Pharmazell (India) Private Limited, (Unit-I) – Chennai” Proposed Expansion of Basic Organic Chemicals (BOC) Manufacturing Facility and Product Quantity

Pre-Feasibility Report Pharmazell (India) Private Ltd.,

PRE FEASIBILITY REPORT

For

“Pharmazell (India) Private Limited, (Unit-I) – Chennai” Proposed Expansion of Basic Organic Chemicals (BOC) Manufacturing facility and Product Quantity

S. No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kancheepuram District, Tamil Nadu

December 2016

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Pre-Feasibility Report Pharmazell (India) Private Ltd.,

CHAPTER–1

EXECUTIVE SUMMARY

Executive S.No. Description Summary 1. Identification of Pharmazell (India) Private Ltd, (Unit – I). was incorporated in the Project year 1993 in the name of “Diamalt Pharmorganica Private Limited” & established the factory in the year 1994. Trial production was started in the year 1995. The company is located at Madras Export Processing Zone (MEPZ), Tambaram, and Chennai- 600045.

The plant mainly produces L-Cysteine Hydrochloride monohydrate, L-Cysteine Hydrochloride anhydrous and S-Carboxy methyl cysteine (carbocisteine) which finds application in pharmaceutical food processing and food preservation.

Pharmazell (India) Private Ltd., proposed to expand its manufacturing facility and product quantity located at S.No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai

The proposed project is categorized as „B‟ of 5(f) (as per the Gazette Notification dated 14th September, 2006. 2. Project M/s. Pharmazell (India) Private Ltd, (Unit – I), Chennai. Proponent 3. Brief Description The current report deals with increase in expansion of product quantity of Project from 1819.2 TPA to 2119.2 TPA (Carbocysteine product quantity increased from 300 TPA to 600 TPA) at MEPZ, Kadaperi Village, Tambaram, Chennai, Kancheepuram district in the state of Tamil Nadu.

The Carbocisteine product is a muculative agent which is used for cough syrup manufacturing. Salient features 4. Total plot area 2.587 Acres (10,470 Sqm) 5. Product Quantity 2119.2 TPA 6. Location Particulars Details Latitude 12°56'51.87" N Longitude 80°07‟14.48" E Total Plot Area 10,470 Sq.m (2.587 Acres) Land Use Category Industrial Use Zone NH 48 – Chennai to Trichy Highway Nearest Highway (GST Road)

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Nearest Railway Station Tambaram (2 km) Chennai International Airport Nearest Airport (5.5 km) Nearest Harbour Chennai Port (25 km)

7. Project Cost 57.49 Crores (Existing: 54.49 Crores + Proposed : 3Crores) 8. Water For Existing Requirement Total Fresh water requirement : 228 KLD For Industrial use : 213 KLD For Domestic use : 15 KLD

Proposed: Total Fresh water requirement : 332 KLD For Industrial use : 313 KLD For Domestic use : 17 KLD For Green Belt Requirement : 2 KLD (STP Treated water from MEPZ)

Sewage & Effluent Generation: Existing: Domestic Sewage : 2 KLD Effluent generated from the plant : 110 KLD Low TDS Stream : 100 KLD I. Cooling Tower bleed off = 17 KLD II. Process & washing Waste water = 35 KLD III. Raw water RO Reject = 48 KLD High TDS stream : 10 KLD I. Softener regeneration = 2.5 KLD II. DM plant regeneration = 2 KLD III. Boiler Blow down = 3 KLD, IV. Scrubber bleed off = 2.5 KLD

Proposed: Domestic Sewage : 2 KLD Effluent generated from the plant : 159 KLD Low TDS Stream : 145 KLD I. Cooling Tower bleed off = 20 KLD II. Process & washing Waste water = 80 KLD III. Raw water RO Reject = 45 KLD High TDS stream : 14 KLD I. Softener regeneration = 4 KLD II. DM plant regeneration = 4 KLD

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III. Boiler Blow down = 4 KLD IV. Scrubber bleed off = 2 KLD

Details of Recycled & Recovered water: Exiting: Recycled water from ZLD : 80 KLD (Used for cooling tower make up) Recovered pure steam condensate : 10 KLD (Used for boiler feed)

Proposed: Recycled water from ZLD : 100 KLD (Used for cooling tower make up) Recovered pure steam condensate : 20 KLD (Used for boiler feed) 9. Source MEPZ 10. Power Supply The power requirement for the proposed project is 2000 kVA and it is sourced from the nearby TNEB grid which is distributed through the substation within project premises. 2 Nos. of 750 kVA DG set has been installed at the plant as back-up power supply source for the plant. 11. Alternative Site No alternative site has been considered and the existing plant is situated inside the MEPZ. 12. Quantity of Existing: waste Bio Degradable waste : 10 Kg/day Nonhazardous waste (Packing materials, Used Insulation waste, Metal scrap) : 16 Kg/day Industrial hazardous waste : 0.418 Tons/day

Proposed: Bio Degradable waste : 21 Kg/day Nonhazardous waste (Packing materials, Used Insulation waste, Metal scrap, Domestic recyclable) : 40 Kg/day Industrial hazardous waste : 0.59 Tons/day 13. Total waste The waste water generated from the plant would be 145 KLD. water generation The effluent generated from the plant will be segregated as HTDS, LTDS and utility streams and treated in the “Existing Waste water recycling plant (ZLD)”. 120 KLD of Treated water is recycled for cooling tower make up and Boiler feed. 14. Land use & land The plant is located within the Madras Export Processing Zone Ownership (MEPZ) and land use is Industrial Use Zone as per Chennai Metropolitan Development Authority (CMDA).

