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List of Annexures Annexure – I Plant Layout Annexure – II Manufacturing Process Annexure – III Details of Storage of So

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List of Annexures Annexure – I Plant Layout Annexure – II Manufacturing Process Annexure – III Details of Storage of So List of Annexures Annexure – I Plant Layout Annexure – II Manufacturing Process Annexure – III Details of Storage of Solvents Annexure – IV Water Balance & Details of Treatment and disposal of Effluent Annexure – V Details of Treatment and Disposal of Solid Waste Annexure – VI List of Raw materials & Quantity of Consumption Annexure – VII Point Source Emissions – Stack Emission Characteristics Annexure – VIII Details of Fugitive Emissions Annexure – IX Risk Identification Annexure – X Topo Map & Administrative Set-up Map Annexures 1 GCPL ANNEXURE – I PLANT LAYOUT Annexures 2 GCPL Annexures 3 GCPL Annexures 4 GCPL ANNEXURE – II MANUFACTURING PROCESS Annexures 5 GCPL Manufacturing Process Existin g Calcium Gluconate Gluconic Acid procured from market is neutralized with Calcium carbonate, filtered, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTERATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Calcium Gluconate Gluconic acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONO DELTA LACTONE + CaCO + WATER 3 FILTRATION CRYSTALLISATION (NEUTRALISATION) PACKING MILLING DRYING CENTRIFUGING Annexures 6 GCPL Sodium Gluconate Gluconic acid brought from the market is neutralised with Sodium bi-carbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. CONCENTRATION NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Sodium Gluconate Gluconic acid is neutralised with Sodium carbonate / Sodium Bicarbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONIC ACID + SODIUM CARBONATE / BICARONATE FILTRATION DRYING SIEVING (NEUTRALISATION) PACKING Annexures 7 GCPL Potassium Gluconate Gluconic acid brought from the market is neutralized with Potassium carbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. CONCENTRATION NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Potassium Gluconate Gluconic acid is neutralised with Potassium carbonate / Potassium Bicarbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONIC ACID + POTASSIUM CARBONATE / BICARONATE FILTRATION DRYING SIEVING (NEUTRALISATION) PACKING Annexures 8 GCPL Magnesium Gluconate Gluconic acid brought from the market is neutralised with Magnesium carbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. CONCENTRATION NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Magnesium Gluconate Gluconic acid is neutralised with Magnesium carbonate, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONIC ACID + MAGNESIUM CARBONATE (NEUTRALISATION) FILTRATION DRYING SIEVING PACKING Annexures 9 GCPL Zinc Gluconate Gluconic acid brought from the market is neutralised with Zinc carbonate/Zinc Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. CONCENTRATION NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Zinc Gluconate Gluconic acid is neutralised with Zinc carbonate/Zinc Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONIC ACID + ZINC CARBONATE / ZINC OXIDE (NEUTRALISATION) FILTRATION DRYING SIEVING PACKING Annexures 10 GCPL Manganese Gluconate Gluconic acid brought from the market is neutralised with Manganese carbonate/ Manganese Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. CONCENTRATION NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process for the manufacture of Manganese Gluconate Gluconic acid is neutralised with Manganese carbonate/ Manganese Oxide, filtered, concentrated, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Alternate process GLUCONIC ACID + MANGANESE CARBONATE / MANGANESE OXIDE FILTRATION DRYING SIEVING (NEUTRALISATION) PACKING Annexures 11 GCPL Calcium Lactate Lactic Acid is neutralised with Calcium carbonate, filtered, crystallised, centrifuged, dried, milled and packed. NEUTRALISATION FILTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Calcium Glubionate In this process, calculated quantities of both Calcium Gluconate and Calcium Lactobionate are charged in the blender and mixed, sieved and packed. BLENDING SIEVING PACKING Alternate Process for the manufacture of Calcium Glubionate Calculated