FORM I
I. Basic Information
S.No Item Details
1. Name of the Project M/s. Kumar Organic Products Limited, Jigani Industrial Area, Anekal Taluk, Bangalore, Karnataka- 560105Existing and Proposed Expansion of Cosmaceutical, Active Pharmaceuticals and Specialty Chemicals
2. S. No. in the Schedule 5(f)
3. Proposed Existing Capacity- 1940 MT/A. Capacity/area/length/tonnag ProposedTotal Capacity Capacity: 4940- 3000MTPA. MT/A. e to be handled/command area/lease area/number of Details given in item No.5. wells to be drilled.
4. New/Expansion/Modernizatio Expansion. n
Page 1 of 23 S.No Item Details
5. Existing capacity/Area etc., Existing Products Proposed Products Qua Quanti S. S. ntity Name ty Name No No MTP MTPA A Zinc Phosphate/0r
1 Triclosan 1200 1 Ethyl 600 hexyle glycerine
2 Minoxidil 60 2 Zinc Citrate 600 3 4-Hexyl resorcinol 40 3 Zinc Lactate 1800 4 CiclopiroxOlamine 20 5 PiroctoneOlamine 60 6-pyrrolidino 2,4-
6 diaminopyrimidine 20 3-oxide 6-pyrrolidino 2,4- diaminopyrimidine 7 20 3-oxide, monohydrate
8 n-Butyl Resorcinol 20 Ethyl hexyl 9 500 glycerin
Total 1940 3000 Grand Total 4940 MTPA (12 Numbers) Though the project site is located in KIADB industrial area, 6. Category of Project i.e. ‘A’ or Since the unit does not have EC, as per MoEF&CC ‘B’ Notification No. S.O.804 (E) 14th March, 2017 it has been categorized as ‘A’ and Schedule 5(f).
7. Does it attract the general Yes
condition? If yes please Bannergatta National Park is about specify. 2.4 km from Project Site (by road )
7.88 km from Project Site (aerial distance).
Page 2 of 23 S.No Item Details
8. Does it attract the specific Yes. condition? If yes please The site is located in Jigani Industrial Area of KIADB. specify.
9. Location M/s. Kumar Organic Products Limited,
KIABD Industrial Area, Jigani,
Anekal Taluk,
Bangalore, Karnataka- 560105.
Plot/survey/khasra No. Existing Plot no.: 36A/B/60/62/63/64/65
New Expansion : Plot no. 83P and 84
Village Jigani
Tehsil Anekal
District Bangalore
State Karnataka
10. Nearest Railway Bangalore railway station-40 KM.
station/Airport along with the Airport-60 KM. distance in Kms.
11. Nearest town, city, District Bangalore Head quarters along with distance in kms.
12. Village Panchayats, Zilla M/s. Kumar OrganicProducts LTD
Parishad, Municipal Usha Krishna Tower, Corporation, Local Body Plot no. 36B, road no.3 &5, (complete postal addresses with phone nos. to be given) Jigani Industrial Area, Anekal Taluk,
Page 3 of 23 S.No Item Details
Bangalore-560105, Karnataka.
+91-80-27825376
13. Name of the applicant Mr. S. N. Singh
14. Registered Address M/s. Kumar OrganicProducts LTD
Plot no. 36B,
Usha Krishna Tower,
Road no.3 &5, Jigani Industrial Area,
Anekal Taluk,
Bangalore-560105, Karnataka.
15. Address for Correspondence M/s. Kumar Organic Products LTD
Plo. 36B, Usha Krishan Tower,
Road no.3 &5, Jigani Industrial Area,
Anekal Taluk,
Bangalore-560105, Karnataka.
Name Mr. S. N. Singh
Designation Director-Works (Owner/Partner/CEO)
Address M/s. Kumar OrganicProducts LTD
Plo. 3B, Usha Krishan Tower,
Road no.3 &5, Jigani Industrial Area,
Anekal Taluk,
Bangalore-560105, Karnataka.
Pin Code 560105
E – mail [email protected] Page 4 of 23 S.No Item Details
Telephone No. Tel: +91-80-27825376.
Mob no: 09845810177.
16. Details of Alternative sites Existing unit. examined, if any. Location of these sites should be shown on a topo sheet.
17. Interlinked Projects None
18. Whether separate application Not Applicable of interlinked project has been submitted.
19. If yes, date of submission Not Applicable
20. If no, reason Not Applicable
21. Whether the proposal involves Not Applicable approval/clearance under: if yes, details of the same and their status to be given.
(a) The Forest Conservation Act, 1980? (b) The Wildlife Protection Act, 1972? (c) The C.R.Z notification, 1991?
22 Whether there is any Government Order/Policy No. relevant/relating to the site?
Page 5 of 23 S.No Item Details
23. Forest Land involved No forest land is involved. (hectares)
24. Whether there is any litigation No pending against the project and/or land in which the project is propose to be set up?
