PROJECT

Projects

Environmental & Social Review Summary

Project Number

9531

Company Name

GRUPO KUO SAB DE CV

Date ESRS Disclosed

Feb 5, 2010

Country

Mexico

Region

Latin America and the Caribbean

Last Updated Date

Jan 2, 2017

Environmental Category

B - Limited

Status

Completed

Previous Events

Approved : Dec 6, 1999
Signed : Jan 21, 2000
Invested : Jan 21, 2000

Sector

Petrochemical

Industry

Manufacturing

Department

Regional Industry MAS LAC & EUR

Project Description

5

Environmental Review Summary (ERS)

Project Name Mexico: Girsa II

Region Latin America

Sector Petrochemicals

Project No. 9531


1. The proposed project aims to pursue continuous modernization and competitiveness of existing plants, add new capacities to achieve economies of scale, support the ongoing cost reduction program and develop strategic alliances with world scale partners on core and specialty products. Specifically the project will (a) increase capacity and reduce costs at various facilities; (b) establish operating joint-ventures and marketing alliances; (c) implement quality, process and technology improvements and (d) support Girsa’s maintenance and environmental expenditures over the next 3 years.

2. This is a category B project according to IFC’s environmental review procedure because specific impacts may result which can be avoided or mitigated by adhering to generally recognized performance standards, guidelines or design criteria. The review of this project consisted of appraising technical and environmental information submitted by the project sponsor and technical and environmental appraisal. The following potential environmental, health and safety impacts of the project were analyzed:

· site selection, and site selection procedures;
· air emissions;
· liquid effluent handling, treatment and discharge;
· fuel and hazardous materials storage and handling;
· solid and hazardous waste handling and disposal;
· contingency; and emergency and response plans;
· employee training; and
· general health and safety issues.


The sponsor has presented plans to address these issues and demonstrated that the proposed project will comply with applicable local regulations and World Bank policies and guidelines. The measures proposed to address the project’s potential environmental impacts during its implementation are described in a Corrective Action Plan (CAP) (See Appendix A) and summarized in the paragraphs that follow.

3. Girsa has various facilities located in several Mexican cities. They include (a) three plant sites owned by its phosphate subsidiary, Quimir, respectively located in Lechería, Tultitlán and Coatzacoalcos; (b) two plants owned by its Polystyrene subsidiary, Resirene, located in Coatzacoalcos and Tlaxcala, (c) two facilities located in Cosoleacaque and Tula under the supervision of its Phenol subsidiary, and (d) two facilities, owned by Insa, and its carbon black subsidiary, Nhumo, in Tampico. Other facilities include PCR’s two plants located at Salamanca and Vallejo, and production operations in Querétato, Zitácuaro, Lerma, Tula, San Luis Potosí and Ocoyoacac as well as a raw material storage terminal in Altamira.

Quimir - Lechería
4. This plant produces sodium phosphates and has three industrial operations and two pilot plants. Two of the industrial operations produce sodium phosphates for the detergent industry and the other operation produces latex used in various applications including paper, chewing gum, etc. The fuel used is natural gas and the boiler air emissions are controlled with low NOx burners. The main process emissions from the sodium phosphate operations, which are mostly carbon dioxide (CO2), will be collected and sent through a pipeline to be used by a third party. The remaining air emissions from the sodium phosphate operations are controlled by dust collectors before they are released to the atmosphere and the collected material is re-circulated back into the process. The emissions from the latex operations are flared.

5. The solid sludges generated in the sodium phosphates process are sold as fertilizers and the residues generated at the emulsion operations are sold to a cement plant to be used as alternative fuel. This plant is ISO 9000 certified. On January 1st 1997, the Mexican government issued a new wastewater regulation based on a system of duties and incentives, and the establishment of reasonable allowances for the gradual evolution of existing operations; Girsa in complying with these regulations and is committed to take necessary actions to comply as well with future applicable Mexican regulation and World Bank guidelines as described in the CAP.

6. Girsa will maintain its development effort in order to boost productivity of the sodium phosphate operations. The sponsor has committed to design, build, and operate any modifications or projects to implement these developments in full compliance with the applicable Mexican regulation and World Bank guidelines. Girsa will submit to IFC an assessment of the environmental impacts and the control measures to be implemented to achieve compliance.

Quimir - Tultitlán
7. This plant produces phosphoric compounds including sodium trypolyphosphate and technical and food grade phosphoric acid. It uses natural gas and underground water. The air emissions generated in the processes are controlled (i.e., scrubbers, cyclones and demisters) prior to being discharged to the atmosphere. In addition, Girsa will implement operational process changes that will further reduce the generation of NOx and will install low NOx burners in the boiler and the dryer and a new scrubber to reduce particulate, combustion gases and water vapor emissions. The above improvements will reduce the emissions concentrations to the applicable World Bank guidelines levels. The cake from filtration operations is sent to a government-authorized landfill.