quantities of Calcium Gluconate and Calcium Lactobionate are mixed in DM water, filtered, dried, sieved and packed. MIXING FILTERING DRYING SIEVING PACKING Annexures 12 GCPL Calcium Lacto Gluconate In this process, calculated quantities of Calcium Lactate and Calcium Gluconate are charged in the blender and mixed, sieved and packed. BLENDING SIEVING PACKING 2. Alternate Process for the manufacture of Calcium Lacto Gluconate Calculated quantities of Calcium Lactate and Calcium Gluconate are mixed in DM water, filtered, dried, sieved and packed. MIXING FILTERING DRYING SIEVING PACKING 3. Alternate Process for the manufacture of Calcium Lacto Gluconate Calculated quantities of Gluconic Acid, Lactic Acid are reacted with calcium carbonate, filtered, dried, sieved and packed. GLUCONIC ACID + LACTIC ACID + CaCO3 (NEUTRALISATION) FILTRATION DRYING SIEVING PACKING 4. Alternate Process for the manufacture of Calcium Lacto Gluconate GLUCONO DELTA LACTONE + LACTIC ACID + CaCO 3 (NEUTRALISATION) FILTRATION DRYING SIEVING PACKING Annexures 13 GCPL Calcium Lactobionate Calculated quantities of Lactose, Sodium bromide, Calcium Carbonate are mixed in water, electrolysed, filtered, vaccum concentrated, crystallised with alcohol, centrifuged, milled, dried and packed in bags/ Fibre drums. LACTOSE, SODIUM BROMIDE, CALCIUM CARBONATE, ELECTROLYSIS FILTRATION DM WATER VACCUM CONCENTRATION CRYSTALLISATION PACKING MILLING DRYING CENTRIFUGING Annexures 14 GCPL Calcium Borogluconate : 1. Calculated quantities of calcium gluconate and Boric acid are charged in the blender and mixed sieved & packed. BLENDING SIEVING PACKING 2. Alternate Process Calculated quantities of calcium gluconate & Boric acid dissolved in DM Water, filtered, spray dried, sieved & packed. CALCIUM GLUCONATE + FILTERED DRIED BORIC ACID + DISSOLVED IN DM WATER PACKED SIEVED Ferrous Gluconate : CALCIUM FILTERATIO CONCENTRATIO GLUCONATE + N N FERROUS SULPHATE + DM WATER DRYING PACKING MILLING Annexures 15 GCPL Manufacturing Process P roposed 1 IRON SUCROSE Ferric Chloride is dissolved in water and sodium bicarbonate solution is added to precipitate ferric hydroxide which is filtered. Above ferric hydroxide is mixed with sucrose and heated to get iron sucrose in solution. Which is concentrated to get thick mass which is added with vigorous stirring to DNS and then methanol to precipitate iron sucrose solid. This is centrifuged and slurried with DNS and acetone again to remove the impurities. The wet material is dried under vacuum, pulverized, redr ied, milled, blended as needed and packed. Raw material: Ferric Chloride Sodium carbonate Sucrose DNS denatured spirit Methanol Acetone Raw material consumption per kg of output Ferric Chloride = 0.2 kg / kg Sodium Carbonate = 0.04 kg / kg Sucrose = 2 kg / kg DNS = 8 L / kg Methanol = 5 L / kg Acetone = 1 L / kg Annexures 16 GCPL PROCESS FLOW CHART Sodium carbonate solution Water + Ferric Chloride Filtration of Ferric MLR collection h ydroxide Ferric hydroxide Cake + Su gar Heat DNS Concentrated Filtration MLR collection Filter Mass methanol DNS Acetone Filtration MLR collection Vacuum Drying Milling, Blending & Packing Annexures 17 GCPL 2. CALCIUM DOBESYLATE Stage-I: Sulphuric acid is a dded to a suspention of hydroquinone in ethylene di chloride. After the sulfonation, water is added and aqueous layer separated. Stage-II: aqueous layer is neutralized with a slurry of calcium carbonate in water, centrifuged to separate calcium sulfate. Liquid from centrifuge is concentrated, chilled, the product filtered and washed with isopropanol and dried. Raw material: Hydroquinone Sulphuric acid Calcium carbonate Ethylene di chloride Isopropanol Raw material consumption per kg of output Hydroquinone = 1.2 kg Sulphuric acid = 1.6 kg Calcium carbonate = 1.6kg/kg Ethylene di chloride = 4L/kg Isopropanol = 2L/kg Annexures 18 GCPL PROCESS FLOW CHART Stage-1 Hydroquinone + ethylene di ch loride sulphuric acid layer separation Stage-II Aqueous layer calcium carbonate cen trifu ge Liquid from centrifuge concentrated Residu e ch illed Crystallisation Centrifugation isopropanol Dryin g Milling, Blending & Packing Annexures 19 GCPL 3. TIEMMONIUM METHYL SULPFATE (TMS) Morpholine is reacted with 2-acetyl thiophene and p-formaldehyde in the presence
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