PRE-FEASIBILITY REPORT
CONTENTS
PAGE LIST OF CONTENTS NO. 1.0 EXECUTIVE SUMMARY 5 1.1 GENERAL 5 1.2 SILENT FEATURES OF THE PLANT SITE 5 1.3 PROPOSED PRODUSTS 6 1.4 RESOURCE REQUIREMENT 6 1.5 POLLUTION POTENTIAL AND MITIGATIVE MEASURES 7
2.0 INTRODUCTION 2.1 BACKGROUND 9 2.2 NATURE OF THE PROJECT 9 2.3 PROJECT PROPONENT 10 2.4 NEED FOR THE PROJECT & PROJECT BENEFITS 11
3.0 PROJECT LOCATION & SITE ANALYSIS 3.1 LOCATION 12 3.2 SITE ANALYSIS & INFRASTRUCTURE SETUP 14 DETAILS OF ALTERNATIVE SITES AND JUSTIFICATION OF SITE 3.3 15 SELECTION
4.0 PROJECT DESCRIPTION 4.1 DETAILS OF PRODUCT AND PRODUCTION CAPACITY 16 4.2 LAND AND PROJECT LAYOUT 17 4.3 RESOURCE REQUIREMENTS 20 4.4 DETAILS OF MANUFACTURING PROCESS 22 4.5 RAW MATERIAL REQUIREMENTS 47 4.6 DETAILS OF PRODUCTS & RAW MATERIALS 48 4.7 DETAILS OF MACHINERIES & UTILITIES 49 4.8 SOLVENT RECOVERY SYSTEM 50
5.0 POLLUTION POTENTIAL AND CONTROL MEASURES 5.1 WATER POLLUTION 54 5.2 AIR POLLUTION 61 (A) PROCESS GAS EMISSION 61 (B) FLUE GAS EMISSION 64 (C) FUGITIVE EMISSION 64
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5.3 HAZARDOUS WASTE GENERATION AND MANAGEMENT 65 5.4 NOISE POLLUTION 66
6.0 PROJECT SCHEDULE & COST ESTIMATES 68 6.1 SCHEDULE OF APPROVAL AND IMPLEMENTATION 68 6.2 CAPITAL INVESTMENT 68
7.0 REHABILITATION AND RESETTLEMENT (R&R) PLAN 69
8.0 FINAL RECOMMENDATION 70
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LIST OF TABLES Page No. Table ‐ 1 Details of Key Persons of the Company 11 Table ‐ 2(A) List of Existing Products 16 Table ‐ 2(B) List Of Proposed Products & By‐Products 16 Table ‐ 2(C) Details of Proposed Products 17 Table ‐ 3 Break‐up of Area 17 Table ‐ 4 Details of Fuel Consumption 21 Table ‐ 5 Details of Manpower Requirement 21 Table – 6 (A) Summary of Mass Balance ‐ Oxyclozanide Process, Stage ‐I 27 Table – 6 (B) Summary of Mass Balance for ‐ Oxyclozanide Process, Stage ‐II 28 Table – 6 (C) Summary of Mass Balance ‐ Oxyclozanide APCM(stage I) 29 Table – 7 (A) Summary of Mass Balance ‐ Oxyclozanide Process, Stage –I 33 Table – 7 (B) Summary of Mass Balance for ‐ Oxyclozanide Process, Stage ‐II 34 Table – 7 (C) Summary of Mass Balance ‐ Oxyclozanide APCM (stage I) 35 Table – 8 (A) Summary of Mass Balance for Glibenclamide – Stage‐I 39 Table – 8 (B) Summary of Mass Balance for Glibenclamide – Stage‐II 40 Table ‐ 9 Summary of Mass Balance for 1, 2, 4‐Triazole 43 Table ‐ 10 Summary of Mass Balance for 4‐Amino ‐1, 2, 4 ‐ Triazole 46 Table ‐ 11 Raw Material Requirements 47 Table ‐ 12 Details Of Product & Raw Material 48 Table ‐ 13 Details of Machineries and Utilities 49 Table ‐ 14 Details of Solvent Consumption And Mass Balance 51 Table‐15 Summary of Solvent Consumption and Mass Balance 52 Product wise Water Consumption & Wastewater Generation for Table‐16 (A) 55 proposed project Table‐16 (B) Category wise Water Consumption & Wastewater Generation 56 Table ‐ 17 Stage wise Characteristics of Effluent 58 Table ‐ 18 Detail Of Proposed Effluent Treatment Plant 59 Table –19 (A) Details of Gaseous Emission 61 Table –19 (B) Details of Process Gas Stack 61 Table –20 Details of Air Pollution Measures for Process Stack 62 Table –21 Details of Scrubbing System 62
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Table –22 Details of Flue Gas Stack 64 Table –23 Hazardous Waste Generation and Management 65 Table –24 Capital Cost 68
LIST OF PLATES / DRAWINGS Page No.
Figure ‐ 1 Location Map of Project Site 12 Google Image showing the area within 10 Km Radius from the Figure ‐ 2 13 Project site
Drawing ‐ 1 Key Plan & Plant Layout 19 Drawing ‐ 2 Schematic Diagram of the Solvent Recovery System 52 Drawing ‐ 3 Water Balance Diagram (For Proposed Project) 57 Drawing ‐ 4 Schematic Diagram of Effluent Treatment Plant 60
Drawing ‐ 5 Schematic Diagram of Air Pollution Control Equipment – HCl& SO2 63
LIST OF ANNEXURE
Annexure ‐I : Copy of Consent to Operate (CC&A / CTO) obtained from GPCB for the existing unit Annexure ‐II : Provisional Certificate for the Membership of TSDF/CHWIF of SEPPL
GLOSSARY E / P / T : Existing / Proposed Expansion / Total After Expansion APCM : Air Pollution Control Measure ECC : Environmental Clearance Certificate EMP : Environmental Management Plan GPCB : Gujarat Pollution Control Board HDPE : High Density Poly Ethylene KVA : Kilo Volt Ampere MoEF : Ministry of Environment & Forest MS : Mild Steel PGVCL : Paschim Gujarat Vij Company Ltd. SS : Stainless Steel TPH : Ton per Hour
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1. EXECUTIVE SUMMARY
1.1. General M/s. Ascent Pharma is an existing small scale unit located at Survey No. 163/9 & 11, S.I.D.C. Road, Veraval (Shapar), Ta: Kotada Sangani, Dist: Rajkot, Gujarat and involved in the manufacturing of various Inorganic Chemicals with the production capacity of 50 MT/Month. Now the unit proposes to manufacture various Bulk Drugs & Drugs Intermediates (Synthetic Organic Chemical) with total production capacity of 55 MT/Month.
The proposed project is covered under Category 5(f)‐A as per new EIA Notification of Ministry of Environment & Forest (MoEF), dtd. 14/09/2006. Therefore, unit requires obtaining Environmental Clearance from Ministry of Environment & Forest (MoEF), New Delhi. The unit has been granted “Consent to Operate (CTO/CC&A)” from Gujarat Pollution Control Board (GPCB) for its existing plant vide order No. AWH‐49497, dated 13/09/2012, which is valid up to 17/05/2017.
1.2. Silent Features of the plant site: The proposed project will be set up in existing industrial premises located in the Shapur‐ Veraval Industrial area and no additional land will be required. The project site is located in the well‐developed Shapar‐Veraval industrial area, having all basic infrastructure facilities like availability of water supply, natural gas, electricity, transport, telecommunication systems etc. Plant site is only 13.33 km away from Rajkot City which is well connected by road and rail to rest of India. The proposed products will be manufactured within the existing industrial establishment, which would facilitate existing infrastructure mainly covering utility services. There is no protected area notified under the Wild Life (Protection) Act (1972) & Eco‐ sensitive area notified under Section 3 of the Environment (Protection) Act‐1986 exists within 10 Km radius areas from the Plant Site. The project site is intended for the industrial purpose and thus no displacement of population will require.
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1.3. Proposed Products: The unit proposes to manufacture following Bulk Drugs & Drugs Intermediates (Synthetic Organic Chemical) with total production capacity of 55 MT/Month. Sr. No. Name of Product Capacity MT/Month 1 Oxyclozanide 25 2 Glibenclamide 20 3 ‐A 1,2,4 Triazole 10 3‐B 4‐Amino ‐1,2,4 Triazole Total 55 BY‐product 1 Hydrochloric Acid 15.50 2 Sodium bi sulphite 25.73 3 Phosphorous Acid‐Aq 3.237
1.4. Resource requirement: Land: The total land available with the existing unit is @ 2292 sqmt (0.57 acres) and no additional land would be required for proposed project. Water: Presently The water requirement of the unit is met by private water supplier through tanker and same source will be utilized after proposed project. The total fresh water requirement for the existing unit is 2.7 KL/day which will be increase up to 11.51 KL/day. Power: At present the total connected load of power is 45 KVA and which will be increased up to 60 KVA after proposed project. The power required is procured from Pashchim Gujarat Vij Company Ltd. (PGVCL) and the same source will be utilized after proposed expansion. Fuel: After the proposed project, LDO/FO will be required for the new steam boiler (0.6 TPH), which will be kept working and fire‐wood/Agro‐waste will be required for the as stand‐by steam boiler (0.3 TPH). Manpower: Total 11 personnel are working in the existing plant and after the proposed project the company has planned to employ about 27 additional personnel comprises: Management ‐6, Supervisory‐6 and Workers‐15. Finance: The unit is a Small Scale Unit and has made capital investment of Rs. 48.57 lacs in the existing plant and the estimated cost for the proposed project will be about Rs. 36.50 Lacs. Capital cost towards Environmental protection measures for proposed project will be Rs. 5.50 Lacs.
