearances, • infrastructure development; Industrial development strategies in the context of “Regional Development”; Soft and hard factors for the siting of industry and commerce; Recycling of abandoned industrial sites for ecological enhancement and urban development; Institution Abstract

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Eco-Industrial Estate Schwarza – site plan

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Contact Mr. Egon Weyh (Industrial Estates and Development) Address LEG Thüringen - Industrial Estate Schwarza-Rudolstadt Breitscheidstraße 152 D - 07407 Rudolstadt T: +49 (0)3672 / 4787-0 E-mail: [email protected]; [email protected] Main issues addressed Related documents on the CD Industrial Policy Chemical parks BMU Memorandum on ecological industrial policy BMU Brochure on corporate social responsibility BMU Brochure on innovative technology for the environment Marketing Investors Guide issued by the Bavarian State Ministry of Economic Affairs, Infrastructure, Transport and Technology Brochure on the Environment issued by the Bavarian State Ministry of Economic Affairs, Infrastructure, Transport and Technology Brochure on Bavaria issued by the Bavarian State Ministry of Economic Affairs, Infrastructure, Transport and Technology

Other www.invest-in-bavaria.com relevant Websites

Visit Zweckverband Abfallwirtschaft Saale-Orla Theme Central Services: Operation and Management Solid Waste Management and Waste Incineration Institution Abstract Contact Dr. Zaso Cichonski Address Zweckverband Abfallwirtschaft Saale-Orla 07381 Pößneck Wohlfarthstraße 7 Phone : +49-(09 36 47- 44 17-0 - Fax : +49-(09 36 47 – 44 17 44 E-mail : [email protected] ; [email protected] Main issues addressed Related documents Schematic plan of the new waste incineration plant on the CD Fotos of the site visit 1 (Chimney), 2 (Chimney), 3 (Group), 4 (Burner House), 5 (Group)

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Background Papers Waste Management in Germany Federal Act on promoting closed substance cycle waste management Closed cycle waste management concept Commercial Waste Ordinance, background Ordninance on Biowaste Treatment Waste balances Waste recovery OECD recommendations on environmental sound management of waste

Other relevant Websites

Visit EMS – Energy & Media-Support Schwarza Theme Central Services: Operation and Management; Energy and media supply Institution The power plant in Schwarza is one of the most advanced plants in Germany. Abstract It is a cogeneration plant using a combined gas-steam-process. This process in combination with an expansion-motor for reducing the pressure of the fired natural gas increases the energy efficiency above 90%. With this rate of energy efficiency the power plant fulfills the requirements of the “Ecological Tax Reform Act”. The plant fulfills also the emission requirements of the “Federal Imission Control Act”. Due to the modernisation since 1990 the smog and pollution situation in the Saale valley has been significantly improved. The plant not only supplies the industrial estate but also SMEs outside the estate, the nearby municipalities of Schwarza and Bad Blankenburg are supplied with heating energy. Contact Mr. Filleböck Address Energie- und Medienversorgung Schwarza GmbH Breitscheidstraße 160 07407 Rudolstadt Phone: +49-(0)3672- 48900 – Fax: +49-(0)3672 – 489019 Internet: www.ems-schwarza.de Email : [email protected] www.ems-schwarza.de Main issues Ownership and Operation addressed • The plant is owned by EMS. EMS is obliged by LEG to offer its services and products at a moderate but cost covering price in order to sustain the competitiveness of the estate and to make it attractive for new companies. • EMS has particular contracts with its customers. • Biogas produced by the WWTP is also used for electricity production. Pollution control and monitoring • Operation of the power plant is ruled by the Federal Immission Control act, the Ordinances for Steam Boilers and Containers under pressure and the Thuringian Water Act, which is based on the Federal Water Act. • The smoke gases have to be continuously monitored by EMS, the records

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have to be kept; unannounced controls are made by the competent authority. • Surface and sanitation waste water is piped to the WWTP operated by INTROTEC. Waste waters from production are partially discharged to River Saale; the discharge is self-monitored by EMS (COD). The competent authority can do unannounced controls. Wastewater from the ion- exchanger is piped to the WWTP. Related Presentation documents Group Foto on the CD Federal Immission Control Act 4th Ordinance on the Immission Control Act (Installations requiring a permit) 13th Ordninance on the Immission Control Act (Large Combustion and Gas Turbine Plants) Technical Instructions on Air Quality Control Inventory of Air Quality and Health Institutions in Europe Ecological Tax Reform Renewable Energies Act National Action Plan on Emission Trading Act on the introduction of project-based mechanisms in accordance with the Kyoto Protocol