8. On January 1st 1997, the Mexican government issued a new wastewater regulation based on a system of duties and incentives, and the establishment of reasonable allowances for the gradual evolution of existing operations; Girsa in complying with these regulations and is committed to take necessary actions to comply as well with future applicable Mexican regulation and World Bank guidelines as described in the CAP.

Quimir - Coatzacoalcos
9. This plant produces sodium phosphates. At this site, Girsa is also considering some actions to enhance the productivity of its operations and has committed to design, build and operate any modifications or projects that may be required in compliance with Mexican regulations and World Bank guidelines. Girsa will submit to IFC an assessment of the environmental impacts and the control measures to be implemented to achieve compliance.

Resirene - Coatzacoalcos
10. This plant produces polystyrene in a close circuit with no atmospheric releases. The treated wastewaters are re-used in the cooling tower and the solid residues generated by the process are sent to a cement kiln for destruction. This plant will implement various minor projects to improve the overall operation and ensure keeping in compliance with the applicable Mexican regulation and World Bank guidelines.

Fenoquimia - Coatzacoalcos
11. This plant produces phenol, acetone, methyl metacrylate, and sulfuric acid for internal use. The air emissions will continue to be in compliance with World Bank guidelines and the wastewater treatment plant will be upgraded as described in the CAP to comply with the applicable World Bank guidelines levels. The by-products produced are recovered from the liquid effluents and re-circulated back to the process. All process solid residues generated are either returned to the process or sold for re-use. Girsa will introduce operational improvements to the process to further reduce the amount of residues generated, reduce raw material and natural gas consumption, and reduce the risk of accidents.

Insa Emulsion - Tampico
12. This plant produces various types of synthetic rubber. The air emissions generated in the polymerization area are collected and re-circulated back into the system. Additional process air emissions are sent to a flare. The fuel used is natural gas and the boiler as well as the dryer have low NOx burners. The process solid residues are disposed in a government-authorized landfill. Associated to this operation is a maritime terminal in Altamira where butadiene, which is used as raw material, is received and initially stored. Girsa has developed and implements strict safety measures to minimize the risk of accidents.

13. Girsa will improve raw material handling measures and will replace several safety devices and the existing fire response system to further reduce the risk of explosion and fugitive emissions and to ensure overall plant safety. Water use will continue to be reduced. This plant is ISO 9000 certified.

14. On January 1st 1997, the Mexican government issued a new wastewater regulation based on a system of duties and incentives, and the establishment of reasonable allowances for the gradual evolution of existing operations; Girsa in complying with these regulations and is committed to take the necessary actions to comply as well with future applicable Mexican regulation and World Bank guidelines as described in the CAP.

15. As part of this operation, Girsa will build anew plant (ParaTec) to expand the production of acrylonitrile-butadiene rubbers (NBRs). This project will operate with zero NOx discharges. Girsa will install the appropriate air emission control devices to ensure that the additional air emissions generated are released at levels below the applicable World Bank guidelines. It will also build a wastewater treatment plant to treat process and domestic waters to the applicable World Bank guidelines. A HAZOP for the different phases of the project has been developed. Copy of the HAZOP conclusions will be submitted to IFC.

16. Insa Solución will install a wastewater treatment plant to treat process and domestic waters and will control its air emissions so that this project will comply with the applicable World Bank guidelines.

Nhumo - Tampico
17. This plant produces carbon black. Girsa will implement a project, known as Vulcano, which will allow half of the combustion gases generated to be used to produce vapor for its operations as well as for neighboring industrial facilities without using additional fuel. The other half of the combustion gases will be flared. In addition, Girsa will install a dust collection system in the packing and transportation area and will improve the operation of the wastewater treatment plant to ensure compliance with World Bank guidelines as described in the CAP. This plant is ISO 14000 certified.

PCR - Salamanca
18. This plant produces consumer goods (i.e., adhesives, sealants etc.) Girsa has installed air pollution control devices (i.e., dust and organic gas collectors and gas adsorption units) and already complies with the applicable air emissions World Bank guidelines. The sludge generated in the wastewater treatment plant is re-circulated back into the process. This plant is ISO 9000 certified.

19. To complement the current operation, Girsa has acquired an existing polyurethane-based shoe adhesive operation. This project is known as Simon. Girsa has committed to operate this plant or design, build and operate any project for further improvement in full compliance with the applicable Mexican regulation and World Bank guidelines. For these potential improvements, Girsa will submit to IFC an assessment of the environmental impacts and the control measures to be implemented to achieve compliance.