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1.5. Pollution Potential and Mitigative Measures: Presently there is no effluent generation form the existing unit and unit maintains the Zero Effluent Discharge. The industrial effluent generation from the proposed project will be @ 2.10 KL/day among them 0.40 KL/day of condensate water from process will be recovered & reused in cooling make‐up. The remaining effluent from APCM, boiler, cooling and washing will be treated in to own effluent treatment plant (ETP) comprising of Primary, secondary & Tertiary treatment. The treated effluent will be used for gardening and plantation within the premises. There will be process gas emission of HCl & SO2 from the manufacturing of Oxyclozanide. The adequate scrubbing system like two stage water scrubber followed by alkali scrubber will be provided for the control of process gas emission Presently the unit has installed one Wood fired steam boiler (0.3 TPH‐ Working) and one LDO/FO fired steam boiler (0.3 TPH‐ stand by). The unit will install one new steam boiler (0.6 TPH‐ Working) for the proposed project where LDO/FO will be used as fuel. After proposed project, new LDO/FO based steam boiler will be kept working and the existing LDO/FO based steam boiler will be dismantled. The existing wood fired boiler will be kept as stand‐by. For the existing wood fired steam boiler, the unit has installed Cyclone Separator as an APCM and no APCM is required for the existing as well as proposed LDO/FO fired steam boiler. A common stack with adequate height of 12 m is provided for proper dispersion of pollutant from the steam boilers. The main sources of hazardous waste generation from proposed manufacturing activity will be Process Waste viz. Inorganic residue, Distillation Residue, Spent Carbon and Spent Solvent. The Dried sludge will be generated from effluent treatment plant. The ancillary source of hazardous waste generation will be discarded bags/ liners/ drums/ Carboys/ Containers from storage and handling of raw materials and spent oil generation from plant machinery. The unit will provide an adequate designated storage area for the hazardous waste storage and has obtained provisional membership of GPCB approved TSDF/CHWIF of M/s. Saurashtra Enviro Projects Pvt. Ltd. The unit has developed green belt area in 2,200 m2 (9.26% of total land area) within the industrial premises, which will be expanded up to 6,600 m2 (27.78% of total land area)
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after proposed expansion. At present unit has planted around 230 nos. of trees of various types within premises, which will be increased up to 725 nos. during proposed expansion. The unit has developed @ 340 sqm (14.83 %) area for the green belt/gardening within the industrial premises, which will be expanded to 760 sqm (33.16%) during the proposed project.
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2. INTRODUCTION
2.1. Background M/s. Ascent Pharma is an existing small scale unit located at Survey No.163/9 & 11, S.I.D.C. Road, Veraval (Shapar), Taluka: Kotada Sangani, District: Rajkot, Gujarat. The plant commissioned in October 2009. Presently, the unit is involved in the manufacturing of various Inorganic Chemicals. Now, the unit proposes to expand its manufacturing activity and intend to manufacture Bulk Drugs & Drugs Intermediates. The proposed products are covered under Category 5 (f)‐A as per new EIA notification of Ministry of Environment & Forest (MoEF) dated 14/09/06. Therefore, unit requires to obtain Environmental Clearance from Ministry of Environment & Forest (MoEF), New Delhi. As a part of application for obtaining Environmental Clearance, the unit requires to submit Form‐1 and Pre‐Feasibility Report of the proposed project.
The objectives of the report are, a) To assess the feasibility of the proposed project. b) To identify various sources of pollution and anticipate the impacts of the proposed project on the environment. c) To evaluate Environmental Management Plan, to prevent and mitigate the adverse impact on environment caused due to proposed project. d) Propose the Terms of Reference to carry out EIA Study for the proposed project
2.2. Nature of the Project: Presently Ascent Pharma is involved in manufacturing of Inorganic chemicals with total production capacity of 50 MT/ Month. Now the unit intend to manufacture various Bulk Drugs & Drugs Intermediates with capacity of 55 MT/Month. Thus, this is an brown field project where unit is adding new products along with required infrastructure for production and waste management.
The proposed products are Synthetic Organic Chemicals and covered under Category 5(f)‐A as per new EIA notification of Ministry of Environment & Forest (MoEF) dated 14/09/06.
The Proposed project for the manufacturing of various Synthetic Organic Chemicals (Bulk Drugs & Drugs Intermediates) will be carried out within the existing premises.
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The unit believes in sustainable development and equally concern about environment preservation and pollution control. The unit has provided an adequate Environmental Management System to meet desired norms of effluent discharge (Water + Air + Solid) as per the statutory recruitments for their existing unit and also proposes to expand its continuous endeavor for the pollution prevention and betterment of environment.
2.3. Project Proponent: M/s. Ascent Pharma has been promoted by:
1. Mr. R. M. Ghonia (Managing Partner) 2. Mr. Vipul Baldha 3. Mr. G. G. Gajipara
Details about the promoters are given below:
1. Mr. R. M. Ghonia aged about 41 years, a postgraduate in organic chemistry from Saurashtra University having rich experience of 17 years in the Pharmaceutical Industry. He was with Ficom Organic Ltd., Ankleshwar for 2.5 years and United Phosphorus Ltd., Ankleshwar for 6.5 years and since last 9 years he is associated with Ascent Pharma as managing partner. He was looking after production, process scale up, plant erection and regulations. His vast knowledge and experience about the Pharma Industry will be of immense help in production and factory administration of their proposed project.
2. Mr. V. R. Baldha aged 35 years has done Post Graduate in Analytical chemistry from Saurashtra University having 12 years of experience in Quality Control. He has worked with Gujarat Organic, Ankleshwar for 3 years and since last 9 years he is associated with Ascent Pharma as managing partner. He was looking for Quality Control and other regulatory aspects.
3. Mr. G. G .Gajipara, aged 44 years a graduate in chemistry from Saurashtra University having 20 years of vast experience in Production, Maintenance in Pharma industry. He has worked with Ficom Organic Ltd., Ankleshwar for 8 years and with H. N. Dyechem, Ankleshwar for 3 years. Since last 9 years he is associated with Ascent Pharma as managing partner. He was looking after maintenance and production.
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Table‐1: Details of Key Persons of the Company
Sr. Name of the Experience, Qualification Designation Key Responsibilities No. Director Years M.Sc. Managing Production, Quality control and 1. Mr. Vipul Baldha 12 (Anal. Chem.) Partner Marketing M. Sc. Managing Production, Design and Factory 2. Mr. Ramesh Ghonia 17 (Org. Chem.) Partner administration B. Sc. Managing Maintenance, Production and 3. Mr. Girish Gajipara 20 (Chem.) Partner General Administration
2.4. Need For the Project & Project Benefits: Being a ‘Life Saving Drug’, there is a huge demand and potential of marketing in Gujarat, India and around the world.
In fact, bulk drugs/ API’s are normally not used in their basic form, so the demand for basic drugs emanates from formulation industries manufacturing medicines in various forms. As medicines are highly consumed in all seasons, there are thousands of companies in India, which are manufacturing tablets, capsules & syrups of the proposed products. In India, it is highly demanded in the states like Gujrat, Uttarakhand, Punjab, Haryana, Uttar Pradesh, Andhra Pradesh, Tamilnadu, Maharashtra, West Bengal, etc. These states are the hub of the Pharmaceuticals markets.
There is huge demand for Export in countries like Sri Lanka, Iran, Bangladesh, Pakistan, Bhutan, Vietnam, Africa, Nigeria, Singapore, Malaysia, Jordan etc.
The project will provide direct employment to skilled workforce and indirect employment (transport, services deliveries etc.) to semi‐skilled and unskilled workers. Thus, the project will have numerous induced impacts on society by generation new employment opportunity and will lead to improvement in the social infrastructure in the region.
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3. PROJECT LOCATION & SITE ANALYSIS: 3.1. Location: The Project is situated at Survey No. 163/9 & 11, S.I.D.C. Road, Veraval (Shapar), Taluka: Kotada Sangani, District: Rajkot, Gujarat. The location map of project site is shown in Figure‐1 and the area covering 10 km radial distance from the project site is given as Figure‐2. Figure ‐1: Location of Project Site
Location of Rajkot District in Gujarat
Project site
Location of Project Site in Rajkot District
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Figure ‐2: Google Image of 10 km radial distance from the project site
Location Location Name Location Location Name Code Code Project Site 6 Ribda
1 Shapar Veraval 7 Rib 2 Khokhaddal 8 Pipliyapal 3 Lothda 9 Shapar 4 Padaval 10 Dholra 5 Gundasara
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3.2. Site Analysis & Infrastructure setup The salient features of the project site and study area are given below; 1. Location : 2. Geographical Locations : SOI Toposheet No. F42‐K16 Altitude :196m above MSL Latitude 22° 8'54.73"N Latitude 22° 8'54.15"N N E Longitude 70°47'54.57"E Longitude 70°47'55.52"E Latitude 22° 8'53.43"N Latitude 22° 8'54.15"N S W Longitude 70°47'54.57"E Longitude 70°47'53.78"E
3. Land use of Project site : 100% Industrial Land
4. Infrastructure Setup : (a) Village / Habitation : Veraval : @ 4.0 km ,North East Shapar : @ 2.2 km , North West (b) Town (c) City : Rajkot : @ 13.33 km North (d) Highways : National Highway No. 8B ‐ @ 1.5 km East (e) Railway Station : Ribda : @ 4.2 km South (f) Sea Coast : Arabian Sea: @ 179 km West (g) Domestic Airport : Rajkot : @ 10.83 km NNE (h) International Airport : Ahmedabad : @ 207 km ENE
(i) Defence installations : None
5. Place of Interest / Tourist places : (a) Rampara vidi ‐ Wildlife Sanctuary : @ 71 km NNE (b) Naranka ‐ Reserved forest : @ 6.6 km ESE 6. Protected areas within 10 Km radius from the Plant Site (if, any) : There is no protected area notified under the Wild Life (Protection) Act (1972) & Eco‐ sensitive area notified under Section 3 of the Environment (Protection) Act‐1986 exists within 10 Km radius areas from the Plant Site.
7. Displacement of population : None 8. Seismic Zone : The area is falling in Zone‐ III having moderate Damage Risk Zone (MSK‐ VII).
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3.3. Details of Alternative Sites and Justification of Site Selection
Alternative of sites has not been examined as it is an existing unit and proposed project for manufacturing of synthetic organic chemicals (Bulk Drugs & Drugs Intermediates) will be carried out within the same premises.
The existing unit is situated in the well‐developed Shapar‐Veraval industrial area having about 600 nos. of small and large scale industries involved in the manufacturing of various dyes and dye intermediates, Bulk drugs, chemicals, pharmaceutical, machineries, mechanical parts, casting, oil, etc.