Visit Engineering and Projektmanagement Consulting ltd. Theme Planning process for industrial sites Institution EPC Group is specialised in development of innovative, efficient and high Abstract quality processes and industrial plants. EPC was one of the planners of the conversion of the industrial site in Schwarza. EPC Group consits of different companies: • EPC Engineering Consulting GmbH being specialised in industrial plant construction (polyamide polyesters, polypropylene, renewable raw materials, biodiesel etc.), execution of development measures for industrial sites, site management, administration and marketing of industrial commercial buildings and settlement of new investors; • EPC Technology GmbH being specialised in the development of new processes, design and planning of industrial plants particularly in chemical, fine chemical and pharmaceutical industry; • HI Bauprojekt GmbH being specialised in planning of industrial and commercial buildings, traffic facilities and bridge buildings; • EPC Industrial Engineering GmbH being specialised in the plants life cycle for e.g. polymer, textile and technical yarn production; • EPC Anlagenbau Rudisleben GmbH being particularly experienced in plant construction from chemical to food industry in eastern Europe and Asia. Contact Mr. Henkel Address EPC Engineering Consulting GmbH Breitscheidstraße 152 07407 Rudolstadt - Germany Phone: +49 (0) 36 72 / 30 23 00 - Fax: +49 (0) 36 72 / 30 23 77 E-Mail: [email protected]; [email protected]

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www.epc-online.de Main issues Permit Procedures addressed Customer / Proprietor / Investor

Consulting and assistance of permit procedures acc. to Authority BImSchG, acc. to Water and Waste Materials Law Engineering Reply / fulfillment of authority requirements Consulting in application of international law Pinpointing of solutions and technologies in process technology

Construction and operation Authorities of permit-requiring plants

Municipality, admin. Identification of emissions and Coordin district, country immissions, safety-technical ation verification Energy supplier/ Nature of plants, materials, products, admin.unions combustibles, fuels, lubricants

Monitoring of air / noise, EU contract award environmental protection committee

Related Presentation documents Press release on biodiesel plant on the CD

Workshop GTZ - German Agency for Technical Cooperation Abstract Workshop on EID: “Site planning and risk and emergency concepts” Agenda: • Short introduction to the workshop and GTZ (Mr. Janssen, Mr. Glasbrenner) • Industrial Risk Management Approaches of GTZ (Mrs. Klein) • Industrial Risk Management and Environmental Compliance in Germany (Dr. Jochum) • Industrial Risk Management Approach of BAYER Industrial Services (Dr. Waniczek) Contact Mr. Guntram Glasbrenner, Ms. Johanna Klein Address Deutsche Gesellschaft für Technische Zusammenarbeit (GTZ) GmbH Dag-Hammarskjöld-Weg 1-5 65760 Eschborn - Germany Telephone +49 6196 79-0 - Telefax +49 6196 79-1115 e-mail: [email protected]; [email protected] Main issues GTZ can provide service packages on: discussed • Chemical Safety Management for SMEs (Chemical Management Guide and Training programme) • Linkages with s GTZ projects aiming at Eco-Industrial Development and

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Industrial Safety and Risk Management (e.g. PRC, Indonesia, Philippines)

It was agreed upon, that the comprehensive training programme on development, transformation and management of eco-industrial estates currently developed by InWEnt and GTZ will also focus on risk management and emergency issues particularly for small and medium industries and for industrial estates composed by such industries. It was emphasized by the participants that the IALAs (Industrial Areas Local Authorities in AP) would be e.g. entitled to establish own firebrigades for the industrial areas under their responsibility. Related Industrial Risk Management and Environmental Compliance in GER (Dr. Jochum) documents Risk Management Issues in the work of GTZ (Mrs. Klein) on the CD Risk Management Approach Of BAYER (Dr. Waniczek) Group Foto Lunch Group Foto Workshop Federal Legislation 12th ordinance on the Federal Immission Control Act – on major accidents Technical Guidelines by the Federal Accident Commission Guide for identification and control of exothermic chemical reactions Guide for plant safety Guide for retention of hazardous substances Guide on potentially hatadous dust-ais mixtures part I, part II Guideline 23 on Article 7 SEVESO Directive Guideline 24 on Article 9 SEVESO Directive Guideline 31 on safety management systems Guideline 38 on combatting interference by non-authorized persons Guideline land-use planning Report on expecting and auditing installations Evaluation of experience reports on safety checks EU Legislation EU SEVESO Directive Harmonised criteria for EU SEVESO Directive FAQ on EU SEVESO Directive Land use planning guidance according to EU SEVESO Directive International Activities and General Papers Convention on transboundary effects of industrial accidents European Technology Platform on Industrial Safety (ETPIS) – Presentation ETPIS – Summary ETPIS – general presentation on the preparation ETPIS – Vision Paper Fire Safety research Safety for sustainable European industry growth Methodology and structures to prevent hazardous incidents Eco-Industrial development Competence clusters in Germany Chinas guidelines for eco-industrial estate planning Shanghai Eco-industrial Park Studies Other www.kas-bmu.de (Federal Accident Commission; Federal Commission on

