Caustic - Chlorine Sector - Under Pressure
Author: Sunita Narain
What would you say of an industry that takes common salt and turns it into one of the most environmentally deadly substances we know of today, namely chlorine?
And what if in its production process it uses yet another deadly substance, mercury? We are talking about India’s caustic-chlorine industry. Centre for Science and Environment’s (CSE) Green Rating Project has recently completed the environmental rating of this sector’s life cycle. Fascinating journey it was. Green rating, as CSE practices it, is a great teacher of detail and substance. It took us over one year to understand the sector. During this period, we took it apart from skin to bones to its entrails and then worked carefully to see what would be the best way to put it together again. Something like virtual reengineering for a green industry.
When we began the exercise, the caustic-chlorine sector sounded very dull. It had none of the environmental tragedies of the paper sector or the glamourhorror of the automobile sector — both of which we had rated earlier (see ‘Enter the green rating project’ Down To Earth, Vol 8, No 5, and ‘Setting out’ Down To Earth, Vol 10, No 13). In ignorance I asked my colleague Chandra Bhushan, who coordinates this programme, what is this industry? His stock answer was that this sector manufactures the lifeline for the modern industrial sector. Interesting. Yes. But still what is its environmental story?
I was to eat my words. As information on the sector unfolded, it became clear that this rating is the stuff that Hindi films are made of. It has romance — making modern chemicals from the salt of the seas.
It has success — as early as in 1985, an oleum leak in the Delhi-based Sriram Fertilisers and the subsequent legal directions forced the entire sector to substantially clean up its safety record. Some parts of the industry are even close to the global best industry in this sector. But still, action is only when there is a push. So the industry works on safety of chlorine, but forgets about another equally dangerous chemical — hydrogen, which is highly inflammable. It improves safety in the plant, but does little to inform people living outside its factory compound on the dangers and emergency planning.
It has tragedy — mercury is used in the process. Before we began work we heard from regulators that the problem of mercury contamination from this sector “is taken care of”. But as we fished and fished some more, we found to our horror that not only is the problem not taken care of, but it is of deadly and frightening proportions. We learnt the bestkept secret was that a large proportion of the mercury that enters the plant is not accounted for. Nobody knows where it goes. What we have found on this deadly mercury trail still leaves unanswered many issues. But most of all it calls for urgent action — to set new regulations for these plants and, if nothing else works, to close down these plants as fast as possible. It is clear with the data we have on mercury that a massive human tragedy is in the making.
It has drama — it manufacturers a product like chlorine which when is used by a chemical industry to manufacture chlorofluorocarbons (CFCs), which we now know are responsible for damaging the earth’s ozone layer, and because of which, we have increased incidences of cancers. It is now being used in the plastic industry to manufacture polyvinylchloride or PVC as we know it. When burnt it releases dioxins — deadly toxins. Wonder chemical or chemical of death? Who is going to steer the industry towards, not just cleaner production. But to manufacture “clean” products. Clearly, it would be in the interest of the caustic-chlorine industry to ensure long-term usage of their product. In that case, should they not be steering the entire industry towards finding environmentally safe uses? But this needs leadership. It needs foresight.
Most of all, the terms of engagement must change. The circle of responsibility must be extended. The green rating of the caustic-chlorine teaches us this.
The Indian caustic-chlorine industry is about four per cent of the global industry, which is comparatively small. The annual production capacity is 2.25 million tonnes, but rarely more than 1.8 million tonnes is produced. The industry comprises about 25 large companies that alone account for 90 per cent of production. In India, caustic soda is primarily used in the manufacture of pulp and paper, detergents, viscose, aluminium, petroleum refining and metal cleaning. Chlorine is mainly used for hydrochloric acid (HCl) production, pulp and paper bleaching in polyvinylchloride (PVC) and other chemicals.
The market conditions are such that caustic soda is in demand in India, while chlorine is not. Globally, the industry requires more chlorine than caustic soda. Though Indian companies have excess chlorine, they cannot export it simply because of the major hazards associated with the transportation of chlorine.
Chlorine also finds a place in the list of toxic and hazardous substances banned for transnational transportation under the Basel Convention. As a result, India is faced with a double edged sword — on one hand, it has a growing chlorine stock that it cannot dispose and on the other hand, the dumping of caustic soda is forcing the sector to compete with international prices. This has pushed the sector to desperation and it has repeatedly looked for government intervention.
Background pollution
It is ironic that companies that appear green and clean at the production plant are sometimes the ones that produce the most environmentally-damaging products. Just as in the case of the caustic-chlorine sector. It is a sector where 70 per cent of production is at par with the global best technology — membrane cells. But the remaining 30 per cent production from the polluting mercury cell technology alone accounts for 40 per cent of mercury pollution in India from industrial operations (except coal based uses). There is also a paradox: it is a sector that saved millions of lives by providing clean drinking water, but is also responsible for compromising the environment as a safer place and for maintaining the fertilisation and abundance of life. The industry is accused of producing products that mimics hormones in animals, and accumulates in the foodchain.
Shades of green
Indian caustic-chlorine industry operates in extreme. At one level, it is as good as the global best performance, and at the other it is as bad as it can get. GRP has found that the level of environment management of the Indian causticchlorine industry is nothing less than the global best. The sector has slowly moved away from the toxic mercury cell process and today more than 70 per cent of the sector uses the best available membrane cell technology in their production plant. Compared to Europe and the US, where more companies are using the polluting mercury cell and diaphragm cell technology respectively, the performance of Indian causticchlorine sector in moving towards membrane cell technology is significant.
Even at the production plant, the performance of Indian caustic-chlorine sector in energy and raw material consumption is more or less comparable to the global best performance. But in water consumption and toxic mercury emissions it fares poorly. The energy consumed by Indian causticchlorine industry is probably the least in the world and their consumption efficiency too rivals the global best performance.