(a) Name of the Court (b) Case No. (c) Orders/directions of the court, if any and its relevance with the proposed no project. II. Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
S.No. Information/Checklist Yes Details thereof (with approximate confirmation /No quantities /rates, wherever possible) with source of information data
1.1 Permanent or temporary change No NA in land use, land cover or topography including increase in intensity of land use (with respect to local and use plan)
1.2 Clearance of existing land, No NA vegetation and buildings?
1.3 Creation of new land uses? No NA
1.4 Pre-construction investigations No NA e.g. bore houses, soil testing?
1.5 Construction works? No NA
1.6 Demolition works? No NA
Page 6 of 23 S.No. Information/Checklist Yes Details thereof (with approximate confirmation /No quantities /rates, wherever possible) with source of information data
1.7 Temporary sites used for No NA construction works or Housing of construction workers?
1.8 Above ground buildings, No NA structures or earthworks including linear structures, cut and fill or excavations
1.9 Underground works including No NA mining or tunneling?
1.10 Reclamation works? No NA
1.11 Dredging? No NA
1.12 Offshore structures? No NA Annexure 1
1.13 Production and manufacturing Yes Provided at processes?
1.14 Facilities for storage of goods or Yes Capacity (MT) S. No Description Total materials? Existing Proposed
1. Raw materials 400 600 1000 Hazardous Raw 2. 5 - 5 Materials 3. Solvents 60 10 70 Products 4. 400 600 1000 Storage
Existing Facility
1.15 Facilities for treatment or Yes a. Solid waste disposal of solid waste or liquid Waste Quan Collectio Disposal method tity n effluents? (kg/ method day)
Organic 2126 Bins Sent to cement Annexureindustry for2.co- incineration. Annexure 3. Inorgani 3945 Bins Authorized dealer c Page 7 of 23 S.No. Information/Checklist Yes Details thereof (with approximate confirmation /No quantities /rates, wherever possible) with source of information data
Annexure 4. ETP 1900 Trolleys Authorised dealer Sludge Hazardous Waste Hazardous waste will be properly disposed as per the Hazardous waste Management rule 2008 and amendment in 2016. Hazar Quantity Wast dous e Tota Method of waste Cate Exis Additi l handling Gener gory ting onal Prop ated osed Collected in leak proof containers 1.5 and disposed only Used 0.8 2.3 5.1 KL to KSPCB Oil KLD KLD D registered authorized re- processor Spent 1 1 Sent to authorized 28.2 cataly MT 0 MTD dealer sts D Spent 10 Co-incineration in 28.3 0 10 MT carbon MT cement industries. Proces Stored in secure 101 s 1012 manner and handed 2.5 28.1 residu 0 .5 over to KSPCB MT e and MTA authorized A waste incinerator 123 1830 MS 0 600 33.1 Nos/ Drums Nos Nos/A Stored in secure A /A manner and handed over to KSPCB HDPE 650 950 300 authorized recycler 34.1 Used Nos/ Nos/ Nos/A Liners A A ETP Sludg e/Che mical Stored in secure 22.5 sludge 10.5 33 manner and handed 35.3 MT from MTA MTA over to KSPCB A clarifi authorized TSDF er and evapor ator
Annexure 5 KSPCB authorization for Existing facilities b. Liquid waste. management
Existing 92 KLD Proposed 110 KLD including existing
Page 8 of 23 S.No. Information/Checklist Yes Details thereof (with approximate confirmation /No quantities /rates, wherever possible) with source of information data
will be treatedAnnexure at ETP. 6.
ZLD scheme-
1.16 Facilities for long term housing No Local labours will be utilized. Hence no of operational workers? housing facilities are required for the workers.
1.17 New road, rail or sea traffic No The present road facilities will be utilized for during construction or the proposed construction and operation operation? work
1.18 New road, rail, air waterborne No The present road facilities will be utilized for or other transport the proposed construction and operation infrastructure including new or work altered routes and stations, ports, airports etc?
1.19 Closure or diversion of existing No NA transport routes or infrastructure leading to changes in traffic movements?
1.20 New or diverted transmission No NA lines or pipelines? 1.21 Impoundment, damming, No NA culverting, realignment or other changes to the hydrology of watercourses or aquifers?
1.22 Stream crossings? No NA
1.23 Abstraction or transfers of No NA water form ground or surface waters?
1.24 Changes in water bodies or the No There is no change in water bodies or land land surface affecting drainage surface, and will not affect the drainage. or run-off?