19 Coaching of Key Personnel and Overseas Training Programme on Eco-Industrial Development and Transformation – India/Germany relevant Process Safety) Websites

Visit Industrial Park Hoechst Theme Former Hoechst AG estate, conversion to an estate comprising a great variety of companies (80 companies, chemical, process and pharmaceutical industries) Operation and management of the site, logistics, services; Company Competence and Performance and site The Industrial Park Höchst is a state-of-the-art chemical and pharmaceutical abstract site whose full range of services is without peer in the market. With 22,000 employees, the site boasts an optimum infrastructure for more than 80 companies – from multinational corporations to innovative service providers. Being centrally located in Europe’s heartland, near the financial center of Frankfurt, it provides perfect access to international monetary and material flows. What connects the Industriepark Höchst to Hoechst AG? The Industrial Park Höchst was built on the foundations of the Hoechst AG parent plant. Infraserv GmbH & Co. Höchst KG was established in 1998, when Hoechst AG’s individual operations were transferred to independent companies. Its expansion shows no signs of stopping: 2 billion euros were invested in the Park within the last five years alone. This shows that the Industriepark Höchst is an attractive site for companies in the chemicals, pharmaceuticals and process industries. And there are still 74 hectares of fully pre-developed land available for new facilities. Infraserv Höchst: Site operator in Frankfurt-Höchst Infraserv GmbH & Co. Höchst KG operates the Industriepark Höchst. With its proven know-how and maximum reliability, Infraserv enables its customers to focus on their core business. And that boosts their bottom line dramatically. As a leading site operator, the company offers its customers everything they need to make their business successful: from fitting laboratories to providing extensive logistics services to disposing of waste. Contact Mrs. Mayer Address Infraserv - Industriepark Höchst 65926 Frankfurt am Main Telephone: +49 69 305-46300 - Fax: +49 69 305-29029 [email protected] Main issues The presentation given to the participants introduced history and current set-up addressed of the Industrial Park in Hoechst. The main assets like internal structures, logistics, traffic links all over Europe and range of available services were highlighted. A detailed presentation and discussion focussed on the services provided by Infraserv and Infraserv Logistics (e.g. warehousing, transport and cargo handling, distribution, dangerous goods and hazardous materials management, etc.) and the risk and safety management at the site, e.g.: • occupational health and safety concepts and measures, • medical centre at the park; • fire and disaster prevention (chemicals management, security measures, alarm systems, local fire brigade, necessary infrastructure and equipment,

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layout and construction of buildings etc.) • plans for emergency situations and evacuation (escape routes, emergency exits etc.); • information sytems and procedures, safety audits and information of employees • regular training and exercises; • supervision by the competent authority • environmental care (e.g. catch basins for used fire fighting waters); • General Security (e.g. access-control) Related Presentation INFRASERV Hoechst documents Group Foto on the CD Chemicals Management EU REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) Directive EU REACH regulation REACH in brief Guidance on fulfilling REACH How can industry prepare for REACH? Industry’s contributions to REACH Safe use of chemicals under REACH National profiles in chemicals management Deficitis in US and European chemicals legislation Self-responsibility as a regulatory concept Other www.ReachReady.co.uk relevant Websites

Visit Guided Tour to Ruhrgebiet Theme Conversion of former industrial and mining areas; spatial planning, recycling of former industrial areas – demonstration of the concept, organisation, management and final visual appearance Abstract The Ruhr District is an urban area in North Rhine-Westphalia, Germany, consisting of a number of large formerly industrial cities bordered by the rivers Ruhr to the south, Rhine to the west, and Lippe to the north. Although the largest conurbation in Europe, the Ruhr District is not much more than 150 years old – and it is only in these last one and a half centuries that the region has taken on those specific characteristics that make it so unique. In just a few decades, therefore, the process of industrialisation transformed this former agricultural expanse with its small villages and towns into the largest industrial area in Europe. It was much later, in the wake of the achievements accompanying the industrial revolution in the mid-19th century, that coal mining and steel production became possible on an industrial scale, creating work for large numbers of people. As a result of immigration from eastern Germany and Eastern Europe, the population of the area burgeoned and the “Ruhrgebiet” developed into a conurbation of enormous proportions, becoming home to more than five million people. The significance of the Ruhr District for the management of industrial