Moreover, site selection was guided by many factors like existing infrastructure, availability of land, water sources, fuel transportation, power availability etc. Specific site selection criteria for the existing project of M/s. Ascent Pharma are given below.
The project site is located in the well‐developed Shapar‐Veraval industrial area, having all basic infrastructure facilities like availability of water supply, natural gas, electricity, transport, telecommunication systems etc. Plant site is only 13.33 km away from Rajkot City which is well connected by road and rail to rest of India. Project site is well connected to National Highway‐8B. Existing plot size is adequate for the proposed project requirement. Availability of existing infrastructure facilities. Availability of trained and skilled manpower into nearby villages. There is no historical place, sanctuaries, forestland or prime agriculture land within 10 km radius from the project site. The project site is intended for the industrial purpose and thus no displacement of population will take place.
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4. PROJECT DESCRIPTION
4.1. Details of Product and Production Capacity:
The unit is presently involved in the manufacturing of various inorganic chemicals with total production capacity of 50 MT/Month and having CTO/CC&A from GPCB vide order No. AWH‐ 49497, dated 13/09/2012, which is valid up to 17/05/2017.
Now, the unit proposes to manufacture various Bulk Drugs & Drugs Intermediates with the production capacity of 55 MT/Month. The details of existing and proposed products along with production capacity are given hereunder in Table‐2 (A) and 2 (B) respectively.
Table‐2 (A): List of Existing Products:
Sr. Capacity Name of Product Use of Product No. MT/Month 1. Potassium Nitrate 10.0 Fine Chemicals 2. Potassium Sulphate 10.0 Fine Chemicals 3. Magnesium Hydroxide 10.0 Fine Chemicals 4. Potassium Chloride 10.0 Fine Chemicals 5. Potassium Iodide 10.0 Fine Chemicals Total 50.0 ‐‐
Table – 2 (B): List of Proposed Products & By‐Products: Sr. No. Name of Products / By‐Product Capacity, MT/Month Products 1 Oxyclozanide 25 2 Glibenclamide 20 3 ‐A 1,2,4 Triazole 10 3‐B 4‐Amino ‐1,2,4 Triazole Total 55 By‐Product 1 Hydrochloric Acid 15.5 2 Sodium bi sulphite 26.0 3 Phosphorous Acid‐Aq 3.3
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Table – 2 (C): Details of Proposed Products:
Sr. Name of CAS Use of IUPAC Name Synonyms No. Product Number Product 2,3,5‐Trichloro‐N‐ (3,5‐dichloro‐2‐ Anthelmintic 1 Oxyclozanide 2277‐92‐1 ‐‐‐ hydroxyphenyl)‐ drug 6‐hydroxybenzamide 5‐chloro‐N‐(4‐[N‐ (cyclohexylcarbamoyl) Antidiabetic 2 Glibenclamide 10238‐21‐8 Glyburide sulfamoyl]phenethyl)‐ drug 2‐methoxybenzamide Pyrrodiazole Intermediate 3 ‐A 1,2,4 Triazole 288‐88‐0 1H‐1,2,4‐triazole 1,2,4‐triazole for API pyrrodiazole 4H‐1,2,4‐ 4‐Amino ‐ 4‐Amino‐4H‐1,2,4‐ Intermediate 3‐B 584‐13‐4 Triazol‐4‐ 1,2,4 Triazole triazole for API amine;
4.2. Land and Project Layout:
The total land available with the existing unit is @ 2292 sqmt (0.57 acres) and no additional land would be required for proposed project. Out of total land available, the unit has developed @ 340 sqm (14.83 %) area for the green belt/gardening for the betterment of the environment. The green belt/ gardening area will be expanded to 760 sqm (33.16%) during the proposed project. The detail breakup of the land is given in Table‐3 and Key Plan & Plant Layout is shown in Drawing‐1.
Table‐ 3: Break‐up of Area
Sr. Area (Sqmt) % of Total Particular No. Existing Proposed Total Land 1 Process Plant 353 147 500 21.82 2 Raw Material & Product Storage 74 26 100 4.36 3 Utility 20 ‐ 20 0.87 4 Storage (Hazardous Chemicals) 5 45 50 2.18 5 Storage (Fuel) 7 13 20 0.87 6 Hazardous Waste Storage Area 11 13 24 1.05 7 Effluent Treatment Plant 38 62 100 4.36
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8 Scrap yard 11 9 20 0.87 9 Parking Area 14 ‐ 14 0.61 10 Administrative Building ‐ 50 50 2.18 11 Security, Clock & Eng room 57 ‐ 57 2.49 12 Road 30 ‐ 30 1.31 13 Green Belt 340 420 760 33.16 14 Undeveloped 1,332 ‐785 547 23.87 Total 2,292 ‐ 2,292 100.00
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Drawing‐1: Key Plan & Plant Layout
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4.3. Resource Requirements: (a) Water Presently entire water requirement of the unit is met by private water supplier through tanker and same source will be utilized after proposed project. The total fresh water requirement for existing unit is 2.7 KL/Day and the additional water requirements of the proposed project will be 8.81 KL/Day. Thus, the total fresh water requirement after the proposed project will be 11.51 KL/Day.
As per Guidelines issued by Central Ground Water Authority, Ministry of Water Resources, New Delhi vide Letter No. 21‐4/Guidelines/CGWA/2009‐832, Dated 14/10/2009, the unit falls under White Zone (Safe)and do not covered under the list of critical areas published by CGWA. Also the water requirement of the plant is 11.51 KL/Day which falls within the limit of 1000 KLD as per CGWA, therefore the unit does not require obtaining permission from CGWA for the use/abstraction of ground water.
(b) Power At present the total connected load of power is 45 KVA, which is procured from Pashchim Gujarat Vij Company Ltd. It is expected that the power requirement will be increased up to about 60 KVA after the proposed project. Thus, the additional power requirement for the proposed project will be 15 KVA, which will be procured from Pashchim Gujarat Vij Company Ltd.
(c) Fuel Presently the unit uses fire‐wood and LDO/FO as fuel for two steam boilers (0.3 TPH each), out of which Wood fired steam boiler is Working and LDO/FO fired steam boiler is stand by.
After proposed project, LDO/FO will also be required for their new steam boiler (0.6 TPH), which will be kept working. After proposed project, the existing LDO/FO based steam boiler will be dismantled and the existing wood fired boiler will be kept as stand‐by. The details of fuel consumption are given in Table‐4.
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Table‐4: Details of Fuel Consumption
Sr. Status Fuel Consumption Fuel Used In No. Existing Proposed Existing Proposed Fire Steam Boiler ‐ 5.0 10.0 1 Working Stand by wood 0.3 TPH MT/Month MT/Month Steam Boiler ‐ 1.25 2 LDO/FO Stand by Dismentled ‐‐ 0.3 TPH KL/Month Steam Boiler ‐ 2.50 3 LDO/FO N.A. Working ‐‐ 0.6 TPH KL/Month
(d) Manpower The manpower is one of the main resource requirements to operate and maintain the plant in a better and efficient way. Total 11 personnel are working in the existing plant and after the proposed project the company has planned to employ about 27 additional personnel at various cadres and in various departments as tabulated below:
Table‐5: Details of Manpower Requirement
Supervisory Mgmt. Staff Workers Total Description Staff E P E P E P E P Administration 01 02 02 02 02 03 05 07 Production & allied services 01 02 02 03 02 07 05 12 Stores & Dispatch ‐‐ 01 ‐‐ 01 01 03 01 05 Others ‐‐ 01 ‐‐ ‐‐ ‐‐ 02 ‐‐ 03 Total 02 06 04 06 05 15 11 27 * E‐Existing, P‐Proposed
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4.4. Details of Manufacturing Process: 1) Oxyclozanide
1(a) (Route‐I‐ Using Thionyl Chloride)
a) Manufacturing process:
Stage: 1 [Crude Oxyclozanide]
Charge Mono Chloro Benzene, 3, 5, 6‐Trichloro Salicylic Acid and Thionyl dichloride into the reactor. Start Scrubber pump and Heat to 60o in 2 hrs than heat 80oC in 2 hrs, Distilled out excess Thionyl dichloride. Transfer the material in to another reactor contain mixture of 2, 4, Di chloro – 6‐ Amino phenol and Mono Chloro Benzene, HCl scrub through Scrubber. Reflux Material for 3 hrs. Cool the reaction mass and filter it. Dry the wet cake in Dryer. Unload the product as Crude Oxyclozanide.
Stage: 2 [Oxyclozanide]
Charge Acetone, Crude Oxyclozanide and Activated Carbon into the reactor. Heat the reaction mass to 60~65°C. Stir& reflux the reaction mass at 60~65°C. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass Stir the reaction mass and filter it. Wash the wet cake with Chilled Acetone. Dry the wet cake in Dryer. Unload the product as OXYCLOZANIDE.
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Material balance Diagram – Process STAGE: 1
SO2 Gas: 40.75
HCl Gas: 46.5 3,5,6 Tri chloro salicylic Acid: HCl (30%) & 153.5 Reactor Scrubber Thionyl chloride:75.75 NaHSO3 as Mono chloro benzene: 410 By Product
552
2,4 Di chloro ‐6‐Amino Reactor Phenol: 113.25
Mono chloro benzene: 410 SO2 Gas: 40.75
1075.25 Distilled MCB: 980
Distillation Mono chlorobenzene:205 Centrifuge Distillation & Evaporation Loss: 20.0
Distillation 275.25 Residue: 5
Drying Drying Loss: 20.0
255.25
255.25 kg Crude
Oxyclozanide
All quantities are expresses in Kg/Batch
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STAGE: 2
Crude Oxyclozanide: 255.25 Acetone: 786 Reactor Activated Carbon:10.25
1051.5
Filter Spent Carbon to CHWIF: 10.5
Acetone Distilled: 697.5 1041
Centrifuge Distillation Distillation Loss:
Acetone: 4.75 30.25
Distillation Residue: 5.0 313
Drying Drying Loss: 63.0
250
250 kg Oxyclozanide
All quantities are expresses in Kg/Batch
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Material balance Diagram ‐ APCM
HCl : 46.5 Byproduct HCl Water Scrubber SO2: 40.75 (30%): 155 Water: 108.5 (Sale)/HW/ETP
Cl2: 40.75
NaOH: 25.99 Alkali Scrubber Byproduct NaHSO3: Water: 190.58 257.32 (Sale)
Pre-Feasibility Report Page 26 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals d) Summary of mass balance
Summary of mass balance for Oxyclozanide from stage 1 & 2 for is given in Table ‐6(A) & Table –6(B) and for APCE is given in Table – 5(C).