1.25 Transport of personnel or No The existing roadways/facilities will be used materials for construction, for the transport of materials and personnel. operation or decommissioning? Through public transports only. Page 9 of 23 S.No. Information/Checklist Yes Details thereof (with approximate confirmation /No quantities /rates, wherever possible) with source of information data
1.26 Long-term dismantling or No NA decommissioning or restoration works?
1.27 Ongoing activity during No NA decommissioning which could have an impact on the environment? Existing facility 1.28 Influx of people to an area either No 262 nos. temporarily or permanently? Proposed expansion Total (38 contract workers) 30 nos. 292 nos. 1.29 Introduction of alien species? No NA
1.30 Loss of native species or genetic No NA diversity?
1.31 Any other actions? No NA
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply): S.No. Information/checklist Ye Details thereof (with approximate confirmation s/ quantities /rates, wherever possible) No with source of information data
2.1 Land especially undeveloped or No Industrial area developed by KIDAB agricultural land (ha) Water Consumption: 165 KL/day, Sourced from KIADB and private water supply will be 2.2 Water (expected source & Yes used. competing users) unit: KLD (165 KLD Existing + 35 KLD Proposed)
Propo Total Total water Exist sed (KLD) Break-up S. Water ing (KLD) No requirement (KL (KLD Trea D) Fresh ) ted 1 Process 60 20 80 20 60
2 Washing 5 1 6 1.2 4.8
Page 10 of 23 3 Boiler Feed 60 1 61 21 40
4 Chiller 5 0.5 5.5 5.5 0
5 Domestic 10 2.5 12.5 12.5 0
6 Other utilities 10 3 13 13 0
7 Green belt 15 7 22 22 0 104. Total 165 35 200 95.2 8
Note; 80% Treated waste is recycled and 20% make water is used. Annexure 7 Water supply agreement letter . 2.3 Minerals (MT) No
2.4 Construction material – stone, No NA aaggregates, sand / soil (expected source – MT)
2.5 Forests and timber (source – No NA MT) Capacity 2.6 Energy including electricity Yes Details Propos Source Existing Total and fuels (source, competing ed Power users) Unit: fuel (MT), 500+250 BESCO Requirement 400 1150 energy (MW) =750 M (kw) 640+250+ Back-up 125 400 1415 DG sets (KVA) =1015 Diesel Appro Appro Approx. Requirements x. x. HP 12 (KL/Month) 5 17 Fuel oil 15 5 20 BPCL (KL/Month) Solid Local Fuel/Briquette 18 3.6 21.6 supplier (T/D)
Boiler: Furnace oil/Briquette fired boiler 1 No having capacity of 3TPH. Additional requirement due to proposed expansion is 0.6 TPH. Furnace oil source is BPCL.
Page 11 of 23 2.7 Any other natural resources No NA (use appropriate standard units) 3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
S.No. Information/Checklist Yes/No Details thereof (with approximate confirmation quantities/rates, wherever possible) with source of information data
3.1 Use of substances or materials, Yes This is a Pharmaceutical Ingredients which are hazardous (as per manufacturing process and solvents MSIHC rules) to human health or will be used in the process. A the environment (flora, fauna, and water supplies) separate storage facility is provided for the storage of solventsAnnexure and Raw8 materialsand APIs MSDS(RM MSDS9 ).
3.2 Changes in occurrence of disease No NA or affect disease vectors (e.g. insect or water borne diseases)
3.3 Affect the welfare of people e.g. by Yes Systems are already in place. changing living conditions? For expansion, the same will be followed.
Employment generation of local people.
3.4 Vulnerable groups of people who No No such activities involved in the could be affected by the project existing as well as projected activity. e.g. hospital patients, children, the No hospital and schools are available elderly etc., within 3 kilometers.
3.5 Any other causes No
Page 12 of 23 4. Production of solid wastes during construction or operation or decommissioning (MT/month)
S.No Information/Checkli Yes/N Details thereof (with approximate . st confirmation o quantities/rates, wherever possible) with source of information data
4.1 Spoil, overburden or No NA mine wastes
4.2 Municipal waste Yes Kg/Day Type Disposal Method (domestic and or Existing Proposed commercial Organic 57.6 64.8 Local Municipal bins Sent to KSPCB Inorganic 62.4 70.2 wastes) Authorized recyclers Total 120 135
Hazardous Waste
4.3 Hazardous wastes (as Yes per Hazardous Waste Hazardous waste will be properly disposed as per the Hazardous waste ManagementQuantity rule 2008 and Waste Hazardous Management Rules) amendment 2016. Method of Categor waste Existin Propose Total handling y Generated g d Collected in leak proof containers and 1.5 0.8 2.3 disposed 5.1 Used Oil KLD KLD KLD only to KSPCB registered authorized re- processor Sent to 1 28.2 Spent catalysts 1 MTD 0 authorized MTD dealer Co- incineratio 10 28.3 Spent carbon 0 10 MT n in MT cement industries. Stored in secure manner 1012. Process residue 1012.5 and handed 28.1 0 5 and waste MTA over to MTA KSPCB authorized incinerator 1230 600 1830 Stored in 33.1 MS Drums Nos /A Nos/A Nos/A secure manner HDPE Used 650 300 950 and handed 34.1 Liners Nos/A Nos/A Nos/A over to KSPCB Page 13 of 23 S.No Information/Checkli Yes/N Details thereof (with approximate . st confirmation o quantities/rates, wherever possible) with source of information data
authorized recycler
Stored in secure ETP manner Sludge/Chemica 22.5 10.5 33 and handed 35.3 l sludge from MTA MTA MTA over to clarifier and KSPCB evaporator authorized TSDF
4.4 Other industrial process No NA wastes
4.5 Surplus product No NA
4.6 Sewage sludge or other Yes Existing unit : 22.5 MTPA. sludge from effluent Annexure 4 Stored in secure manner and handed over to treatment KSPCB authorized TSDF, .