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development lies in many fields, in particular: • The Ruhr Settlements Association founded nearly 100 years ago had been the first regional planning approach for a large industrialised area based on an association approach (members of the association the cities, municipalities, counties etc.) • The establishment of River Associations (Ruhr, Emscher, Lippe) as early as 1906 as, again, an innovative and comprehensive, regionalised approach in both water quantity as well as water quality management. This model has been successfully repeated in any regions of the world. • The transformation of changes and now obsolete land uses and land use patterns in form of comprehensive, large programmes, for example the ten- year project "International Building Exhibition (IBA) Emscher Park". It had been based on a structural programme of 1988 with the objective of giving a strong impulse to the derelict Emscher area and with the main goal of urban development and ecological renewal in the highly contaminated former industrial and coal mining area. The programme was begun in 1989 and successfully completed in 1999. The entire Emscher Park project contains together with other programmes highly relevant developments programmes for example: • Further development of the Ruhr District greenbelt system • Re-naturalization of the river Emscher, the principle open sewer of the central region into its original stage • Preservation and conversion of former industrial estates including their technical monuments into new uses with also a strong focus on cultural promotion Address ENTWICKLUNGSGESELLSCHAFT ZOLLVEREIN MBH Gelsenkirchener Straße 181 Zollverein Schacht XII, Halle 6 D-45309 Essen Phone +49 (0)201.8 30 36-36 and +49 (0)180.4 00 00 86 Fax +49 (0)201.8 30 36 20 and +49 (0)201.3 71 91 26 Email: [email protected] Email: [email protected] Email: [email protected] www.zollverein.de www.route-industriekultur.de Main issues The programme included visits of the “Duisburg-North Country Park” which addressed combines the industrial cultural heritage, nature and a fascinating light-show. At the centre of the park there is a decommissioned steel mill (furnace), the old industrial facilities of which are today being put to a variety of different uses. The former factory buildings have been converted to accommodate cultural and corporate functions; an old gasholder has become the biggest artificial diving centre in Europe; alpine climbing gardens have been created in the former ore storage bunkers, and an extinct blast furnace has been developed into a panoramic tower. A highlight of the concept summarised above had been the visit of the “Zeche Zollverein”. Zeche Zollverein is acknowledged to be the most beautiful coal mine in the Ruhr District. Not least because of its international significance it had been awarded the title of a “World Cultural Heritage Site” by UNESCO. Its architects Fritz Schupp und Martin Kremmer were inspired by the Bauhaus

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style to build this harmonic industrial complex along two axes following the principles of symmetry and geometry. The result is Zollverein Shaft XII, a very model of a major modern coal mine. In 1989 the North-Rhine Westphalian State Development Company (LEG) and the city of Essen set up a project business entitled "Bauhütte Zeche Zollverein Shaft XII" to carefully restore the site as befitting its status as a monument. This has paved the way to new uses. The former boiler house, now the seat of the North-Rhine Westphalia Design Centre was redesigned in the 1990s by the top architect Lord Norman Foster. One of the aims of the Emscher Park International Building Exhibition (IBA) (see above) was to restructure disused industrial land, improve the living conditions in the area ecologically and give fresh, forward-looking impulses to social and cultural establishments. This aim has been realised at Zollverein in exemplary fashion. The site was the most important project of the IBA and now stands as a beacon for the successful structural transformation in the Ruhr District Main objectives and topics covered by this visits included: • The need for comprehensive and integrated spatial development concepts in spatial industrial management considering also changed industrial patterns and future needs for additional development sites; • Demonstration and discussion of the organisational and managerial tasks and institutional forms to optimally guide the transformation of an industrial site into new uses; • Understanding of the paradigm of many institutional and organisational solutions in industrial change management also for the Indian context. Related Brochure “Zeche Zollverein” documents Plan “Landschaftspark Duisburg-Nord” on the CD