Table – 6(A): Summary of Mass Balance ‐ Oxyclozanide Process, Stage ‐I Capacity of Finished Product MT/Month : 25.00 batch size kg : 250 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 3, 5, 6 Tri Chloro Salicylic Acid 153.5 0.614 15.350 Reactant 2 Thionyl Chloride 75.8 0.303 7.575 Reactant 3 2, 4 –Di chloro – 6‐ Amino Phenol 113.3 0.453 11.325 Reactant 4 Mono Chloro Benzene (Fresh) 45.0 0.180 4.500 Solvent 5 Mono Chloro Benzene (Recovered) 980.0 3.920 98.000 Total 1367.5 5.470 136.750 Output Intermediate 1 Crude Oxyclozanide 255.25 1.021 25.525 product stage/crude 2 Mono Chloro Benzene (Recovered) 980.0 3.920 98.000 Recovered Solvent
3 SO2 Gas 40.8 0.163 4.075 To scrubber 4 HCl Gas 46.5 0.186 4.650 HW to CHWIF for 5 Distillation Residue 5.0 0.020 0.500 Incineration 6 Distillation loss 20.0 0.080 2.000 To Atmosphere 7 Drying loss 20.0 0.080 2.000 Total 1367.5 5.470 136.750
Pre-Feasibility Report Page 27 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
Table – 6(B): Summary of Mass Balance for ‐ Oxyclozanide Process, Stage ‐II Capacity of Finished Product MT/Month : 25 batch size kg : 250 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 Crude Oxyclozanide 255.25 1.021 25.525 Reactant 2 Acetone (Fresh) 93.25 0.373 9.325 Solvent 3 Acetone (Recovered) 697.5 2.790 69.750 4 Activated Carbon 10.25 0.041 1.025 Catalyst Total 1056.3 4.225 105.625 Output
1 Oxyclozanide 250.0 1.000 25.000 Finished product 2 Acetone (Recovered) 697.5 2.790 69.750 Recovered Solvent 3 Spent Carbon 10.5 0.042 1.050 HW to CHWIF for 4 Distillation Residue 5.0 0.020 0.500 Incineration 5 Distillation loss 30.3 0.121 3.025 To Atmosphere 6 Drying (Solvent) loss 63.0 0.252 6.300 Total 1056.3 4.225 105.625
Pre-Feasibility Report Page 28 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
Table‐6(C): Summary of Mass Balance ‐ Oxyclozanide APCM(stage I)
Sr. Quantity Name of Raw Material No. Kg/Batch Kg/Kg of Product MT/Month Remarks Water scrubber Input
1 Water 108.50 0.434 10.85 Scrubbing Media 2 HCl Gas 46.5 0.186 4.65 To Scrubber Total 155.00 0.620 15.50 Water scrubber Output HW/Sale as By 1 Hydrochloric Acid (30 %) 155.00 0.620 15.50 Product/ETP Total 155.00 0.620 15.50 Alkali scrubber Input
1 Caustic 25.99 0.10 2.60 To Scrubber 2 Water 190.58 0.76 19.06 Scrubbing Media 3 SO2 Gas 40.8 0.16 4.08 Total 257.32 1.03 25.73 Alkali scrubber Output
1 Sodium bi Sulphite 257.32 1.03 25.73 Sale as By Product
Total 257.32 1.03 25.73
1) Oxyclozanide:
1(b) (Route – 2‐ Using Phosphorus Trichloride)
a) Manufacturing process: Stage: 1 [Crude Oxyclozanide]
Charge Mono Chloro Benzene, 3, 5, 6‐Trichloro Salicylic Acid and Phosphorus Trichloride in to the reactor. heat 80oC in 4 hrs, Add Water and separate out aqueous layer (phosphoric acid) and Transfer organic layer in to another reactor contain mixture of 2, 4, Di chloro – 6‐ Amino phenol and Mono Chloro Benzene, HCl scrub through Scrubber. Reflux Material for 3 hrs. Cool the reaction mass and filter it. Dry the wet cake in Dryer. Unload the product as Crude Oxyclozanide.
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Stage: 2 [Oxyclozanide]
Charge Acetone/Methanol Crude Oxyclozanide and Activated Carbon into the reactor. Heat the reaction mass to 60~65°C. Stir& reflux the reaction mass at 60~65°C. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass Stir the reaction mass and filter it. Wash the wet cake with Chilled Acetone. Dry the wet cake in Dryer. Unload the product as OXYCLOZANIDE.
(b) REACTION CHEMISTRY
OH OH O Cl COOH o Cl Cl C OH 80 C Cl + 1/3 Cl P + HO P 4 hrs Cl Cl Cl OH Cl Cl 3,5,6 -Trichloro Salicylic Acid phosphorous trichloride 2,3,5-trichloro-6-hy phosphorous acid droxybenzoyl or chloride 2,3,5-trichloro-6-hydroxybenzoic M.W. 137.33 acid M.W. 259.901 M.W. 241.456 Cl
Cl HO OH O OH O Cl HO o Cl Cl 130 C N Cl HCl + H + 3 hrs Cl H2N Cl Cl Cl Cl
2,3,5-trichloro-6-hydroxyben 2,4 - Dichloro -6 -Amino Phenol Oxyclozanide zoyl chloride or M.W. 401.456 4,6 - Dichloro -2 -Amino Phenol M.W. 259.901 M.W. 178.016
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(c) Material Balance Diagram: Process Stage: 1
3, 5, 6 Tri Chloro Salicylic Acid: 153.5 Phosphorus Tri chloride: 29.12 Mono Chloro Benzene: 500 Reactor Water: 15.0 697.62
Aq. Layer H PO : 32.37 3 3
Organic Layer
Water: 54.25 Scrubber 665.25 HCl: 77.50 sale as by‐ Product
2, 4 Dichloro‐6‐Amino Phenol: 113.25 Reactor Mono Chloro Benzene: 500 HCl Gas: 23.25
1255.25 MCB ML Distilled 1005 MCB: 980
Mono Chloro Benzene: 25 Centrifuge Distillation Distillation & Evaporation Loss: 25 275.25
Drying
Evaporation Loss: 20 255.25 255.25 Crude Oxyclozanide
All values are expressed in kg/Batch
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Stage: 2
Crude Oxyclozanide : 255.25 Acetone /Methanol : 766 Reactor Activated Carbon : 10.25
1031.5
Filter Spent carbon to TSDF: 10.5
1021
Filtrate
Acetone Recover Acetone/ Cooling 1021 ML: 796 Methanol Distilled 698
Distillation Acetone/Methanol: 25 Centrifuge
Evaporation Distillation 250 Loss: 63 Residue: 5 Distillation Loss: 30.0 250 Oxyclozanide
All values are expressed in kg/batch
Pre-Feasibility Report Page 32 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals d) Summary of Mass Balance Summary of mass balance Of Oxyclozanide stage 1 to 2 is given in Table ‐7(A) to Table – 7(C). Table – 7(A): Summary of Mass Balance ‐ Oxyclozanide Process, Stage ‐I capacity Finished Product MT/Month : 25.00 capacity Intermediate Product MT/Month : 25.0 batch size kg : 250.00 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 3, 5, 6 Tri Chloro Salicylic Acid 153.5 0.614 15.350 Reactant 2 Phosohorus Tri chloride 29.1 0.116 2.912 Reactant 3 2, 4 –Di chloro – 6‐ Amino Phenol 113.25 0.453 11.325 Reactant 4 Mono Chloro Benzene (Fresh) 45.0 0.180 4.500 Solvent 5 Mono Chloro Benzene (Recovered) 980.0 3.920 98.000 6 Water 15.0 0.060 1.500 Total 1335.87 5.343 133.587 Output Intermediate 1 Crude Oxyclozanide 255.25 1.021 25.525 product stage/crude 2 Mono Chloro Benzene (Recovered) 980.0 3.920 98.000 Recovered Solvent
3 Aq. H3PO3 32.37 0.129 3.237 Sale as By Product 4 HCl Gas 23.3 0.093 2.325 To Scrubber 5 Drying (Solvent) loss 45.0 0.180 4.500 To Atmosphere Total 1335.87 5.343 133.587
Pre-Feasibility Report Page 33 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
Table – 7(B): Summary of Mass Balance for ‐ Oxyclozanide Process, Stage ‐II Capacity of Finished Product MT/Month : 25 batch size kg : 250 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 Crude Oxyclozanide 255.25 1.021 25.525 Reactant 2 Acetone/Methanol (Fresh) 93 0.372 9.300 Solvent 3 Acetone/Methanol (Recovered) 698 2.792 69.800 4 Activated Carbon 10.25 0.041 1.025 Catalyst Total 1056.5 4.226 105.650 Output
1 Oxyclozanide 250.0 1.000 25.000 Finished product 2 Acetone/Methanol (Recovered) 698.0 2.792 69.800 Recovered Solvent 3 Spent Carbon 10.5 0.042 1.050 HW to CHWIF for 4 Distillation Residue 5.0 0.020 0.500 Incineration 5 Distillation loss 30.0 0.120 3.000 To Atmosphere 6 Drying loss 63.0 0.252 6.300 Total 1056.5 4.226 105.650
Pre-Feasibility Report Page 34 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
Table‐7(C): Summary of Mass Balance ‐ Oxyclozanide APCM(stage I)
Quantity Sr. Name of Raw Material Kg/Kg of No. Kg/Batch MT/Month Remarks Product Water scrubber Input 1 Water 54.25 0.217 5.43 Scrubbing Media 2 HCl Gas 23.3 0.093 2.33 To Scrubber Total 77.50 0.310 7.75 Water scrubber Output HW/Sale as By 1 Hydrochloric Acid (25%) 77.50 0.310 7.75 Product/ETP
Total 77.50 0.310 7.75 2)
Pre-Feasibility Report Page 35 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
2) GLIBENCLAMIDE
(a) MANUFACTURING PROCESS: Stage: 1 [CHIC SALT]
Charge Acetone & Sulphonamide of Glibenclamide into the reactor. Start addition of caustic flack’s solution. Chill to 5~10°C. Charge Cyclo Hexyl Iso Cynate. Stir the reaction mass between 10~15°C. Raise the temperature to 25~30°C. Charge Liq. Ammonia and heat the reaction mass to 50~55°C. Stir the reaction mass between 50~55°C. Cool to 25~30°C. Filter the product. Wash the product with Acetone. Dry the product in Dryer. Unload the product as Chic Salt of Glibenclamide
Stage: 2 [GLIBENCLAMIDE]
Charge Methanol, Chic Salt of Glibenclamide and Charcoal into the reactor. Stir the reaction mass for 1.0 hour. Transfer this reaction mass to another reactor through filter which is previously ready with hyflow bed to remove charcoal. Chill the reaction mass to 10~15°. Start purging of HCl gas up to 2.0 pH. Stir the reaction mass and filter it. Wash the wet cake with Methanol. Dry the wet cake in Dryer. Unload the product as GLIBENCLAMIDE.