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total land area of 2.587 Acres (10,470 Sq.m) for Pharma development. 15. Conclusion Pharmazell (India) Private Ltd., (Unit-I) – Chennai, proposes to expand its Basic Organic Chemicals (BOC) manufacturing facility in order to provide affordable medicines to all. BOC manufacturing facility not only increases the market availability of organic chemicals but also reduces the import burden on the country and also support the government by paying the taxes will contribute the growth of Indian economy and strengthen the socio-economic values in the area. The proposed expansion project will adopt the state of the art technologies and a dedicated team of environmental professionals for treatment and recycling of effluents, operation and monitoring of all pollution control equipment. Pharmazell has a defined EHS policy and a robust Environmental Management system supported by a well-defined organizational structure to ensure the prevention of pollution and to protect the environment.

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CHAPTER - 2 INTRODUCTION OF THE PROJECT

2.0 IDENTIFICATION OF PROJECT AND PROJECT PROPONENT Pharmazell (India) Private Ltd. was incorporated in the year 1993 in the name of “Diamalt Pharmorganica Private Limited” & established the factory in the year 1994. Trial production was started in the year 1995. The company is located at Madras Export Processing Zone (MEPZ), Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai in the State of Tamil Nadu - 600045.

The company name was changed from “Diamalt Pharmorganica Private Limited” to “Bfgoodrich Diamalt Private Limited” in the year 1998. Again company name was changed from “Bfgoodrich Diamalt Private Limited” to Noveon Diamalt Private Limited” in the year 2001. Pharmazell acquired part of “NOVEON” and hence the company name was changed to “Pharmazell (India) Private Limited” in the year 2006.

“Pharmazell (India) Private Limited” got its first CTO order (No.16426 dt.27.2.1998 for Water & No.12551 dt. 27.2.1998 for Air) from TNPCB in the name of Diamalt Pharmorganica Pvt. Ltd., with validity up to 31.03.1999.

The company got enhancements in the year of 2008 vide the CTO order No. 21627 for Water Act and No. 17664 for Air Act dt.29.8.2008 with validity up to 31.03.2009. Recently the company got enhancements TNPCB vide Order No. 160814840869 for Water Act and CTO Order No. 160824840869 for Air Act dated 13.07.2016 with validity up to 31.03.2017. The present study is the proposed expansion of Basic Organic Chemicals (BOC) with the production quantity of 1819.2 TPA to 2119.2 TPA (Carbocysteine product quantity increased from 300 TPA to 600 TPA in the land extent of 2.587 Acres Acres at S.No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai

Pharmazell (India) Private Limited is one of the leading Pharmaceutical companies in India, engaged in the development, manufacturing and distribution of Organic Chemical.

Pharmazell (India) Private Limited currently consists of more than 150 employees, consistently ranked among fastest growing pharmaceutical companies in India.

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2.1 BRIEF DESCRIPTION OF THE NATURE OF PROJECT

Pharmazell (India) Private Limited is one of the leading Pharmaceutical companies in India, engaged in the development, manufacturing and distribution of Basic Organic Chemicals (BOC) at S.No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai in the year of 1994.

The company proposes to expand its Basic Organic Chemicals (BOC) manufacturing capacity in the existing premises with a total investment of Rs. 57.49 Crores including the existing investment of Rs 54.49 Crores (GFA certificate Attached as Annexure-IV). The project site lies between 12°56'51.87" North latitude and 80°07‟14.48" East longitude. The project site is well connected by the National and State High Ways.

2.2 Company Profile

A Thorough Understanding of Our Clients Needs: PharmaZell develops and produces pharmaceutical active ingredients (API), provides services for formulation development and compiles required regulatory documents/dosiers for both the originator and generic pharmaceutical industry. Being a German enterprise with multinational development and production sites as well as a globally acting sales organization we are a long lasting reliable and stable partner for our customers on all continents. We develop tailor made solutions based on a broad and flexible technology platform together with our customers striving to solve their problems efficiently and with full commitment. PharmaZell follows ethical principles and acts responsibly caring about the environment, our business partners and employees.

The Best of Both Worlds: A technology platform that is as extensive as it is flexible is complemented by intensive and trust-based collaboration with customers that comprises countries and continents. At five locations in Germany, Italy, Switzerland and India, the Company employs over 800 professionals. Corporate headquarters are located in Raubling, Bavaria, with a sales branch situated in Cleveland, Ohio.

Adding to Our Competitive Edge: PharmaZell places particular emphasis on continuously optimizing its development and production processes. A culture of innovation is as much one of the Company„s core values as is acting according to ethical principles with respect to staff, partners, and the

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Pre-Feasibility Report Pharmazell (India) Private Ltd., environment. R&D departments develop production processes and formulations that are turned into commercial products at high speed and in accordance with market and cost requirements. A continuously adapted supply chain ensures optimal quality and reliable product supply.