Visit BAYER Chemical Park Leverkusen Theme Industrial owner (BAYER), including additional companies (Chemical industries, BAYER special branch companies, electronics, coating industries). Management, Operation, Facilities and Central Services; Planning of Industrial Estates (discussion of planned activities in AP) Company Bayer is a research-based, growth-oriented global enterprise with core and site competencies in the fields of health care, nutrition and high-tech materials. abstract Bayer Industry Services GmbH & Co. OHG under the umbrella of Bayer is the operator of Germany's largest chemical park network, with sites at Leverkusen, Dormagen and Krefeld-Uerdingen. The parks offer comprehensive services for the establishment of a now industry/plant such as: • Provision of all types of utilities, and ensuring the efficient operation of raw material and product logistics; • Planning and operation of infrastructure facilities, lease of office and laboratory space, management of facilities; • Assembly and maintenance of plants and apparatus, construction of special machinery; • Authorizations in accordance with building, operation, atmospheric concentration, emission and water permits and provision of services to ensure the safe operation of laboratories, pilot plants, plants and chemical processes;

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• Analytics for research, development and production; • Disposal of all liquid and solid waste in our own wastewater treatment plants, incineration plants and landfill sites; • Environmental management; • Occupational safety and health protection; • Employee training. • Operational services include: • Smooth cooperation between Chemical Park companies, authorities and nearby residents; • Site planning and development; • Environmental monitoring; • Traffic safety; • Fire protection and site security; • Communications and crisis management; • Energy portfolio management; • Site marketing. Contact Dr. Waniczek Address Bayer Industrial Services – Bayer Chemiepark Leverkusen Geb. Q21 BIS-MV Chemieparkmarketing 51368 Leverkusen Phone: +49 (0) 214 / 30-70705 – Fax: +49 (0) 214 / 30 – 31918 http://www.bayerindustry.com/ e-mail: [email protected] Main issues The visit hosted by the firm and chaired by the principle communication addressed manager, Dr. Joerg Michael Soeder, facilitated mutual information exchange, establishment of business contacts and visits of relevant facilities and services. The meetings and visits were also attended by representatives from GTZ in the field of eco-industrial development, namely Mrs. Klein and Dr. Koenig. The meeting ended with a mutual discussion round and final conclusions of the overall visit to Germany. The meeting started with a presentation of the company followed by visits to the Leverkusen Park. The guided tour included a visit demonstration of the fire protection and site security centre focussing on managerial tasks and their solution. The Indian visitors were briefed, and presented with the organisational and managerial tasks and responsibilities; the facilities and equipment were demonstrated to them. After the visit to the Leverkusen Park the environmental management facilities (Environmental Services) nearby were also inspected and explained. Highlights of the visit included: • Wastewater (effluent) treatment systems with focus on the Bayer development of Tower Biology (Turmbiologie) – a modern activated sludge technology • The different (altogether 4) waste incineration plants • Waste separation and management systems • The landfill site for hazardous wastes BAYER Environmental Services (ES) are specialist for all kinds of waste management and rehabilitation projects; they are offering a particularly wide range of services. These include disposal of hazardous waste, collection and

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recycling of wastes, treatment of effluents, cleaning large containers, drums tankers and other vessels, or provision of advisory services on the optimal use of environmental technologies. In addition, ES is capable of evaluating and rehabilitation of chemically contaminated land and sites. Each of such services can be provided individually. The visitors were in particular made aware of the costs of modern industrial pollution control in comparison with the total turnover of the chemical park. It was revealing to the Indian visitors that with a total annual turnover of some 30+ Billion EURO the turnover (including profit) of Environmental Services is in the range of 300 Mio EURO – just 1% of the total turnover. This clearly shows that even in the sector of chemical industries, surely an environmentally critical undertaking, effective pollution control and environmental protection cost less than 1% of the total turnover. The meeting ended with a frank and concrete discussion on future business collaboration between BAYER and the representatives of the Andhra Pradesh Industrial Infrastructure Corporation (APIIC). Common interests were identified and next steps defined (please refer to chaper 4 above). The meeting ended with mutual affirmation of a fruitful future collaboration in the field of eco- industrial development. Related Presentation BAYER Industrial Services documents Presentation BAYER Environmental Services on the CD Presentation Systemic Waste Management Presentation Waste Water Incineration Presetation BAYER Technological Services

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6 Consolidated Summary of the Evaluation

Consolidated Summary Sheet for Participant - Evaluation of the Training Course – CSPT Overall Summary Programme / Course / Coaching of Key Personnel for Eco-Industrial Estate Workshop Title Development and Transformation Code EP-EIE-6