(b) REACTION CHEMISTRY Synthesis of Glibenclamide :- O O S
O NH2
Cl NH
OCH 3
Sulphonamide of Glibenclamide M.W. 368.835 or 5-chloro-2-methoxy-N-[2-(4-sulfamoyl phenyl)ethyl]benzamide
NCO
NaOH + Acetone Methanol
Cyclo hexyl isocynate M.W. 125.168
O O O S NH NH O
Cl NH
Glibenclamide OCH 3 M.W. 494.003
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(c) PROCESS FLOW DIAGRAM: GLIBENCLAMIDE
Stage: 1
Acetone : 400 Sulphonamide: 76.2 Reactor Caustic soda flakes: 8.3 Cyclo hexyl iso cyanate: 26 Acetone Liq. Ammonia : 7 Distilled: 375 517.5
Acetone ML Distillation Distillation Centrifuge Acetone: 25 Recover Loss: 8.20 390.5
152 Inorganic Salt/Residue: 7.3
Drying Drying Loss: 45.0
107
107 Kg CHIC Salt
All values are expressed in kg/batch
Pre-Feasibility Report Page 37 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
Stage: 2
CHIC Salt : 107 Methanol : 1200 Reactor Activated Carbon: 2.0
1309
Spent carbon to TSDF: 2 Filter
1307
Methanol Filtrate Methanol Recover HCl Gas: 7.5 Distilled ML: 1244.5 1175
1314.5 Distillation
Methanol: 50 Centrifuge Inorganic Salt Distillation Loss: 14.5 55
120
Drying
Drying Losses: 20
100
100 kg Glibenclamide
All values are expressed in kg/batch
Pre-Feasibility Report Page 38 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
d) Summary of Mass Balance
Summary of mass balance Of Glibenclamide stage 1 to 2 is given in Table ‐8(A) to Table – 8(B). Table‐8(A): Summary of Mass Balance for Glibenclamide – Stage‐1
capacity Finished Product MT/Month : 20.0 capacity Intermediate Product MT/Month : 21.40.0 batch size kg : 100.00 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Remarks No. Kg/Kg of Kg/Batch MT/Month Product Input 1 Sulphonamide 76.2 0.762 15.240 Reactant 2 Acetone (Fresh) 50.0 0.500 10.000 Solvent 3 Acetone (Recovered) 375.0 3.750 75.000 4 Caustic Soda Flaks 8.3 0.083 1.660 5 Cyclo Hexyl Isocynate 26.0 0.260 5.200 6 Liq. Ammonia 7.0 0.070 1.400 Total 542.50 5.425 108.50 Output
1 CHIC Salt 107.00 1.070 21.400 Intermediate Product
2 Acetone (Recovered) 375.00 3.750 75.000 Solvent Recovered
3 Inorganic salt 7.30 0.073 1.460 To TSDF
Distillation Evaporation 4 8.20 0.082 1.640 loss To Atmosphere 5 Drying loss 45.00 0.450 9.000
Total 542.50 5.425 108.50
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Table‐8(B): Summary of Mass Balance for Glibenclamide –stage‐ II
capacity Finished Product MT/Month : 20.0 batch size kg : 100.00 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Remarks No. Kg/Kg of Kg/Batch MT/Month Product Input 1 CHIC Salt 107.00 1.070 21.400 Intermediate Product
2 Methanol (Fresh) 75 0.750 15.000 Solvent 3 Methanol (Recovered) 1175 11.750 235.000
4 Hydrochloric Acid gas 7.5 0.075 1.500
5 Activated Carbon 2.00 0.020 0.400 Catalyst Total 1366.5 13.665 273.300 Output 1 Glibenclamide 100.0 1.000 20.000
2 Methanol (Recovered) 1175.0 11.750 235.000 Solvent Recovered
3 Inorganic salt 14.5 0.145 2.900 To TSDF HW to CHWIF for 4 Spent Carbon 2.0 0.020 0.400 Incineration 5 Distillation loss 55.0 0.550 11.000 To Atmosphere 6 Drying loss 20.0 0.200 4.000
Total 1366.5 13.665 273.300
Pre-Feasibility Report Page 40 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
(2) 1, 2, 4 ‐ TRIAZOLE a) Manufacturing Process: Charge Xylene and Hydrazine hydrate into the reactor. Start addition of Formic acid slowly below 60o than purge Ammonia Gas slowly in 2 hrs than heat to reflux at 142‐145oC for 8 hrs, and continuously distilled out azeotrope of water and Xylene in receiver. Separate out water from bottom and upper layer xylene is continuously transferred in to reactor for 8 hrs. Cool the reaction mass at RT and filter it. Dry the wet cake in Dryer. Unload the product as 1, 2, 4 ‐ Triazole. b) Reaction Chemistry
Pre-Feasibility Report Page 41 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
c) Material Balance Diagram: Process
Formic Acid: 408 320 Condensate Hydrazine Hydrate: 142 Reactor Water Ammonia Gas: 76 Xylene (Fresh): 24 Xylene (Recovered): 558 Gravity Xylene Water: Xylene Water:16 Separation 16
304 Water to Cooling tower 304
Distilled Xylene: 588 904
Centrifuge Distillation Distillation Loss: 24.0 Xylene (Recovered) : 30
Distillation Residue: 4 318
Drying Drying Loss: 18.0
300.0 kg 1, 2, 4‐Triazole
All values are expressed in kg/batch
Pre-Feasibility Report Page 42 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
d) Summary of Mass Balance Summary of mass balance for 1, 2, 4‐Triazole is given in Table‐9. Table‐9: Summary of Mass Balance for 1, 2, 4‐Triazole capacity of Finished Product MT/Month : 10 batch size kg : 300 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 Hydrazine Hydrate 142.0 0.473 4.733 Reactant
2 Formic Acid 408.0 1.360 13.600 Reactant
3 Ammonia Gas 76.0 0.253 2.533 Reactant
4 Xylene(Fresh) 24.0 0.080 0.800 Solvent 5 Xylene (Recovered) 588.0 1.960 19.600
6 Xylene water 16.0 0.053 0.533 Recovered & Reuse
Total 1254.0 4.180 41.800 Output
1 1,2,4 – Triazole 300.0 1.000 10.000 Finished Product
2 Xylene (Recovered) 588.0 1.960 19.600 Recovered Solvent
3 Xylene water 16.0 0.053 0.533 Recovered & Reuse HW to CHWIF for 4 Distillation Residue 4.0 0.013 0.133 Incineration 5 Distillation Evaporation loss 24.0 0.080 0.800 To Atmosphere 6 Condensate water 304.0 1.013 10.133 To Cooling Tower 7 Drying (solvent) loss 18.0 0.060 0.600 To Atmosphere Total 1254.0 4.180 41.800
Pre-Feasibility Report Page 43 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
(3) 4‐Amino ‐ 1, 2, 4 ‐ TRIAZOLE a) Manufacturing Process Charge Xylene and Hydrazine hydrate into the reactor. Start addition of Formic acid slowly below 600 than heat to reflux at 142‐145C0 for 8 hrs, and continuously distilled out azeotrope of water and Xylene in receiver. Separate out water from bottom and upper layer xylene is continuously transferred to reactor for 8 hrs. Cool the reaction mass at RT and filter it. Dry the wet cake in Dryer. Unload the product as 4‐Amino ‐1, 2, 4 ‐ Triazole. b) Reaction Chemistry
Pre-Feasibility Report Page 44 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals
c) Material Balance Diagram: Process
Formic Acid: 233 263 Hydrazine Hydrate: 336 Condensate Reactor Water Xylene (Fresh): 24 Xylene (Recovered): 618 Xylene Water: 13 Gravity Xylene Water: Separation 13
249 Water to Cooling tower 250
Distilled Xylene: 648 961
Centrifuge Distillation Distillation Loss: 24.0 Xylene (Recovered) : 30
Distillation Residue: 4 315
Drying Drying Loss: 15.0
300.0 kg 4‐ Amino‐1, 2, 4‐Triazole
All values are expressed in kg/batch
Pre-Feasibility Report Page 45 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals d) Summary of Mass Balance Summary of mass balance for 4‐Amino ‐1, 2, 4 ‐ Triazole is given in Table‐10.