20. In addition, a new distribution center associated with PCR’s operations will be built in Salamanca. This center will be located in Salamanca. Girsa will submit to IFC an assessment of the environmental impacts and the control measures to be implemented to ensure compliance with the applicable World Bank guidelines.

21. To reduce noise emissions, the equipment at all plants is regularly maintained and if necessary, additional measures will be taken to comply with the World Bank guidelines.

22. Girsa will also implement various projects in the other plants to enhance operations and ensure full compliance with the applicable Mexican regulations and World Bank guidelines. Girsa is committed to inform IFC of any initiative that generate environmental impacts and will submit the proposed mitigation actions before such project is implemented.

23. Girsa has established an environmental health and safety (EH&S) group, designated CASH (Control Ambiental, Seguridad e Higiene) which is doing an outstanding job in identifying problems, establishing corrective and proactive action programs, training personnel, and monitoring performances. As part of CASH, Girsa performs risk analyses during and after commissioning of new projects and is committed to ensure that any new project improves the already good EH&S conditions of the operations. CASH also coordinates an emergency response system for the transportation of raw materials and finished products, based on well-trained and well-equipped teams across the system of Girsa plant sites. CASH operates both at the corporate level with a specialized group of professional and at the plant level with a responsible environmental person who reports to the plant manager.

24. Girsa has strict measures to handle the raw materials as well as the final products. Specific measures include, double containment walls around the tanks to avoid the risk of ground contamination in case of a leak or an accidental spill, temperature controls to ensure the materials are maintained at the recommended safe state, and the installation of visual and sound alarms, sprayers, explosion sensors, and concentration monitors. Ammonia is the refrigerant used. Strict fire and safety measures are also implemented at all Girsa operations. All plants have well-equipped systems to respond to emergencies, perform periodic fire drills, and have well trained fire-brigades available at all times.

25. Girsa will continue to provide to and require the use of personal protective equipment by all its employees. Hard hats are provided for all personnel, and dust masks and hearing protection are provided for personnel working in areas with high dust and noise levels, respectively. In addition, there are showers and eye sprayers for the employees’ use. The well-equipped medical facilities at each one of the plants will continue to be operated. The employees receive pre-employment and periodic medical check-ups.

26. Girsa’s qualified EH&S personnel will continue implementing health and safety programs and will continue training employees in occupational health and industrial safety issues to ensure that the environmental, health and safety measures are enforced and that the employees are properly trained as specified on the applicable Mexican regulation and World Bank guidelines.

27. By project completion, Girsa’s operations will be in compliance with the relevant World Bank guidelines and policies and with the Mexican environmental standards. Girsa will annually submit to IFC a monitoring report to ensure ongoing environmental compliance during the life of the project. Minimum information to be provided in the annual monitoring report is provided in Appendix B

28. Based on its review of available information regarding potential environmental impacts and proposed mitigation measures, IFC concludes that the proposed project is being designed to meet Government of Mexico requirements, and World Bank policies, and environmental, health and safety guidelines.

29. IFC will monitor Girsa’s ongoing compliance with World Bank policies and guidelines during the life of the project by evaluating environmental performance reports submitted annually to IFC by the sponsor and by conducting periodic site reviews during project supervision.
APPENDIX A
ENVIRONMENTAL, HEALTH & SAFETY
GIRSA CORRECTIVE ACTION PLAN
5/12/1999
PLANT
Note: IFC standards referred in the General Environmental and Health and Safety Guidelines of July 1, 1998
APPENDIX B

MONITORING REPORTS MINIMUM REQUIREMENTS

For each one of Girsa plants:

· CAP status including key developments or deviations from the original;
· status of the mitigation actions for the projects defined during that year;
· stack emission monitoring results;
· process and domestic water liquid effluents concentrations;
· ambient noise levels;
· significant incidents, if any;
· annual statistics for occupational accidents and illnesses including number of employees, work hours and lost-time incidents;
· rate of work related accidents and incidents
(Rate = # of incidents/# of workers)
· interactions with the local communities; and
· industrial, safety, and environmental employee training programs.

Environmental impacts and mitigation actions for the projects already identified but requiring further definition need to be submitted as soon as they are available before the implementation of the project takes place. Please do not wait for submittal of this information with the annual monitoring report.

The environmental impacts and mitigation actions for any new initiative and/or project not yet identified will have to also comply with the requirements above mentioned.

Environmental and Social Mitigation Measures

Broad Community Support