Proposed unit: 10.5 MTPA.
4.7 Construction or No NA demolition wastes
4.8 Redundant machinery No NA or equipment
4.9 Contaminated soils or No NA other materials
4.10 Agricultural wastes No NA
4.11 Other solid wastes No NA 5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Details thereof (with approximate quantities/rates, wherever possible) with source of information data S.No. Information/Checklist Yes confirmation /No
5.1 Emissions from combustion of Yes The movement of the vehicle around the fossil fuels from stationary or project site also increases the emission mobile sources load.
DG sets are attached to the building, adequate DG stack height above PageGL will14 of be23 Details thereof (with approximate quantities/rates, wherever possible) with source of information data S.No. Information/Checklist Yes confirmation /No
provided for safe emission of the flue gases.
5.2 Emissions from production Yes All the reactors have condensers to processes condense the solvent vapors.
In case of toxic fume emissions, the reactor vents are connected to the scrubber to neutralize the toxic vapors.
5.3 Emissions from materials No Transportation of materials will be handling including storage or through closed system, drums and through transport pipelines.
5.4 Emissions from construction No NA activities including plant and equipment
5.5 Dust or odours from handling No The dust is minimized by water sprinkling. of materials including The sewage is treated in Common Effluent construction materials, sewage Treatment Plant. and waste
5.6 Emissions from incineration No No incineration activity is involved of waste
5.7 Emissions from burning of No No burning activity is involved waste in open air (e.g. slash materials, construction debris)
5.8 Emissions from any other No NA sources
Page 15 of 23 6. Generation of Noise and Vibration, and Emissions of Light and Heat:
Details thereof (with Information/Checklist approximate quantities/rates, S.No. Yes/No confirmation wherever possible) with source of information data
6.1 From operation of equipment e.g. Yes The DG sets will be in operation engines, ventilation plant, crushers only during power failure. Moreover, the DG rooms will be acoustically enclosed.
For ventilation plant, thermopack (duck insulation) will be provided for reducing the noise levels.
Noise of existing project is monitored on regular basis and is less than 75 dB.
6.2 From industrial or similar processes No Noise generation at source will be complied by keeping the noise within the prescribed limits.
6.3 From construction or demolition Yes Will be controlled with proper maintenance of equipments.
6.4 From blasting or piling No NA
6.5 From construction or operational No Will be controlled through proper traffic maintenance.
6.6 From lighting or cooling systems No Negligible.
Existing / proposed units:
Lead LIGHTs have been provided/ proposed
6.7 From any other sources No NA
Page 16 of 23 7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:
S.No. Information/Checklist Yes/No Details thereof (with confirmation approximate quantities/rates, wherever possible) with source of information data
7.1 From handling, storage, use or No Storage, handling and spillages of spillage of hazardous materials hazardous material is taken care by following the written procedures (SOPs) and waste disposal is made according to local standards.
Proper storage facilities will be provided to prevent the risk of contamination.
7.2 From discharge of sewage or other No sewage and other effluents in effluents to water or the land ETP. (expected mode and place of The treated water is used for discharge) flushing and gardening
7.3 By deposition of pollutants emitted No Gaseous emission is scrubbed and to air into the land or into water stack emissions are test performed accordingly / planned.
7.4 From any other sources No NA
7.5 Is there a risk of long term build up No NA of pollutants in the environment from these sources?
Page 17 of 23 8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
S.No. Information/Checklist Yes/No Details thereof (with confirmation approximate quantities/rates, wherever possible) with source of information data
8.1 From explosions, spillages, fires etc No Hazardous substances like from storage, handling, use or solvents will be used in production of hazardous operational phase. substances Proper handling procedures will be followed as recommended in the MSDS for the solvents and any hazardous materials
8.2 From any other causes No NA
8.3 Could the project be affected by No The project site falls under natural disasters causing seismic zone-II according to the environmental damage (e.g.floods, Indian Standard Seismic Zoning earthquakes, landslides, cloudburst Map. Further it is not flood prone etc)? or landslide prone area. Hence, no risk due to natural hazards is envisaged. However suitable seismic coefficients in horizontal and vertical directions will be adopted while designing the structures.
Page 18 of 23 9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Details thereof (with approximate quantities/rates, wherever possible) with source S. No. Information/Checklist Yes/No of information data confirmation
.