Table‐10: Summary of Mass Balance for 4‐Amino ‐1, 2, 4 ‐ Triazole Capacity of Finished Product MT/Month : 10 batch size kg : 300 Working Days Per Month : 26
Quantity Sr. Name of Raw Material Kg/Kg of Remarks No. Kg/Batch MT/Month Product Input
1 Hydrazine Hydrate 336.0 1.120 11.200 Reactant 2 Formic Acid 233.0 0.777 7.767 Reactant 3 Xylene(Fresh) 24.0 0.080 0.800 Solvent 4 Xylene (Recovered) 648.0 2.160 21.600 5 Xylene Water 13.0 0.043 0.433 Recovered & Reuse Total 1254.0 4.180 41.800 Output
1 4 ‐Amino‐1,2,4 – Triazole 300.0 1.000 10.000 Finished Product 2 Xylene (Recovered) 648.0 2.160 21.600 Recover Solvent 3 Xylene Water 13.0 0.043 0.433 Recovered & Reuse HW to CHWIF for 4 Distillation Residue 4.0 0.013 0.133 Incineration 5 Distillation Evaporation loss 24.0 0.080 0.800 To Atmosphere 6 Condensate Water 250.0 0.833 8.333 To Cooling Tower 7 Drying loss 15.0 0.050 0.500 To Atmosphere Total 1254.0 4.180 41.800
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4.5. Raw Material Requirements: Various raw materials will be required for manufacturing of proposed products. Details of raw material requirement for proposed products are given below in Table‐11. Table‐11: Details of Raw Material Requirement
MT/Month Sr. Product Name of Raw Material Kg/Kg Group No. Code Product wise Total Maximum 1 (a) 0.453 11.325 1 2, 4‐Dichloro‐6‐Amino Phenol 11.325 11.325 1(b) 0.453 11.325 1 (a) 0.614 15.350 2 3, 5, 6‐Trichloro Salicylic Acid 15.350 15.350 1 (b) 0.614 15.350 1 (a) 0.373 9.325 9.325 3 Acetone 19.325 2 0.500 10.000 10.000 4 Acetone/Methanol 1 (b) 0.372 9.300 9.300 9.300 1 (a) 0.041 1.025 1.025 5 Activated Carbon 1 (b) 0.041 1.025 1.425 2 0.02 0.400 0.400 6 Ammonia Gas 3‐A 0.253 2.533 2.533 2.533 7 Ammonia Liq. 2 0.07 1.400 1.400 1.400 8 Caustic Soda Flaks 2 0.083 1.660 1.660 1.660 9 Cyclo Hexyl Isocynate 2 0.26 5.200 5.200 5.200 3‐A 1.360 13.600 10 Formic Acid 13.600 13.600 3‐B 0.777 7.767 3‐A 0.473 4.733 11 Hydrazine Hydrate 11.200 11.200 3‐B 1.120 11.200 12 Hydrochloric Acid gas 2 0.075 1.500 1.500 1.500 13 Methanol 2 0.75 15.000 15.000 15.000 1 (a) 0.180 4.500 14 Mono Chloro Benzene 4.500 4.500 1 (b) 0.180 4.500 15 Phosohorus Tri chloride 1 (b) 0.116 2.912 2.912 2.912 16 Sulphonamide 2 0.762 15.240 15.240 15.240 17 Thionyl Chloride 1 (a) 0.303 7.575 7.575 7.575 3‐A 0.080 0.800 18 Xylene 0.800 0.800 3‐B 0.080 0.800
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4.6. Details of Products & Raw Materials: The general details about the raw materials and products such as storage, handling, characteristics, source/market etc. are given in following Table‐12. Table‐12: Details Of Product & Raw Material Maximum Storage Storage Sr. Name of Physical Type of Packing storage Market/ Characteristic Pressure Temp. No. Chemicals form packing Size capacity, Source Kg/cm2 ºC MT Products Solid‐ HDPE 25, 50 Local / 1 Oxyclozanide 5 Toxic ATM At RT Crystal Drum Kg Export Solid‐ HDPE 25, 50 Non‐ Local 2 Glibenclamide 5 ATM At RT Crystal Drum Kg Hazardous /Export Solid‐ HDPE 25, 50 Local / 3 1,2,4 Triazole 5 Hazardous ATM At RT Crystal Drum Kg Export 4‐Amino ‐1,2,4 Solid‐ HDPE 25, 50 Local 4 5 Hazardous ATM At RT Triazole Crystal Drum Kg /Export Raw Materials 2, 4‐Dichloro‐6‐ Solid‐ Woven 25, Non‐ 1 10 ATM At RT Local Amino Phenol Powder Bag 50Kg Hazardous 3, 5, 6‐Trichloro Solid‐ Woven 25, Non‐ Local 2 10 ATM At RT Salicylic Acid Crystal Bag 50Kg Hazardous HDPE Local 3 Acetone Liquid 170Kg 10 Flammable ATM At RT Barrel HDPE Toxic & Local 4 Acetone/Methanol Liquid 170Kg 10 ATM At RT Barrel Flammable Solid‐ Woven 25, Non‐ Local 5 Activated Carbon 0.5 ATM At RT Granules Bag 50Kg Hazardous Ammonia Gas Toxic & Local 6 Gas Cylinder 50 Kg 0.5 ATM At RT Flammable Ammonia Liq. HDPE Toxic & Local 7 Liquid 50 Kg 0.5 ATM At RT Barrel Flammable Caustic Soda Flaks Solid‐ Woven Local 8 50 kg 2 Hazardous ATM At RT Flakes Bag Cyclo Hexyl HDPE Local 9 Liquid 50 kg 0.5 Hazardous ATM At RT Isocynate Barrel Formic Acid HDPE Local 10 Liquid 200 Ltr. 2 Hazardous ATM At RT Barrel HDPE Local 11 Hydrazine Hydrate Liquid 200 Ltr. 2 Hazardous ATM At RT Barrel 12 Hydrochloric Acid Gas Cylinder 50 kg 0.5 Hazardous ATM At RT Local HDPE Toxic & Local 13 Methanol Liquid 170 kg 10 ATM At RT Barrel Flammable Mono Chloro HDPE Flammable Local 14 Liquid 235 kg 10 ATM At RT Benzene Barrel Phosohorus Tri HDPE Hazardous Local 15 Liquid 100 kg 0.5 ATM At RT chloride Barrel Solid‐ HDPE Non‐ Local 16 Sulphonamide 50 kg 1 ATM At RT Powder Drum Hazardous
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GI Toxic Local 17 Thionyl Chloride Liquid 300 kg 3 ATM At RT Barrel HDPE Hazardous Local 18 Xylene Liquid 190 kg 3 ATM At RT Barrel
All the above chemicals (raw materials and product) do not have specific threshold limit for storage in the plant as per the Manufacture, Storage and Import of Hazardous Chemical Rules, 1989.
All the products as well as raw materials will be transported by Road and convenient transportation medium will be used.
4.7. Details of Machineries & Utilities: As the proposed project will be in the existing premises, existing infrastructure facilities will also be utilized with the addition of some new machineries and utilities for the proposed project. The lists of plant machineries after proposed project are given in Table‐13. However, the actual requirements of machineries & equipment are not limited to the basic list below as some additional minor requirements can also be cited depending up on necessity noticed during installation & operations.
Table – 13: Details of Proposed Machineries and Utilities
Sr. Process/ Size/ Item Name MoC Qty. No. Activity Capacity 1. Glass Line Reactor R1 Glass Chlorination 1 700 2. SS Reactor R2 SS‐316 Condensation 2 750 3. SS Reactor R3 SS‐316 Carbon Treat 1 1100 4. Glass Line Reactor R4 Glass Purification 1 1500 5. SS Reactor R5 SS‐316 Distillation 1 750 6. SS Centrifuge CF1 SS‐316 Crude Filtration 2 24” X 0.45 met 7. SS Centrifuge CF2 SS‐316 Pure Filtration 1 24” X 0.45 met 8. Multi mill SS‐316 Sieve 1 50 kg/hr 9. Pulverizer 5 HP SS‐202 Micronization 1 25 kg/hr 10. SS Hot air dryer SS‐316 Drying 2 48 Tray 11. Chemical Process Pump SS‐316 Solvent Transfer 3 1500 Ltr/hr 12. Oil vacuum pump 5 HP MS High Vacuum 1 758 mm Hg 13. Water Jet Ventury 5 HP PP Vacuum 1 700 mm Hg
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Sr. Process/ Size/ Item Name MoC Qty. No. Activity Capacity 14. Sparkler Filter SS‐316 Carbon Filtration 1 10.0 Kg 15. Storage Tank SS‐316 Solvent Storage 1 500 Ltr. 16. Storage Tank MS Solvent Storage 1 1500 Ltr. 17. Storage Tank PP Solvent Storage 1 1000 Ltr. Details of Utilities (Proposed) 18. Air Compressor MS Air Generation 1 4 Kg 19. Water Softener MS Softener 1 1000 Ltr/hr 20. Storage Tank PP DM Water Storage 1 3000 Ltr. 21. Storage Tank PP DM Water Storage 1 500 Ltr. 22. Chilling Plant MS Chilling 1 10TR 23. Cooling tower Casting Cooling 1 50TR
4.8. Solvent Recovery System: The industry proposes to manufacture synthetic organic chemicals, which require solvents during various unit processes. The unit intends to use various solvents viz. Mono Chloro Benzene, Acetone and Xylene. The spent solvent generated during the manufacturing process will be recovered by way of distillation and reused in the process. The process of the solvent recovery system is described hereunder; After the completion of the reaction, the spent solvent/mother liquor will be separated by centrifuge and pumped to distillation reactor. It will be subjected to distillation to separate and recover solvent. Firstly, the mass will be distilled at required temperature where pure solvent will be distilled out depending on their boiler points and it will be collected in the recovered solvent storage tank and reused in the process. The recovered solvent will be reused in the process and residue will be sent to TSDF site for the disposal by incineration. Vaccum will also be applied during distillation. The overall requirements and mass balance for the solvent based on mass balance of each product has been worked out which is given in Table ‐14. The schematic diagram of the solvent recovery system is shown in the Drawing‐ 2.
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Measures for achieving maximum solvent recovery:
The entire manufacturing activities & distillation process will be carried out in the totally closed system. Maintenance of the pipeline and valves & fittings will be carried out regularly to avoid any leakages. Reactor will be connected with two numbers of condensers where cooling water and chilled water will be used as media and also equipped with vacuum system as per requirement. The condenser will be provided with the sufficient HTA and residence time to achieve more than 90% recovery.