Seizing Opportunities: With its eyes firmly set on the future, PharmaZell relies on growth. Precisely targeted and continuous investment as well as a permanent optimization process ensures that the company will continuously enhance existing offerings. In addition, staff works at the highest level to develop new, seminal technologies.

Chennai Division: This plant was established in 1994 and is the largest site of the PharmaZell Group. Furthermore, the location at Chennai is PharmaZell„s first production site outside of Germany. Originally, the plant had been built to produce amino acid derivates. During the last years however, the facilities were expanded to perform also complex syntheses.

2.3 DEMAND SUPPLY GAP The Carbocisteine (muculative agent) in the day to day activities has derived significant demand. In order to meet the demand and the quantity of Carbocisteine proposed to be increased.

2.4 EMPLOYMENT GENERATION At present the company has over 170 employees. We have a strong team of R&D Manufacturing, Maintenance, Quality Control and Quality Assurance chemists with very pertinent skills in process development, manufacture and testing of our product range. The team comprises of Engineers, Post Graduates, Graduates and Diploma holders from some of the premier institutes in India.

The expansion facility will generate direct and indirect employment. About 177 employees (including existing 170 employees) will be benefitted due to the proposed project, in that 170 nos. direct employment and 7 nos. of indirect employment.

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CHAPTER - 3 PROJECT DESCRIPTION

3.1 TYPE OF PROJECT

The proposed project is an expansion of Basic Organic Chemicals (BOC) manufacturing unit as per the Environment Impact Assessment (EIA) Notification dated 14th September 2006 and amendments in 2009 & 2011, the proposed project falls under 'Category B1' with project or activity type number '5(f)', which requires preparation of EIA Report to get Environmental Clearance from the State Environmental Impact assessment Authority (SEIAA).

Pharmazell (India) Private Limited, (Unit-I) is one of the leading Pharmaceutical companies in India, engaged in the development, manufacturing and distribution of Basic Organic Chemicals (BOC) at S. No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai in the year of 1994.

3.2 LOCATION

Pharmazell (India) Private Limited (Unit-I) proposes to expand the Basic Organic Chemicals (BOC) manufacturing quantity at .No. 164/1, Plot No. B5 & B6, MEPZ, Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai.

3.3 DETAILS OF ALTERNATE SITE

No alternative site was examined, because this is an expansion of product quantity in the existing plant at Kadaperi Village, Tambaram Taluk, Kancheepuram district of Tamil Nadu. The plant has the following advantages which is favorable for the expansion of product quantity:

. Land availability . Existing setup support for maintenance, utilities and administrative controls (cost benefit). . Feasible power requirement is available . Sufficient water availability . Connectivity of the site

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3.4 PRODUCTS AND PRODUCTIONS QUANTITY

The existing & proposed products and their production quantity are as follows: S. No. Description Quantity / Month

Existing Proposed (After Expansion) Product: 1 Cysteine Hydrochloride 75 T 75 T monohydrate 2 Cysteine Hydrochloride anhydrous 41.6 T 41.6 T 3 Carbocysteine 25 T 50 T Total Production Quantity 141.6 T/M 166.6 T/M ( 1699.2 TPA) ( 1999.2 TPA) By Product: 1 Sodium Hypo Chlorite 10 T 10 T

3.5 RAW MATERIALS REQUIRED AND QUANTITIES

The raw materials required for the manufacture of proposed products are the chemicals and the fuel. The chemicals required for the process are mostly sourced from the local (indigenous) markets. Some of these raw materials will be imported from various countries. Mode of transportation of all raw materials and finished products from the project site is by road to local markets and by road / rail / air / sea.

S. No Name of the raw Material Quantity (T/Month) Existing Proposed (After Expansion) L-Cysteine HCL Mono / Anhydrous 1 HCL 151.6 151.6 2 NaOH 11.6 11.6 3 L-CYSTINE 88.6 88.6 4 ACTIVATED CARBON 0.932 0.932 Carbocisteine 1 HCL 22 38.79 2 NaOH 47 94 3 MCA 16.89 32.4 4 L-Cysteine 26.43 55.89 5 Activated Carbon 0.375 0.6

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3.6 MANUFACTURING PROCESS

Process Description:

L – Cysteine HCI Monohydrate / Anhydrous

The Cysteine Plant Processes L-Cystine an essential amino acid in crystalline form that is transformed into a watery solution and electrochemical processes are used to produce – Cysteine Hydro Chloride. The product finds application is food preservatives and some pharmaceutical applications as well.

Preparation of L-Cysteine Solution

Cystine is passed in the stirrer vessel where HCL and condensate water are mixed in the vessel, after which cystine is stirred in, activated carbon and EDTA solution is added finally. The finished cystine solution is pumped to the filter press. Where it is continuously circulated for filtration until it is clear. Then the solution is stored in a tank. Reduction processing of L- Cystine solution into cysteine hydrochloride solution in the Electrolytic circuit

Cysteine hydrochloride:

The cystine solution pumped from the tanks to the cathode space of the electrolytic cells. The cystine is produced to cysteine by the electrochemical reaction in the cathode space with hydrogen evolved. The Pumps supply the anode space with H2SO4 acid from the tanks. The Traces of chlorine evolves during the process.