9.1 Lead to development of supporting NO The project site is located in KIADB APPROVED industrial area. Facilities, ancillary development or development stimulated by the Since the unit is an Active project which could have impact on Pharmaceutical Ingredients the environment e.g.: manufacturing unit, inside KIADB area, no housing development is • Supporting infrastructure (roads, proposed. power supply, waste or waste water treatment, etc.) Not applicable (for Extractive industries, Supply industries& • Housing development others) • Extractive industries
• Supply industries
• Other
9.2 Lead to after-use of the site, which NO Not Applicable could have an impact on the environment
9.3 Set a precedent for later NO Not Applicable developments
9.4 Have cumulative effects due to NO Not envisaged. proximity to other existing or planned projects with similar effects
Page 19 of 23 III. Environmental Sensitivity
S.No. Areas Name/ Aerial distance (within 15 km.)proposed project location Identity boundary
1 Areas protected under international conventions, national or local legislation for No NA their ecological, landscape, cultural or other related value
2 Areas which are important or Bannerghatta 12.4 km from Project Site (by road ) sensitive for ecological reasons National 7.88 km from Project Site (aerial - Wetlands, watercourses or Park distance), WNW. other water bodies, coastal zone, biospheres, mountains, forests
3 Areas used by protected, Bannerghatta 12.4 km from Project Site (by road ) important or sensitive species National 7.88 km from Project Site (aerial of flora or fauna for breeding, Park nesting, foraging, resting, over distance), WNW. wintering, migration
4 Inland, coastal, marine or No NA underground waters
5 State, National boundaries Tamil Nadu 20 Km State Boundary
6 Routes or facilities used by the No NA public for accessto recreation or other tourist, pilgrim areas
7 Defense installations YesNil NA
8 Densely populated or built-up Jigani and Bangalore. area
Page 20 of 23 S. Name Km Directions (hospitals, No. 9 Areas occupied by sensitive man- schools, places of worship, Schools and Colleges made land uses community facilities) 1 Govt. School 5.38 N Jigani 2 International 8.99 NE Institute of NE Information Technology 3 Vivekananda 2.00 W Kendra Vidyalaya 4 Government 4.34 NE School Hennagra Religious Places
1 Sri Lakshmi 8.91 NW Narashimha Swami Temple 2 Jigani Masjid 2.31 N Hospitals
1 YK hospital 1.50 N 2 Suhas Hospital 1.36 N 3 Vijayashree 1.32 N Hospital
10 Areas containing important, high quality(ground or water scarce resources, resources surface NA No resources, forestry, agriculture, fisheries, tourism, minerals)
11 Areas already subjected to Nil No Notified/Recognized polluted area (those where existing pollution or environmental legal environmental standards are within 15km distance. damage. exceeded)
12 Areas susceptible to natural No This area is generally plain not prone to hazard which could cause the any natural disasters. The area under earthquakes, project to present environmental study falls in Zone-II, according to the subsidence, landslides, erosion, problems ( Indian Standard Seismic Zoning Map. flooding or extreme or adverse Suitable seismic coefficients in horizontal climatic conditions and vertical directions respectively, have ) to be adopted while designing the structures.
Page 21 of 23
List of Annexures:
Annexure 1 Annexure 2 1. Production and manufacturing processes, Annexure. 3 2. Organic Solid waste incineration agreement,Annexure 4 . 3. In-Organic Solid waste disposal agreement,Annexure 5 . 4. ETP Solid sludgeAnnexure disposal 6 agreement, . 5. KSPCB authorization for ExistingAnnexure facilities 7 . 8.6. RawZLD materialsScheme -and products MSDS. Annexure 8 Annexure 9 7. Water supply agreement letter, . and APIs MSDS .
Page 23 of 23 Pre-Feasibility Report Kumar Organic Products Limited
PREFEASIBILITY REPORT
FOR
Existing and Proposed Expansion of Cosmaceutical, Active Pharmaceuticals and Specialty Chemicals (Cosmeceutical, API’s &Specialty Chemicals Manufacturing)
BY
Kumar Organic Products Limited
AT
VILLAGE: JIGANI INDUSTRIAL AREA
TALUK: ANEKAL
DISTRICT: BANGALORE
STATE: KARNATAKA
Prepared by
HUBERT ENVIRO CARE SYSTEMS PRIVATE LIMITED
September 2017
1 Pre-Feasibility Report Kumar Organic Products Limited