Training Institution InWEnt - ifanos c&p Duration from 26.11.2006 to 05.12.2006

Overall training course and objectives 9-1, 6-1 to 6-3 and 5-1 to 5-3 Range of EI- scores Rating** 7 Questions very 5,6 - 7 (>80%) successful 3,5 to 5,5 (>50%) successful 3,4 or below (<50%) unsuccessful

Number of questions Evaluation Rating** where response rounded average is equal to Index (EI)* 1 2 3 4 5 3 1 3 0 0 5,25 successful

Course objectives: 6-1-1 Participants have a sound understanding of the eco-industrial approach and its potential for sustainable development in India;

6-1-2 Participants are familiar with the required planning and clearance processes (internal and external, spatial planning dimension), and infrastructure and service elements in (eco)-industrial estates based on best practices in other countries (Germany) and can transfer these to the Indian background;

6-1-3 A list of further capacity building requirements regarding (eco)-industrial estate planning, marketing and management is compiled

Remarks Please name topics that were not covered, but would have been important for your work! Adminstrative Sanctioning, History of formation of Parks, Establishment of Waste Management, German law in general; Environmental impact assessment of an Industrial Park; I liked especially:

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One concept of business park, industrial park and chemical park, integrative approach of waste management; Industrial Park Hoechst; Everything; Field visits of paper plant, Bayer solid waste treatment; I disliked especially: tight schedule

Organisation and venue 7-1 to 7-11 Range of EI- scores Rating 11 Questions 10 - 11 (90%) excellent 7,7 -9,9 (70%) very good 5,5 - 7,6 (50%) good below 5,5 poor

Number of questions Evaluation Rating** Index where response rounded average is equal to (EI)* 1 2 3 4 5 3 2 6 0 0 7,5 good Remarks In your view, which materials or information were omitted? Administrative Set up in clearing/sanctioning industrial parks;

Analysis & conclusions by participants Follow-up

Which follow-up activities would you recommend?

The concept of developing EIP with full logistics support for industries followed in Germany may be emulated in India; Awareness creation; such training should be held in India too for German counterpart and authorities; taking up some case studies of industrial parks in AP/India;

What action does your institution need to carry out in order to take maximum advantage of this training? The integration of waste water, incinerator and waste land fill sites near the Ind. Areas need to be developed for taking maximum advantage; we should integrate German experience in our plans and policies;

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Further comments and suggestions for improvements suggestions for improvement: Participants may be asked for their expectations well in advance so that some changes may be possible during the course; training should last 3 weeks with some more topics on the subject; typical case studies of parks in India should be taken up;

Awareness, skills and immediate action What kind of awareness did you receive through this training? Changing concept of managing industrial parks and waste management; general environmental awareness; latest technology Which skills did you acquire or improve through this training? Making an impact in the decision process for the need of risk management integration of waste management; site master planning; management skills; As a result of this training, what immediate action can you perform at your work in future? Will try to emulate the ideas by action and also explaining to colleagues the practice followed in Germany - also a report should be submitted to authorities the need of integration of waste management; we will integrate some of the experience in our programmes; day 1 study planning;

Methodology / learning effect - How do you assess 4-1 to 4-5 and 3-1 to 3- 5 Range of EI- scores Rating 11 Questions 9,9 - 11 (90%) excellent 7,7 - 9,8 (70%) very good 4,4 - 7,6 (40%) good below 4,4 poor

Number of questions Evaluation Rating** Index where response rounded average is equal to (EI)* 1 2 3 4 5 4 7 0 0 0 9,25 very good

Relevance and impact of the work 2-1 to 2-4 Range of EI- scores Rating 4 Questions 3,6 - 4 (90%) excellent

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2,8 - 3,5 (70%) very good 2 - 2,7 (50%) good below 2 poor

Number of questions Evaluation Rating** Index where response rounded average is equal to (EI)* 1 2 3 4 5 4 0 0 0 0 4 excellent Remarks Please name topics that were not covered, but would have been important for your work! Administration work on different levels in Germany Please explain the plans for implementation of your skills in brief! Inspection and monitoring; to create awareness to the IALA personnel to implement; The experience gained can be used in India for development of industrial parks What support do you need for an efficient implementation? Administrative Support; Management; planning and implementation

Based on the rounded average of all modules, Questions 3.6 and 3.7 The complexity of the course / module content was just right

The amount of information was high

* Relative weight of mode for Evaluation Index (EI) calculations: Average these weights will automatically be applied in the analysis rounded weight 1 1,00 2 0,75 3 0,50 4 0,25 5 0,00