The trace of chlorine is passed through an absorption tank filled with sodium hydroxide solution to obtain sodium hypo chlorite, which is sold as a byproduct.

The cysteine hydrochloride solution is stored in the tank. The solution in the tank is pumped to the evaporator where its gets concentrated then crystallized in the crystallisers, centrifuged and dried. The condensate from the evaporator and the centrifuge will be recycled for the subsequent batches.

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Flow Chart – L – Cysteine HCI Monohydrate / Anhydrous:

L-Cystine HCI Water/ML Activated Carbon

Spent carbon for Dissolution disposal

Chlorine absorbed as Electrolysis NaOCI in absorption tank

Condensed Evaporation Water for Recycling Crystallization

Condensed Centrifugation Water for Recycling

Drying

Packing

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Process Description – Carbocysteine:

The cysteine hydrochlorides dissolved with water in the reactor vessel where it is added with Mono chloro acetic acid (MCA) and charcoal. Then the pH is adjusted by adding Na OH and then the solution will be circulated through filter press where it gets filtered, then the filtrate is precipitated by adding HCL. The solution will be then centrifuged, dried and packed as product.

Flow Chart - Carbocysteine

L-Cysteine HCl. MCA EDTA

Reaction by adding NaOH

Carbon treatment

Filtrate & dilution with DM Spent Carbon for disposal water

Filtration and Washing

Precipitation by adding HCI reaction by adding NaOH

Centrifugation &Washing Wash water to ETP

Drying

Packing

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3.7 EQUIPMENT DETAILS

The existing and proposed expansion of equipment in the plant for the production of Basic Organic Chemicals (BOC) is as follows: S. No Equipment Name Existing Proposed (After Expansion) Capacity Quantity Capacity Quantity (Nos.) (Nos.) 1. Rubber Lined 6 M3 2 No change Reactor (Dissolution Reactor) 2. Glass Lined Reactor 8 M3 1 No change 3. Glass Lined Reactor 6 M3 3 6 M3 4 4. Glass Lined 6 M3 2 6 M3 3 Crystalliser 5. Glass Lined 2 M3 3 No Change Crystalliser 6. Glass Lined 1 M3 3 No change Crystalliser 7. Cone Dryer 2.5 M3 2 No change 8. Cone Dryer 2.0 M3 2 No change 9. Fluidized Bed Dryer 250 Kg 2 250 Kg 3 10. Centrifuge 48 inches 6 48 inches 7 11. Centrifuge 52 inches 1 No change 12. Rubber Lined - 3 Nos. - No change Evaporator 13. Absorption Tank - 3 Nos. - No change 14. Mixer - 3 Nos. - No change 15. Miller - 2 Nos. - No change 16. Filter Press - 3 Nos. - No change 17. Vacuum pump - 8 Nos. - 11 Nos.

3.8 WATER REQUIREMENT AND WASTE WATER GENERATION

Existing water requirement waste water requirement: Water requirement of the project for the domestic and industrial activity during operation of the plant will be 228 KLD. The water required is met through the MEPZ which satisfy the bore water quality. The existing water requirement is given below:

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Description Fresh water Input (KLD) Process 75 Boiler 10 Domestic 15 RO Reject 48 Cooling tower make up 80 Total water requirement 228

The effluent generated from the plant will be 110 KLD which is treated in the ETP installed in the site. The Zero Liquid Discharge (ZLD) is achieved through the Multi Effect Evaporator (MEE) system The treated water will be recycled in the boiler feed and cooling tower top-up. The waste water generated from the plant is given below:

Parameter Waste water Generated (KLD) Process & washing (LTDS) 35 (to ETP) Cooling tower bleed-off (LTDS) 17 (to ETP) Raw water RO Reject (LTDS) 48 (to UF/RO) Boiler blow down (HTDS) 3 ( to MEE) Wet Scrubber make up (HTDS) 2.0 (to MEE) Softener Reject (HTDS) 2.5 (to MEE) DM reject (HTDS) 2.5 (to MEE) Total waste water generated 110 Domestic Sewage 13 (MEPZ – CSTP)

The overall water balance is given below: Parameter Fresh Recycle Recovered Total Water Waste water Losses water water water requirement Generated (KLD) Input (KLD) (KLD) (KLD) (KLD) (A-B) (KLD) (B) (A) Process & 72.5 - - 72.5 35 37.5 washing DM Reject 2.5 - - 2.5 2.5 0 Boiler Feed 10 - 10 20 3 7 Cooling tower 75.5 80 - 155.5 17 58.5 make up Softener 2.5 - - 2.5 2.5 0 Reject Wet Scrubber 2 - - 2 2 0 make up Ro reject 48 - - 48 48 0 Total 213 80 10 303 110 103 Domestic 15 - - - 13 2 (Sent to MEPZ – CSTP)