During the manufacturing activity 3‐8% of the total solvent is lost; approx. 92 ‐ 97% of solvent is recovered during the process. The fresh solvent requirement will be depended on generation of distillation loss. The details of solvent consumption and mass balance are given below in Table‐14.
Table‐14 Details of Solvent Consumption And Mass Balance
Fresh, MT/Month Recovered, MT/Month Sr. Product Name of Solvent Product Group Product Group No. Code Total Total wise Max wise Max 1(a) 9.33 9.33 69.75 69.75 1 Acetone 19.33 144.75 2 10.00 10.00 75.00 75.00 2 Acetone/Methanol 1 (b) 9.30 9.30 9.30 69.80 69.80 69.80 3 Methanol 2 15.00 15.00 15.00 235.00 235.00 235.00 Mono Chloro 1 (a) 4.50 98.00 4 4.50 4.50 98.00 98.00 Benzene 1 (b) 4.50 98.00 3‐A 0.80 19.60 5 Xylene 0.80 0.80 21.60 21.60 3‐B 0.80 21.60
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Table‐15 Summary of Solvent Consumption And Mass Balance
Sr. Solvent Requirement, MT/Month Solvent Requirement,% Name of Solvent No. Fresh Recovered Total Fresh Recovered Total 1 Acetone 19.33 144.75 164.08 11.78 88.22 100.00 2 Acetone/Methanol 9.30 69.80 79.10 11.76 88.24 100.00 3 Methanol 15.00 235.00 250.00 6.00 94.00 100.00 4 Mono Chloro Benzene 4.50 98.00 102.50 4.39 95.61 100.00 5 Xylene 0.80 21.60 22.40 3.57 96.43 100.00 Total/Average 48.93 569.15 618.08 7.50 92.50 100.00
Drawing‐2: Schematic Diagram of the Solvent Recovery System
C/W OUT
CONDENSER - 1 C/W IN CHILLED WATER OUT CONDENSER -2 CHILLED WATER IN
REFLUX VACUUM =752 mm of Hg
Recovered Solvent COLUMN
S T E A DISTILLATION M
RE-BOILER
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Specification of Distillation Column Diameter & Height : 0.3 m dia & 3.0 m. ht MOC : 316 L Specification of Condenser Nos. : 2 Cooling Media : Cooling water/ Chilled Water Heat Transfer Area : 4 & 2 Sq. m. Residence Time : 1 hr Vacuum : 752 mm of Hg
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5. Pollution Potential And Control Measures
5.1 Water Pollution
(a) Details of Water Consumption & Wastewater Generation
Presently entire water requirement of the unit is met by private water supplier through tanker and same source will be utilized after proposed project. The total fresh water requirement for existing unit is 2.70 KLD and the additional water requirements of the proposed project will be 8.81 KLD.
Based on the material balance and technical experience of the similar industry, the water consumption and wastewater generation for all the products as well as for various categories have been calculated. The Industrial water requirement for manufacturing of pharmaceuticals products will be 8.21 KL/day, which will be mainly used for the Process, APCE, Washing and to make up evaporation/blow down losses from Boiler and Cooling tower and washing. The water consumption for domestic activity will be 2.0 KL/day and for green belt development will be 1.30 KL/day.
The product wise water consumption & waste water generation is given in Table – 16(A) and category wise water consumption and waste water generation is given in Table – 16(B). The water balance diagram is given in Drawing‐3.
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Table –16(A) Product wise Water Consumption & Wastewater Generation for proposed project
Wastewater Generation Capacity Water Consumption, Liter Product Batch size, (To ETP), Liter Product Stream (MT/ Code Kg/batch Per Per Per Per Per Month) Per Day Batch Kg Day Batch Kg
Oxyclozanide PROCESS 0.00 0.00 0.00 0.00 0.00 0.00 HCl Scrubber 1(a) APCE 108.50 0.43 417.31 155.00 0.62 596.15 (Oxyclozanide) SO2 Scrubber APCE 250 25.00 190.58 0.76 733.01 257.32 1.03 989.70* (Oxyclozanide) Oxyclozanide PROCESS 15.00 0.06 57.69 0.00 0.00 0.00 1(b) HCl Scrubber APCE 54.25 0.22 208.65 77.50 0.31 298.08 (Oxyclozanide) Maximum of Product‐1 ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ 57.69 ‐‐‐ ‐‐‐ 0.00 (PROCESS) Maximum of Product‐1 ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ 1150.32 ‐‐‐ ‐‐‐ 596.15 (APCE) 2 Glibenclamide PROCESS 100 20.00 0.00 0.00 0.00 0.00 0.00 0.00
3‐A 1,2,4 – Triazole PROCESS 0.00 0.00 0.00 304.00 1.01 389.74 300 10.00 4 ‐ Amino, 1, 2, 3‐B PROCESS 0.00 0.00 0.00 250.00 0.83 320.51 4 – Triazole Maximum of Product‐3 ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ 0.00 ‐‐‐ ‐‐‐ 389.74 (PROCESS) Total of Process ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ 57.69 ‐‐‐ ‐‐‐ 389.74
Total of APCE ‐‐‐ ‐‐‐ ‐‐‐ ‐‐‐ 1150.32 ‐‐‐ ‐‐‐ 596.15
TOTAL (PROCESS + APCE) ‐‐‐ ‐‐‐ 1,208.01 ‐‐‐ ‐‐‐ 985.90
The scrubbing water generation @ 989.70 L/day from APCE (SO2 Scrubber of Oxyclozanide) will be sold as by‐Product.
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Table – 16(B): Category wise Water Consumption & Wastewater Generation
Sr. Water Consumption, KL/day W/W Generation, KL/day Particulars No. Existing Proposed Total Existing Proposed Total I Domestic 0.50 1.50 2.00 0.40 1.20 1.60 II Gardening Fresh 0.50 0.8 1.30 Nil Nil Nil Reuse Nil 1.70** 1.70 Nil Nil Nil III Industrial a Process 0.50 0.06 0.56 Nil 0.40* 0.40 b APCE Nil 1.15 1.15 Nil 0.60 0.60 c Boiler 1.00 3.00 4.00 Nil 0.40 0.40 d Cooling 0.20 1.8 2.0 Nil 0.20 0.20 e Washing Nil 0.50 0.50 Nil 0.50 0.50 Total Industrial Consumption/ 1.70 6.51 8.21 0.00 2.10 2.10 Generation Process Reuse 0.00 0.00 0.00 0.00 0.40 0.40* Industrial Fresh 1.70 6.51 8.21 0.00 1.70 1.70** (Consumption/Discharge) Total 2.70 8.81 11.51 0.40 2.90 3.30 (Industrial + Domestic) Note: *In case of manufacturing of 1,2,4, triazole and 4‐Amino triazole the condensate water generated from the manufacturing process will be recovered and reused in cooling‐Make‐up. ** The waste water generated from APCM, Boiler, Cooling, Washing @ 1.70 KL/day will be treated into ETP and after achieving GPCB Norms it will be reused in Gardening/irrigation purposes within premises. The unit will develop green belt area up to 760 sq mt within the premises.
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Drawing – 3: Water Balance Diagram (For proposed project)
(1.60) Domestic To soak pit Fresh Water (2.0) via septic tank (11.51) system
Gardening Nil (1.30)
Fresh Industrial (8.21)
(0.56) (1.15) (4.00) (2.0) (0.50)
Process APCE Boiler Cooling Washing (Make up) (Make up)
(0.40) (0.60) (0.40) (0.20) (0.50)
Reuse
(0.40)
(1.70)
To ETP
(1.70)
For gardening/irrigation purposes within the premises
All quantities are expressed in KL/day.
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(b) Wastewater Management System
Presently there is no effluent generation form the existing unit and unit maintains the Zero Effluent Discharge. The industrial effluent generation from the proposed project will be @ 2.10 KL/day among them 0.40 KL/day of condensate water from process will be recovered & reused in cooling make‐up and the unit has proposed to install their own effluent treatment plant (ETP) comprising of Primary, secondary & Tertiary treatment which will be adequate to achieve the discharge norms prescribed by GPCB. After treatment into ETP, the total quantity of effluent will be used for gardening and plantation within the premises.
The Domestic wastewater after the proposed project will be increased from 0.40 KL/day to 1.60 KL/day, which will be discharged in to soak pit through septic tank as per the current practice.
The stage wise characteristics of effluent is given hereunder in Table‐17. The detail of proposed effluent treatment plant is given hereunder in Table‐18 and schematic flow diagram is given in Drawing – 4. Table‐17: Stage wise Characteristics of Effluent Sr. Raw Primary Secondary Tertiary GPCB Parameter Unit No. Effluent Outlet Outlet Outlet Norms 1 pH pH unit 5.0 – 8.0 6.5 ‐ 8.5 6.5 ‐ 8.6 6.5 ‐ 8.7 6.5‐8.5 2 TSS mg/L 200 100 100 80 100 3 TDS mg/L 1200 1300 1300 1300 2100 4 COD mg/L 650 300 100 80 100 5 BOD mg/L 200 100 30 25 30
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Table‐18: Detail Of Proposed Effluent Treatment Plant
m m m
hrs
Sr. Units m3
No. Nos. Liquid Liquid Volume, Time, Depth, Width, Length, Retention 1 Collection cum Treatment Tank 2 1.10 1.10 1.70 4.11 12.34 2 Lime Solution Tanks 1 0.75 0.75 0.75 0.42 ‐ 3 Alum Solution Tank 1 0.75 0.75 0.75 0.42 ‐ 4 Flocculation Channel 1 1.10 0.50 0.50 0.28 0.83 Primary Settling Tank 5 1 1.00 1.00 2.00 2.00 6.00 (Hopper Bottom) 6 Aeration Tank 1 1.50 1.50 2.50 5.63 67.50 Secondary Settling Tank 7 1 1.20 1.20 2.00 2.88 8.64 (Hopper Bottom) 8 Treated Water Collection Sump 1 1.10 1.10 1.70 2.06 6.17 9 Pressure Sand Filter 1 0.3 Dia. X 1.25 HOS 10 Activated Carbon Filter 1 0.3 Dia. X 1.50 HOS 11 Sludge Drying Beds 2 1.00 1.00 0.50 1.00 =
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Drawing‐4: Schematic flow diagram of Proposed Effluent Treatment Plant
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5.2 Air Pollution
The main sources of air pollution will be process gas emission and flue gas emission from the proposed project. There will be also very negligible chances of fugitive emission due to manufacturing activities and raw material handling and transportation. Various potential of air pollution are also briefly described hereunder.