But the amount of mercury pollution it generates is also huge. In addition, to make sure that their eco-friendliness is recognised, companies have obtained internationally-recognised certifications for their environment and health and safety performance. The percentage of total companies having ISO 14001 for environment and ISO 18001 for health and safety is probably the maximum in Indian caustic-chlorine industry.
Out of the factory gates
The ultimate use of chlorine is not within the control of the caustic-chlorine industry, rather it depends on the downstream industry that makes environmentally damaging products like plastics, pesticides and organochlorines. Serious questions of adverse health and environmental effects of chlorine and chlorinated compounds have been raised, with many chlorinated compounds accused of toxic behaviour, mimicking hormones in animals, and accumulating in the foodchain. These compounds could contribute up to 20 per cent of the greenhouse effect. The ozone hole is created by chlorofluorocarbons (CFCs) — a chlorinated product. Even though the caustic-chlorine industry does not have control over downstream uses, it has to take the responsibility for the environmental impact that takes place during the downstream use of its products, since its economics are linked with the downstream uses. If downstream uses get banned due to environmental pressures, the causticchlorine industry too will close down.
With increase in scientific research on the impact of chlorine and chlorinated products on environment, caustic-chlorine industry is likely to come under more environmental pressures. Therefore, it is in the interest of the industry to make sure that its products are used responsibly.
Corporate environment management
It’s more hype than substance. Most companies flash ISO 14001 and ISO 18000 certifications to cover up their poor environmental track record.
GRP found that though 45 per cent companies possessed ISO 14001 certifications, the sector barely scored 36 per cent marks in corporate environment management. The reason is simple: the annual environment audits of the companies is as bad as the annual environment statement that they submit to the PCBs. Precious little has been done to spread awareness among employees about pollution. GRP researchers have often seen workers collecting mercury using bare hands in mercury cell companies and companies disposing their hypo sludge in the open without treatment.
For most Indian caustic-chlorine companies R&D means just testing biological oxygen demand (BOD) and chemical oxygen demand (COD) in wastewater and testing the purity of salt in obscure labs. Companies are content with just displaying their environment policy at the factory gates, but have failed to map an off-site disaster management plan. Most companies prefer to ignore community outreach programmes by shifting the onus on to the local administration.
Although there has been a belated shift from the polluting mercury cell technology to the membrane cells, mercury pollution in India is still very high. India does not produce mercury and relies completely on imports. Between 1998-2001, the annual mercury imports stood at 170-190 tonnes, which is 10 per cent of the global mercury consumption. Mercury consumption by Indian caustic-chlorine companies is at least 50 times higher than the average European consumption.
Though mercury is not supposed to be consumed in the process, it gets lost during operation as soon as it is used. This has led to 70 tonnes of mercury entering the environment every year by existing mercury cell plants. And this trend is only increasing.
Mercury also finds its use in clinical thermometers, fluorescence lamps, metal switches, batteries, pesticides and certain pharmaceutical drugs and agricultural products. All these products too have a short life and they find their way into the environment shortly after they are disposed. Assuming that only 50 per cent of the mercury is released by these industries, the total mercury pollution load generated every year (including the caustic-chlorine industry) will be about 125 tonnes of elemental mercury. This is about five times more than the total mercury compounds dumped into the Minamata Bay in Japan in 36 years (see box: Mercurial deaths). This means that the mercury pollution being generated in India every year is equivalent to five Minamata disasters.
MERCURIAL DEATHS
In 1907, the Chisso Corporation built a factory for manufacturing petrochemicals and plastics in a small fishing village of Japan situated along the shore of Minamata bay. From 1932 to 1968, the corporation dumped an estimated 27 tonnes of mercury compounds into the bay. The first signs of the effects of this dumping began to surface in 1925, when the fish population started declining. But it was only during the mid-1950s that the effects were seen in animals and humans, who consumed the fish. Birds started dying. People began to experience numbness in their limbs and lips. Their speech slurred and their vision got constricted. Some even suffered brain damage. ![]() The corporation’s attempts to cover up the matter proved unsuccessful. And despite the victims testifying, the United Nations did not take any steps to prevent further contamination. |
Other chlorinated compounds such as chlorofluorocarbons (CFCs) and hydro chlorofluorocarbons are potential contributors to ozone depletion. One of the earliest examples of this problem was the pesticide DDT, an organic compound of chlorine, which imitates the action of certain hormones like oestrogen. Another group of chlorine compounds, polychlorinated biphenyls (PCBs), is known to cause fertility-related problems.
Charting a course
While caustic soda is not a problem, chlorine use is an issue that will determine the survival of the Indian caustic-chlorine industry. The chemicals that are being banned/phased out in industrialised countries will soon have to be banned in India as well. But today, 11 per cent of chlorine produced in India is used for paper bleaching at a time when countries around the world are reducing its use. If this trend catches up in India, it will cost the caustic-chlorine industry dear.
Consumption of chlorinated solvents such as HCL, TCE methylene chloride and PVC is bound to decline in future (see box: Backlash!). The sectors that seem least threatened and where chlorine will be used in the next few decades are the pharmaceutical industry, water disinfections and segments that use chlorine merely as a facilitator, wherein no chlorine is present in the final product.
BACKLASH!
The focus is on POPs or persistent organic pollutants — a group of chemicals that are resistant to natural breakdown processes and are also highly toxic. Cracking the whip on these hazardous products is the Stockholm Convention, a global treaty to eliminate POPs. It has already eliminated all existing POPs starting with a list of 12 (known as the ‘dirty dozen’). More chemical products to be banned are on the anvil. It’s time the industry wakes up. |