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Proposed water requirement: The water requirement for the plant after the expansion will be 332 KLD which will be met through the private tanker supply. The quality of water will satisfy the bore well quality and the same is sufficient for the process activities. The proposed water requirement is given below:

The proposed Fresh water requirement is given below: Parameter Fresh water Input Process & washing 190 Boiler Feed 20 Cooling tower make up 100 Wet Scrubber make up 2 Domestic 17 Fire Hydrant system Make up 1 Gardening 2 Total proposed water requirement 332

The effluent generated from the plant total will be 114 (100KLD is low TDS stream) and 14 KLD is High TDS Stream) which will be treated in the ETP installed in the site and followed by The Zero Liquid Discharge (ZLD) is achieved through the Multi Effect Evaporator (MEE) system .The treated water will be recycled in the boiler feed and cooling tower top-up. The waste water generated from the plant is given below:

The waste water generated from the plant is given below:

Parameter Effluent Generation (KLD) Process & washing (LTDS) 80 (to ETP) Boiler blow down (HTDS) 4 (to MEE) Cooling tower bleed-off (LTDS) 20 (to ETP) DM Reject (HTDS) 4 (to MEE) Softener Reject (HTDS) 4 (to MEE) Wet Scrubber bleed-off (HTDS) 2 (to MEE) RO Reject (LTDS) 45 (to UF/RO) Total proposed effluent generation 159 (Except sewage) Domestic Sewage 15 ( MEPZ – CSTP)

The overall proposed water balance is given below:

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Parameter Fresh Recycle Recovered Total Water Waste water Losses water water water requirement Generated (KLD) Input (KLD) (KLD) (KLD) (KLD) (A-B) (KLD) (B) (A) Process & 96 - - 96 80 16 washing DM Reject 4 - - 4 4 0 Boiler Feed 20 - 20 40 4 16 Cooling tower 96 100 - 196 20 76 make up Softener 4 - - 4 4 0 Reject Wet Scrubber 2 - - 2 2 0 make up Ro reject 90 - - 90 45 45 Fire Hydrant 1 - - 1 0 1 system Make up Gardening 2 - 2 0 2 Total 315 100 20 435 159 156 Domestic 17 - - 17 15 2 (Sent to MEPZ – CSTP)

Parameter Effluent Generation (KLD) Process & Washing (LTDS) 80 (to ETP) Boiler blow down (HTDS) 4 (to MEE) Cooling tower bleed-off (LTDS) 20 (to ETP) DM Reject (HTDS) 4 (to MEE) Softener Reject (HTDS) 4 (to MEE) Wet Scrubber bleed-off (HTDS) 2 (to MEE) RO Reject (LTDS) 45 (to UF/RO) Fire Hydrant system Make up 0 Total proposed effluent generation 159 (Except sewage) Domestic Sewage 15 ( MEPZ – CSTP)

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Wastewater generation and Treatment Method for proposed expansion

S. Effluent Source Qty Treatment ETP - RO ETP- Disposal No Stream (KLD) method Permeate RO Method Qty Reject (KLD) Qty (KLD) 1 Low TDS Process 80 Send to ETP 40 40 RO Stream Waste followed by permeate & (LTDS) Water ZLD system Vapour 2 Cooling 20 (UF, RO & 10 10 condensate Tower MEE) send is Bleed off being used 3 Raw water 45 Send to ZLD 22.5 22.5 for cooling RO Reject system (UF, tower, RO Boiler and REJECT SEND TO MEE. 4 High TDS Softener 4 Send to MEE Recycled Stream Reject water from 5 (HTDS) DM Reject 4 ZLD (72.5 6 Boiler 4 RO Blow Permeate down and 27.5 7 Scrubber 2 Vapor Bleed off condensate 8 High TDS ETP RO 72.5 from MEE) Stream Reject is used for (HTDS) cooling tower, Boiler and Salt send to TNWML.

The effluent generated for the proposed product expansion from the plant will be 159 KLD. The effluent generated from the plant will be segregated as HTDS, LTDS and utility streams for effective treatment and treated in the “Waste water recycling plant (ZLD)” consists of ETP (Primary & Secondary treatment), High Pressure RO (HPRO), Multi Effect Evaporator (MEE), Centrifuge, Sludge drying Bed/Filter. Treated water is recycled for cooling tower make up, Boiler feed, Gardening, scrubber maker and fire hydrant. Domestic effluents send to common Sewage Treatment Plant operated by MEPZ. Waste water recycling plant process flow sheet is attached. The effluent treatment scheme is devised on segregation approach (based on Total Dissolved Solids - TDS) which is as follows:

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 High TDS (HTDS) effluent with TDS more than 25,000 mg/L  Low TDS (LTDS) effluent with TDS less than 25,000 mg/L

Treatment method for the HTDS/LCOD effluent Low TDS stream which is generated from the process is passed through ETP & RO. Reject water from RO and High TDs stream will be collected in the MEE feed tank. The combined HTDS effluent sent to Multiple Effect Evaporator (MEE) to enrich the concentration level. The enriched concentration stream is sent to centrifuge to obtain salts and disposed to Tamil Nadu Waste Management Limited (TNWML). Pure steam condensate returns back to boiler & Cooling tower.