TABLE OF CONTENTS 1. EXECUTIVE SUMMARY...... 6 2. INTRODUCTION OF THE PROJECT...... 9 2.1 About the project proponent...... 9 2.2 About the project...... 9 3. PROJECT DESCRIPTION...... 12 3.1 Type of Project...... 12 3.2 Project Location ...... 12 3.3 Major products of the company...... 15 3.4 Details of alternate sites ...... 15 3.5 Size of Operation...... 16 3.6 Project Description...... 17 3.7 Raw Material Required ...... 18 3.8 Resource optimization/recycling and reuse...... 19 3.9 Power and fuels...... 19 3.10 Manpower ...... 19 3.11 WATER REQUIREMENT...... 20 3.12 Utilities...... 21 3.13 Liquid waste management...... 22 3.14 Air pollution control measures...... 24 3.15 Hazardous and solid waste management...... 24 4. SITE ANALYSIS...... 27 4.1 Connectivity ...... 27 4.2 Landform, Landuse, Landownership...... 27 4.4 Existing Land use pattern...... 28 4.5. Existing Infrastructure: ...... 29 4.6. Soil Classification:...... 31 4.7. Climatic data from secondary sources: ...... 32 4.8. Social Infrastructure available: ...... 32 5.1. Planning concept...... 33 5.2. Population Projection...... 33 5.3. Land use planning...... 33 5.4. Assessment of Infrastructure Demand ...... 34 5.5. Amenities/Facilities ...... 34
2 Pre-Feasibility Report Kumar Organic Products Limited
6 PROPOSED INFRASTRUCTURE ...... 35 6.1. Industrial Area: ...... 35 6.2. Residential Area...... 35 6.3. Green belt...... 35 6.4. Social Infrastructure...... 35 6.5. Connectivity...... 35 6.6. Drinking Water Management...... 35 6.7. Sewerage system...... 35 6.8. Industrial waste management...... 35 6.9. Solid waste management...... 37 6.10. Power Requirements and Supply/ Source...... 38 7 REHABILITATION AND RESETTLEMENT (R & R) PLAN ...... 38 7.1. Policy to be adopted (Central/ State) ...... 38 8 PROJECT SCHEDULE AND COST ESTIMATE...... 39 8.1. Likely date of start of construction and likely date of completion...... 39 8.2. Estimated project cost...... 39 9 ANALYSIS OF PROPOSAL...... 40 9.1. Financial and social benefits ...... 40 10 CONCLUSION ...... 41
3 Pre-Feasibility Report Kumar Organic Products Limited
LIST OF TABLES
Table 2.1 Existing & Proposed products and capacity…………………………………………...….10 Table 3.1 The environmental setting of the existing site…………………………………………..…16 Table 3.2 Raw Material Required………………………………………………………………….…18 Table 3.3 Power and fuel requirement………………………………………………………………..19 Table 3.4 Manpower for existing and proposed units……………………………………………….20 Table 3.5 Water requirement………………………………………………………..………………..20 Table 3.6 List of Utilities………………………………………………………………….….………21 Table 3.7 Liquid waste detail…………………………………………………………………………22 Table 3.8 Hazardous waste…………………………………………………………..……………….25 Table 3.9 Municipal Solid Waste details…………………………………..…………………………26 Table 4.1The details of sensitive areas from the site boundary………………………………..…….28 Table 4.2 Existing infrastructure within 10 Km radius from the site………….……………………..31 Table 4.3 Project surrounding features……………………………………………………………....32 Table 5.1 Area details of the facility……………………………………………………………….…33 Table 6.2 Solid waste details………………………………………………………………………....38
LIST OF FIGURES
Figure 3.1Project Site...... 14 Figure 3.2 10 km Radius around project site ...... 14
4 Pre-Feasibility Report Kumar Organic Products Limited
LIST OF ABBREVIATIONS
KOPL Kumar Organic Products Limited ETP Effluent Treatment Plant STP Sewage Treatment Plant kWh Kilowatt per hour WHO World Health Organization ISO International Standard for Organization API Active Pharmaceutical Ingredients R&D Research & Development USFDA Food & Drug Administration (USA) KRC Kumar Research Centre PO Pure Oil
List of annexure
xisting CFE-Annexure 10.
12).). TheE Authorization Letter from KSPCB for Hazard and solid waste disposal Annexure 5. 3). Plant layout of proposed facility is enclosed as Annexure 11.
5 Pre-Feasibility Report Kumar Organic Products Limited
1. EXECUTIVE SUMMARY S. No. Particulars Details Kumar Organic Products limited 1. Name of Company Existing :---Plot No. , Jigani Industrial Area, Anekal Taluk, Bangalore 2. Location Proposed:-- Plot 83( P)36A/B,, 84 adjacent 60, 62, to63, existing 64 and site 65 separated by Road no -6
Though the project site is located in KIADB industrial area, Project Activity, 3. Category as per Since the unit does not have EC, as per MoEF&CC Notification amendments No. S.O.804 (E) 14th March, 2017 it has been categorized as ‘A’ and Schedule 5(f). Cosmaceutical, Active Pharmaceuticals and 4. Name of the project Specialty Chemicals 5. Total Land area 40445.33Manufacturing Sq.m, of9.99 Acre Existing Capacity- 1940 MT/A (9 Products). 6. Product with capacity Proposed Capacity- 3000 MT/A (3 Products). Total Capacity: 4940 MTPA (12 Products). Details as chapter 3, section no. 3.7, Table no. 3.2 7. Raw material Water Consumption: 165 KL/day, Sourced fromKIADB and private water supply will be used. (165 existing + 35 proposed) Break up as follows:
Total Total water S. Existing Proposed (KLD) Break-up (KLD) Water requirement No (KLD) (KLD) Fresh Treated
1 Process 60 20 80 20 60 Water 8. requirement 2 Washing 5 1 6 1.2 4.8
3 Boiler Feed 60 1 61 21 40
4 Chiller 5 0.5 5.5 5.5 0
5 Domestic 10 2.5 12.5 12.5 0
6 Other utilities 10 3 13 13 0
7 Green belt 15 7 22 22 0
Total 165 35 200 95.2 104.8 9. Waste water and Effluent shall be treated in existing system and proposed ETP. mode of disposal Treated effluent shall berecycled/reused to the extent and remaining shall be disposed on land for gardening within premises.