(a) Process Gas Emissions
The only source of process gas emission from the proposed manufacturing activity will be HCl & SO2 gas generated from the manufacturing of Oxyclozanide. The details of gaseous pollutants liberated due to proposed manufacturing activities are given in Table ‐ 19 (A) & details of process gas stack are given in Table – 19 (B).
The adequate scrubbing system like two stage water scrubber followed by alkali scrubber will be provided for the control of process gas emission. The details of Air pollution control system for the process gas emission are given hereunder in Table‐20 and details of scrubbing system is given in Table –21. Schematic diagram of air pollution control measure are given as Drawing – 5.
Table – 19(A): Details of Gaseous Emission
Pollution Rate of Product Expected Reaction Product Load Generation Code Pollutants Time (hr) (kg/Batch) (kg/hr) Oxyclozanide‐stage‐I HCl 46.50 5 to 6 9.0 1 (a) (Using Thionyl Chloride‐SOCl ) 2 SO2 40.75 5 to 6 8.0 Oxyclozanide‐stage‐I 1 (b) HCl 23.25 2 to 3 11.0 (Using Phosphorous tri chloride –PCl3)
Table – 19(B): Details of Process Gas Stack
Sr. Stack attached Height Dia. Temp Polluant Concentration No. To Reactor (m) (m) (°C) mg/NM3 HCl ≤20 mg/Nm3 1. Reactors 15 0.04 40 3 SO2≤40 mg/Nm
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Table – 20 : Details of Air Pollution Measures for Process Stack
Sr. Scrubber attached to Air Air Pollution Control Equipment No. Reactor Pollutant 1st Stage 2nd Stage Water Alkali 1. Reaction Vessels HCl & SO2 Scrubber ‐A Scrubber‐B
Table – 21: Details of Scrubbing System Size of Scrubber, Pump Sr. Scrubbing Capacity of meter Capacity Output No. Media Scrubbing Tank, KL (Ht. and Dia.) M3/Hr A 3.0 X 0.25 Water 0.5 5 Effluent to ETP Sodium Bi Sulphate B 3.0 X 0.25 Caustic 0.5 5 (Sale as by‐Product)
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Drawing – 5– Schematic Diagram of Air Pollution Control Equipment – HCl and SO2
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(b) Flue Gas Emissions
Presently the unit has installed one Wood fired steam boiler (0.3 TPH‐ Working) and one LDO/FO fired steam boiler (0.3 TPH‐ stand by). The unit will install one new steam boiler (0.6 TPH‐ Working) for the proposed project where LDO/FO will be used as fuel. After proposed project, new LDO/FO based steam boiler will be kept working and the existing LDO/FO based steam boiler will be dismantled. The existing wood fired boiler will be kept as stand‐by.
For the existing wood fired steam boiler, the unit has installed Cyclone Separator as an APCM and no APCM is required for the existing as well as proposed LDO/FO fired steam boiler. The flue gas emission will be well within gaseous emission norms described by the GPCB. A common stack with adequate height of 12 m is provided for proper dispersion of pollutant from the steam boilers. The details of flue gas emission are given hereunder in Table‐22.
Table – 22: Details of Flue Gas Stack
Air Status Stack Sr. Stack Concentration Pollution Type of Fuel Ht. & No Attach to Existing Proposed of Polluants Control Dia. Mesures Steam Boiler Fire‐Wood/ Cyclone 1 Working Stand by (0.3 TPH) Agro‐waste PM < 150 Separator mg/Nm3 12 m Steam Boiler SO < 100 Not 2 Stand‐ by Dismentled LDO/FO & 2 (0.3 TPH ) ppm Required 0.2 m NOx < 50 Steam Boiler ppm Not 3 N.A. Working LDO/FO (0.6 TPH) Required
(c) Fugitive Emission
There will be a chance of fugitive emission from the manufacturing process as well as due to storage & handling of raw materials and product. The unit will take adequate precaution for the control of fugitive emission.
The entire manufacturing activities will be carried out in the closed reactors and regular checking and maintenance of reactors and distillation column will be carried out to avoid any leakages. All the motors of pumps for the handling of hazardous chemicals will be flame proof and provided with suitable mechanical seal with stand by arrangement.
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Vacuum distillation with double condenser system will be adopted. The Control of all parameters on a continuous basis will be done by adequate control valves, pressure release valves and safety valves etc. All the flange joints of the pipe lines will be covered with flange guards. All the raw materials will be stored in isolated storage area and containers are tightly closed. Precautionary measures will also be taken while handling various hazardous chemicals. There will also be provision of adequate ventilation system in process plant and hazardous chemical storage area. A regular preventive maintenance will be planned to replace or rectify all gaskets, joints etc. The unit will also develop green belt within the factory premises to control the fugitive emission from spreading in to surrounding environment.
5.3 Hazardous Waste Generation and Management
The main sources of hazardous waste generation from proposed manufacturing activity will be Process Waste viz. Inorganic residue, Distillation Residue, Spent Carbon and Spent Solvent. Dried sludge will be generated from effluent treatment plant. The ancillary source of hazardous waste generation will be discarded bags/liners/drums/Carboys/Containers from storage and handling of raw materials and spent oil generation from plant machinery. The details of hazardous waste generation and handling / Management are given in Table‐23.
Table –23: Hazardous Waste Generation and Management Quantity Physical‐ Type of Source Cat. per Chemical Method of Disposal waste Annum Form Process Inorganic 28.1 52.0 MT Solid Collection, Storage & disposal by Salt Inorganic land filling at TSDF site. Distillation 28.1 14.0 MT Semisolid Collection, Storage, Residue organic Transportation, Disposal by Spent 28.2 18.0 MT Solid incineration of incinerator of Carbon Inorganic nearby CHWI. Spent 28.5 6000 MT Liquid & Collection, Storage & Reuse Solvent Organic after distillation within process OR Sell to GPCB authorized recycler ETP ETP Sludge 34.3 2.0 MT Solid & Collection, Storage, Inorganic Transportation, Disposal by land filling at TSDF site
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Raw Material Discarded 33.3 1000 Nos. Solid‐ Collection, Storage, Storage & Containers Inorganic Decontamination and Disposal Handling / Bags by selling to authorized vendors. Plant and Spent Oil/ 5.1 10 Ltr Liquid‐ Collection, Storage, Machineries Used Oil Organic Transportation, sell to registered Reprocessor/ MoEF approved recyclers
The unit will provide an adequate designated storage area for the hazardous waste storage within premises having impervious floor and roof cover system and leachate collection system. The unit has obtained provisional membership of GPCB approved TSDF/CHWIF of M/s. Saurashtra Enviro Projects Pvt. Ltd. for the disposal of hazardous waste and copy of certificate is enclosed as Annexure‐II.
5.4 Noise Pollution
No D.G. set has been installed and it will be not provided during the proposed project. Hence there is no major source of noise and vibration from the existing as well as proposed manufacturing activity. However, adequate precautionary measure for noise and vibration control measures as described below will be taken by the unit;
Proper and timely oiling, lubrication and preventive maintenance will be carried out for the machineries and equipment to reduce noise generation. The noise generation will be mitigated by installing noise barriers/absorbers around stationery noise sources. Adequate noise control measures such as anti‐vibration pad for equipment with high vibration will be provided. All the vibrating parts will be checked periodically and serviced to reduce the noise generation. The equipment, which generates excessive noise, will be provided with enclosures etc. To minimize the adverse effect on the health, Ear muffs/ earplugs will be provided to the workers working under high noise area. To reduce the noise generation during the transportation activities; the transport contractor will be instructed kept vehicle periodically serviced and maintain as per the requirement of latest trend in automobile industry. Only those vehicles with PUC’s will be allowed for the transportation.
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The transport contractor will be informed to avoid unnecessary speeding of vehicles inside the premises. Noise monitoring will be done regularly at different parts of the plant. Green belt area will be developed to prevent the noise pollution outside the factory premises.
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6. Project Schedule & Cost Estimates
6.1 Schedule of Approval and Implementation
The proposed project has been planned for the manufacturing of Bulk Drugs & Drugs Intermediates within the existing premises. The entire development will take about 6 months for the completion of proposed project. The new construction activities and installation of additional plant & machineries will start after obtaining necessary approval from Ministry of Environment and Forests and State Pollution Control Board (SPCB).
6.2 Capital Investment
The unit is a Small Scale Unit and has made capital investment of Rs. 48.57 lacs in the existing plant and the estimated cost for the proposed project will be about Rs. 36.50 Lacs. The detail breakup of the capital cost is given in Table‐24.
Table – 24: Capital Cost Capital Cost, Rs. In Lacs Sr. Description Proposed No. Existing Total Project 1. Land & Site Development 2.58 2.00 4.58
2. Building 10.80 7.50 18.30
3. Plant & Machineries 35.19 21.50 56.69
4. Environmental Protection Measure ‐‐ 5.50 5.50
Total 48.57 36.50 85.07
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7. Rehabilitation and Resettlement (R&R) Plan M/s. Ascent Pharma is an existing small scale unit located in Shapar‐Veraval industrial area of Taluka Kotada Sangani of District Rajkot in Gujarat. Since, the proposed project for the manufacturing of various Synthetic Organic Chemicals (Bulk Drugs & Drugs Intermediates) will be carried out within the existing industrial premises and no additional land will be required there will not be any displacement of population due to proposed project.
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8. Final Recommendation
The unit has proposed adequate measures for the prevention and control of pollution. With the execution and operation of such control measures along with proper Environmental Management System, there will not be any major potential for negative impact on the environment due to proposed project.
On the contrary, there will be positive impact on the socio‐economic environment since proposed project will generate some permanent and secondary employment. The unit will also establish Cordial relation with the nearby villagers and will carry out social welfare activities according to their needs.
The proposed project will also boosts up ancillary industrial and commercial activity. Thus, it will improve the economic condition of the area.
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