LTDS effluents are collected in equalization tank of 85KL volume. For homogenization mixing arrangement is available in equalization tank. From equalization tank effluent is passed through pH adjustment system followed by aeration tank – 1 (alternatively Aeration tank - 1 will be operated as activated sludge process system) followed by a clarifier followed by settling tank and then send to Aeration tank – 2 followed by a settling tank. Treated effluent will be collected in effluent Feed tank for further treatment. Sludge generated from settling tank and clarifiers will be passed through sludge drying bed/Filter press. The dried sludge (powder form) is packed in HDPE bags and stored in covered shed till one truck load and then sent to TNWML for safe disposal.

Tertiary Treatment: Tertiary treatment system consists of Pre filter (Multi Grade Filter, Iron Removal Filter, Activated Carbon Filter and Bag filter) and followed by UF and RO plant, Permeate water is collected in permeate collection tank. Reject is collected in MEE feed tank.

Permeate water is collected in a storage tank and will send to cooling towers for makeup and boiler feed. Every drop of waste water is collected, treated and recycled back.

3.9 POWER AND FUEL REQUIREMENT The power requirement for the plant is about 2000 kVA and it is sourced from the TNEB. Also, for the back-up power source 2 nos. of 750 kVA capacity DG sets installed to meet the emergency power requirement of the plant.

The plant is already installed with 1 no of Oil Fired Boiler with capacity 3TPH (Tons per Hour) and 5TPH (Tons per Hour). Any one boiler will be used as stand by. Low Sulphur HSD will be sourced from the local market.

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The total fuel required for operation of boilers and DG set is given below: S. No. Boiler / DG set Fuel consumption Fuel type 1 3 TPH - Oil fired Boiler 2.25 T/day Furnace Oil (Stand by) 2 5 TPH (Operational) 6.428 T/day Furnace Oil (Oil fired) 4 DG Sets 2.4 T/day (Assumed as 24 hrs HSD operation)

Emissions: Boilers, DG sets are the main sources contribute to emissions from the plant. Stack height of 9.5mts for DG sets is installed. A stack height of 32mts is installed for the boiler. The same Dust collector followed by Bag filters installed. A stack height of 10mts is installed with Wet scrubber followed by packed column to control the emissions.

All hazardous chemicals are carefully handled in a closed system, thereby preventing any discharge of these chemicals in to air.

In order to control the emissions from process the scrubber system is installed in the site. The existing scrubber is as follows: S. No Number Equipment Capacity Connected Area 1 SCR-1 Scrubber System 45000 CFM Synthetic Process area

The same scrubber system is adequate in order to control the emissions from the proposed process area and utility area.

Details of Source of Emissions & Control Measures: S. No Source of Control Top Height Material of Emission Measures dimensions Construction 1 HCL Storage Tanks (3 Nos.) 2 Vacuum Pump – 11 Nos, Fume Wet Cupboard – 2 Scrubber 0.9 10 FRP Nos. with Stack 3 Reactor – 10 Nos., Crystallizer – 6 Nos. 4 Boiler – 3 T/Hr Common 0.45 32 Mild Steel & 5 T/Hr Cyclonic

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Dust Collector and Common Stack 5 DG set 750 Stack 0.2 9.5 Mild Steel KVA Capacity 6 DG set 750 Stack 0.2 9.5 Mild Steel KVA Capacity

3.10 SOLID WASTE GENERATION

S. No Name of the Solid Quantity Disposal method Waste (MT/Y) Existing Proposed (After Expansion) Non-hazardous Handed over to local waste 1 9.36 36 waste (Domestic) collection system Stored and Disposal to 2 Used / Spent Oil 3.0 3.0 Authorized Recyclers

70 TON 90 TON Stored and Disposal to 3 Spent Carbon (WET (WET Authorized Recyclers WEIGHT) WEIGHT)

Stored and Disposal to 4 Chemical Sludge(A) 25 50 Authorized Recyclers

Stored and Disposal to 5 Evaporated Salt(B) 30 50 Authorized Recyclers

Flue Gas Cleaning Stored and Disposal to 6 Residue (Boiler 12.5 12.5 Authorized Recyclers Chimney)

Discarded Container Stored and Disposal to 7 1.5 2.5 /Barrels Authorized Recyclers

Date Expired Drugs Stored and Disposal to 8 8.0 15 /Medicines Authorized Recyclers

Wastes Residue Stored and Disposal to 9 0.75 0.75 Containing Oil Authorized Recyclers

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Solid waste generation (Existing & Proposed) The proposed solid waste generation after the expansion will consist of domestic solid waste 21Kg/day, nonhazardous waste 36 Kg/day and the hazardous waste 0.59 Tons/day. The domestic waste will hand over to the local body waste collection system, nonhazardous waste will be sent to recyclers and the hazardous waste will be sent to Tamil Nadu Waste Management Limited (TNWML).

3.11 PURPOSE OF EIA

As per the EIA notification dated 14th September, 2006, it is mandatory for the proposed activity to get Environmental clearance before setting up or expansion / modernization. The detailed chart delineating the process is given in Figure 3.1.