There will be no discharge of effluent outside factorypremises; The unit shall be zero liquid discharge.
6 Pre-Feasibility Report Kumar Organic Products Limited
10. Power Capacity Details Source Existing Proposed Total Power Requirement 500+250 400 1150 BESCOM (kw) =750 Back-up 640+250+125 400 1415 DG sets (KVA) =1015 Diesel Requirements Approx. Approx. Approx. HP (KL/Month) 12 5 17 Fuel oil 15 5 20 BPCL (KL/Month) Solid Fuel/Briquette Local 18 3.6 21.6 (T/D) supplier
Boiler: Furnace oil/Briquette fired boiler 1 No having capacity of 3TPH. Additional requirement due to proposed expansion is 0.6 TPH. Furnace oil source is BPCL.
Existing facility 11. Manpower Proposed expansion 262 nos. Total (38 contract workers) 30 nos. Solid and hazardous Refer chapter 3, section292 3.15, nos. pg 36 12. waste 13. Project cost (estimate) 7.5 Crores
Kumar Organic Products Limited (KOPL), established in 1993, is a privately owned and professionally managed enterprise with its Head office in Jayanagar Bangalore and two multipurpose manufacturing sites at Jigani Industrial Area, Anekal Taluk, Bangalore in India, both successfully inspected by US-FDA facility in 2011and 2014 . It is also approved by COFEPRIS (Ministry of Health Mexico). Both the plants are also certified by WHO GMP, ISO 9001:2008, 14001:2004 and have been audited by several Innovators and leading Generic companies from time to time and export their products in 75 countries to meet the requirement of personal care, Skin care , health care as well biotech industries
KOPL provides innovative & integrated API solutions with its decades of experience and skill in the development of novel chemical processes catering to the health care , personal care ,skin care industies. Our continuous investment in research and development generates a steady flow of APIs enabling timely introduction of new products in the market.
Our focus is on niche products; with a presence in more than 75 countries. Our partners are essentially, Personal care, Health care , skin care , companies across the globe for whom we develop a range of new niche ingredients developed in our own R&D in select \categories like Antibacterial, Cosmaceutical and few others specialty chemicals.
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KOPL has special expertise in Antibacterial and Cosmaceutical products.
A perfect blend of Human talent, R&D Labs, Pilot Plant & cGMP manufacturing facilities backed by our Quality Assurance, Regulatory Affairs and Intellectual Property cell gives KOPL an edge.
Our regulatory team is well trained & experienced to comply with US-FDA, EDQM & other regulatory authority requirements. The company has over10 regulatory filings across the globe for its APIs to its credit with an impressivepipeline.
KOPL is an existing Company having its unit located at Plot No. 36/62/63/64/60/65/36 Jigani Industrial Area, Anekal Taluk, Bangalore, developed by KIADB, Bulk Drugs / APIs and specialty chemicals for various Pharmaceuticals, Cosmaceutical and special chemicals Industries.
Now, the Company proposes to manufacture additional new products at adjacent site to our Existing units Separated by Road no 6 in Plot no. 83P and 84as APIs the site used for Personal care and skin care industries
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2. INTRODUCTION OF THE PROJECT
2.1 About the project proponent
Kumar Organic Product Limited is manufacturing various Cosmaceutical, Active Pharmaceuticals and Specialty compounds.Kumar Organic Products Limited is having ISO certification for ISO 9001 and 14001 since 2004 and USFDA certified facility for exiting products.
Plot no. Activities Specification 36A/B Research & Development of new molecules, Biotech Pilot plant, R&D existing Pilot plant 62&63 Manufacturing and storage of materials existing 60&65 Manufacturing and storage of materials existing 64 Utility section, admin and quality control existing 83P/84 Expansion for the manufacturing of Cosmaceutical, APIs and Specialty Proposed Chemicals
The main ingredients Triclosan produced throughout for the year 2014-2015 was 1000 metrictons (MT). The company’s turnover for the year 2014-2015 was Rs. 210.82 Crores and the Profit after Tax was Rs. 35.7 Crores.
2.2 About the project
KOPL manufactures various products at its manufacturing sites inBangalore. At present, 9 products are manufactured amounting to a total of 1940 MT/annum.