Fig 3.1 Process of Environmental Clearance Procedure

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Environmental Impact Assessment (EIA) is a well-planned process to predict the environmental consequences of any kind of development, which is a result of human activities and to suggest appropriate measures in order to reduce adverse effects and also to augment positive effects. The EIA procures a rational and ethical approach for sustainable development. However, it is more scientific process because it not only tells the past, present and the future consequences of going on development, but also predicts the future events which likely to change due to some reasons, In terms of the EIA notification, MoEF dated 14th September 2006, the generic structure of EIA documents shall be as under:

. Introduction . Project Description . Description of the Environment . Analysis of Alternatives (Technology & Site) . Anticipated Environmental Impact & mitigation Measures . Environmental Monitoring Program . Additional studies . Project benefits . Environmental Cost benefits Analysis . EMP . Summary & Conclusion . Disclosure of Consultant Engaged

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CHAPTER - 4 SITE ANALYSIS

4.1 CONNECTIVITY

The nearest city is Chennai at about 18 Km from the plant. It is well connected with the road and rail networks which is feasible for the proposed expansion viability.

Major roads NH 48 – Chennai to Trichy Highway (GST Road) Nearest Sea Port Chennai Port (25 km) Nearest Railway Station Tambaram (2 km) Nearest City Bus Stop Tambaram Nearest Airport Chennai International Airport (5.5 km)

4.2 LAND FORM, LANDUSE AND LAND OWNERSHIP

The proposed expansion in the plant in the land area of about 2.587 Acres (10,470 Sq.m) of Kadaperi Village, Tambaram Taluk, Kacheepuram District, Chennai. The land use is categorized as Industrial use Zone by Chennai Metropolitan Development Authority (CMDA).

The Proposed land use details are given in the below table.

Table 4.1 Land use Breakup S.No. Description Area in (Sq.m) Percentage (%) 1. Total Land Area 10470 100 2. Ground Coverage 6000 57 3. Roads and Pavements 2960 28 4. ETP and other Utilities area 1050 10 5. Green belt area 400 4 6. Solid waste storage/Disposal area 60 1

4.3 EXISTING INFRASTRUCTURE

The plant has the existing ground cover of 6000 Sq.m. A well laid road internal roads are in place also it has easy connectivity with the nearby Chennai city. There is an existing internal water connection pipeline for the entire project site and the storm water drain is also well established along the road network. Power cable lines and the telecommunication lines are available for the existing buildings around the project site.

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4.4 SOIL CLASSIFICATION

Broadly, the soils can be put in four major groups, based on the basic fabric of soils i.e. Soil texture which governs its many other properties. They are: 1) Clayey soil, 3) Red sandy soil

Of the above soils the district is mainly covered by three types of soils namely: 1) Silty loam soil 2) Clay loam soil 3) Silty Clay loam soil.

4.5 CLIMATIC DATA

The climatic conditions of the plant are given below:

Max. Temp –37.6º C Summer Min. Temp - 24.5º C Max. Temp– 21.4º C Winter Min. Temp - 17.0º C Rainfall Intensity 20 mm/Hr Morning - 71% Average Humidity Evening – 34%

4.6 SOCIAL INFRASTRUCTURE AVAILABLE

The plant is situated within the Madras Export Processing Zone (MEPZ), Tambaram. There are number of industries in the area like, Inga Pharmaceuticals, SCI Technologies India Pvt Ltd, Cognizant Technologies. The present site is surrounded by Super Auto Forge Private Limited, GG Organics Export Private Limited and BTR Packaging Private Limited.

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CHAPTER - 5 PLANNING BRIEF

5.1 PLANNING CONCEPT

Pharmazell (India) Private Limited proposes to expand the Basic Organic Chemicals (BOC) product quantity. The BOC drugs which can be manufactured in Indian pharmaceutical industries are of low production quantity which cannot meet the actual demand. In order to meet this demand and to provide healthier environment to the local people we are proposed to expand the product quantity.

5.2 LAND USE PLANNING

The existing & proposed land use breakup is given in table below: S. No. Description Area in (Sq.m) Percentage (%) 1 Total Land Area 10470 100 2 Ground Coverage 6000 57 3 Roads and Pavements 2960 28 4 ETP and other Utilities area 1050 10 5 Green belt area 400 4 6 Solid waste storage/Disposal area 60 1

The land use comes under Industrial Use Zone as per CMDA and there is no change in land use.

5.3 EXISTING INFRASTRUCTURE

The Site has the required Infrastructure to meet the current and proposed requirements such as • Canteen • Potable drinking water • Training block • Laying of Black top / Concrete internal roads • Fire hydrant facility • Rain Water Harvesting Pond • Eye/body wash showers • First Aid kits at all prominent places. • Occupational Health Centre. • Rest Room for employees • Pre-employment and routine medical examinations and the necessary follow up actions • Communication systems like Phone, Internet with safety measures, etc. • Security system at the entrance etc.

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CHAPTER - 6 PROPOSED INFRASTRUCTURE

6.1 INDUSTRIAL AREA

The area has well established internal road networks and also it is well connected to the Chennai city and also to the nearby rail network. The plant is self-sufficient to cater the expansion of the project. Hence, no new infrastructure is proposed.

6.2 NON PROCESSING AREA (RESIDENTIAL AREA)

All the manpower for the proposed project will be sourced from the neighboring villages, hence no colony/ residential area is proposed in the project.

6.3 GREENBELT AREA

Nearly 400 Sq.m area of total land area is developed for greenbelt. Indigenous trees are planted in greenbelt development with the native species.

6.4 SOCIAL INFRASTRUCTURE

The project site is surrounded by schools, community health center and other adequate infrastructures. The impacts by the proposed expansion will be assessed and an appropriate plan of Corporate Social Responsibility (CSR) activity will be planned. Some activities which were noted and will contribute in the social activities are as follows:

• Infrastructure development in the nearby village, schools • Conducting Medical camp

6.5 CONNECTIVITY

The nearest city is Chennai at about 18 Km from the plant. It is well connected with the road and rail networks which is feasible for the proposed expansion viability.

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6.6 DRINKING WATER MANAGEMENT

Water requirement for domestic will be availed from the MEPZ which met the drinking water quality. Water required for the process will be met through the MEPZ supplies.

6.7 INDUSTRIAL WASTE (SEWAGE AND EFFLUENT) MANAGEMENT SYSTEM

The domestic wastewater will disposed to the Common Sewage Treatment Plant which is being operated by MEPZ and the process effluent generated from the plant will be treated in Effluent Treatment Plant (ETP) installed in the site. The ETP installed will give rise to Zero Liquid Discharge (ZLD) through Multi Effect Evaporator (MEE) System installed at the site, so that the treated effluent will be reused for the processes so that there is no discharge of the treated effluent. The effluent stream is divided in to High Level Total Dissolved Solids (HTDS) stream and Low Level Total Dissolved Solids (LTDS) stream and they are treated correspondingly in the ETP.

6.8 SOLID WASTE MANAGEMENT

The solid waste generated from the plant is mainly of hazardous waste (process waste) and non-hazardous waste (domestic waste). The domestic waste will be collected, segregated as biodegradable and non-biodegradable solid waste. The biodegradable solid waste will be handed to over to the local waste collection facility and non-biodegradable waste will be disposed through the recyclers. The hazardous waste mainly consists of organic residue, spent carbon, spent oil and chemical sludge from effluent treatment will be collected and sent to Tamil Nadu Waste Management Limited (TNWML) / authorized recyclers.

6.9 POWER REQUIREMENT

The power requirement for the plant is about 2000 kVA and it is sourced from the TNEB. Also, for the back-up power source 2 nos. of 750 kVA capacity DG sets are installed to meet the emergency power requirement of the plant.

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CHAPTER - 7 R & R PLAN

1.0 REHABILITATION & RESETTLEMENT (R & R) PLAN

The plant is located within the MEPZ, Tambaram (Industrial Estate) which has group of industries. Also, the proposal is expansion of Basic Organic Chemicals in the existing plant. There is no residential settlement in the project site. Hence, the Rehabilitation and Resettlement (R&R) Plan is not applicable in this proposed expansion.

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CHAPTER - 8 PROJECT SCHEDULE & COST ESTIMATES

8.0 PROJECT SCHEDULE & COST ESTIMATES

The time schedule for the expansion will be 24 months after getting statuary approval from related authorities. The total cost of proposed project expansion is Rs.57.49Crores. The copy of the GFA certificate is enclosed as Annexure – IV.

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CHAPTER - 9 ANALYSIS OF PROPOSAL

9.0 ANALYSIS OF PROPOSAL

The proposed expansion will help in benefitting the local people financially & socially. The expected benefits to the local people are in areas like employment, communication, educational activities and etc. The proposed expansion project will create direct employment opportunities during the construction phase and in the operational phase both semi-skilled and unskilled laborers. There will be social benefits from this proposed project.

The benefits through this proposed project are as follows:  Local people will get direct financial benefit by way of employment.  Local people will get some contracts of supply and services to get indirect income.  Company will contribute in improving education and health facilities in nearby area.

Under the Corporate Social Responsibility the Industry will continue to develop a policy of developing the villages in the vicinity by identifying the requirements. The industry will define environmental monitoring program to monitor the Ambient Air Quality as well as Stack Emissions from the Utilities and scrubbers. Industry will strengthen the existing Environment, Health &Safety Department and also continue to engage recognized laboratories to carry out all necessary monitoring parameters for its activities.

The segregated (HTDS/LTDS) wastewater is being regularly analyzed before and after treatment in ETP-ZLD and the industry will continue the same. Qualified staffs are appointed for the purpose of Operation and Maintenance of the pollution control facilities. Stand-by facilities are provided to all the pumps so as to ensure fail proof treatment, handling and disposal. The hazardous waste is being collected, segregated and disposed to Tamil Nadu Waste Management Limited (TNWML). In order to mitigate the emissions from the DG sets adequate stack and to control emission from process scrubber system has been provided.

Further activities will be analyzed, after the analysis of the baseline data generation and socio- economic survey and the appropriate sustainable development will be contributed by the proposed project. The appropriate amount of Corporate Social Responsibility is proposed to be utilized for these beneficial activities.

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