KOPL proposes to increase their products by including Zinc Phosphate, Zinc Citrate, Zinc Lactate. The capacity of the proposed expansion will be 3000 MT/annum. The total number of products are 12 with capacity of 4940 MTPA. The list of products and their respective capacities given in Table 2.1:
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Table 2.1 Existing and Proposed Products and Capacity
Existing Products Proposed Products Quantity Quantity S. No Name S. No Name MTPA MTPA Zinc Phosphate/0r
1 Triclosan 1200 1 Ethyl 600 hexyle glycerine
2 Minoxidil 60 2 Zinc Citrate 600 3 4-Hexyl resorcinol 40 3 Zinc Lactate 1800 4 CiclopiroxOlamine 20 5 PiroctoneOlamine 60 6-pyrrolidino 2,4- 6 20 diaminopyrimidine 3-oxide 6-pyrrolidino 2,4-
7 diaminopyrimidine 3-oxide, 20 monohydrate
8 n-Butyl Resorcinol 20 9 Ethyl hexyl glycerin 500 Total 1940 3000 Grand Total 4940 MTPA (12 Numbers)
There is an existing CFE is attached in Annexure 10.
2.3 Need for the project
India with its large talented manpower, cost effective chemical synthesis, legal & financial framework is poised to become sourcing destination of bulk Cosmetical APIs used to the global market in personal care , health care and skin care industries.
The project is benefitted to fulfill domestic and exports requirements for the manufacturing of various cosmetics, antibacterial soaps, and emollients, anti ageing creams, lotions, creams and gels without affecting environmental conditions of the area.
The pharmaceutical industry in India ranks third in the world in terms of volume and contributes 10% to the global pharmaceutical production. According to the Department of Pharmaceuticals, the Indian pharmaceutical industry is pegged at Rs 810 bn, which includes domestic sales and exports. The industry is the fourteenth-largest in the world in terms of value and accounted for 1.5% of the global pharmaceutical market. The industry has a lower share in the global market because Indian products are available at a price that is 5-50% lower than that in the developed countries. According
10 Pre-Feasibility Report Kumar Organic Products Limited to the Department of Pharmaceuticals, the sector employs about 340,000 persons and an estimated 400,000 doctors and 300,000 chemists are serving its 1 bn-plus market.
There will be very good opportunity of employment generation of additional qualified staff & unqualified workers directly for 100 nos. and indirectly for 50 nos. due to the proposed expansion project.
2.4 Demand and supply gap
Based on market survey the selected molecules for manufacture have potential for export as well as domestic market.
2.5 Imports v/s. Indigenous production
To ensure the quality of product and control of manufacturing under current good manufacturing conditions, it is preferred to have the manufacture done in- house by procuring basic raw materials.
M/s Kumar Organic Products Pvt. Ltd., has reasonably sound base to overcome the technological barrier to meet the challenges of the industry. The demand for API’s and drug intermediates is on increase, and the industry is poised for substantial growth in the coming years.
2.6 Export possibility
Products are being exported to various countries from the existing sites and products from the proposed expansion also shall be distributed across the globe as per the customer requirements
2.7 Domestic / Export Markets
Over 60 per cent of India’s bulk drug production is exported. India’s pharmaceutical exports are to the tune of Rs 87 billion, of which formulations contribute nearly 55 per cent and the rest 45 per cent comes from bulk drugs.
In financial year 2005, exports grew by 21 per cent. The Indian pharmaceutical market has been forecasted to grow to as much as US$ 25 billion by 2010 as per Organization of Pharmaceutical Producers of India (OPPI) estimates. However, Espicom’s market projections forecast more modest but stable annual market growth of around 7.2 per cent, putting the market at US$ 11.6 billion by 2009.
Domestic pharmaceutical exports, growing at 30 per cent per annum, touched a new height of US$4.8 billion in the financial year 2006-07. The Year’s exports will push the drug sectors contribution to India’s Forex earnings to 7.75 per cent from the current 5 per cent.
The geographical distribution of various products distributed from the existing facility is detailed as below.
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EUROPE & INDIA AFRICA 37% 21%
ASIA 13% NORTH AMERICA 16% LATIN AMERICA 13%
2.8 Employment Generation (Direct and Indirect)
There will be very good opportunity of employment generation of additional qualified staff & unqualified workers directly for 100 nos. and indirectly for 50 nos. due to the proposed expansion project. At present the numbers of employees are 260 nos.
3. PROJECT DESCRIPTION
3.1 Type of Project
To cater the needs of the market, it is proposed to change the product mix at its existing unit atPlot No. 36, 63,63,64,60 and 65, Jigani Industrial Area, Anekal Taluk, Bangalore. The proposed project falls under Category ‘B’, schedule 5 (f) as per the EIA notification dated September 14, 2006 and its amendments. There are no interlinked projects.
3.2 Project Location
The plot of land acquired from the Karnataka State Industrial Area Development Board (KIADB) lies in a notified industrial area. The site is located in Jigani village at Latitude12°46’3.17”N, Longitude 77°38’30.55”E, approximately 10 km from the National highway. Number of other industries exists nearby such as Hikal Ltd., OTIS, KTTM etc. The layout of the site with existing facilities is given as below, while proposed expansion layout is enclosed as Annexure 10. The project location is given in Figure 3.1 and the 10 km radius map from project site is given in Figure 3.2. The 5 Km and 10 Km radius map from the project is given below.
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Site layout plan of existing facilities The existing facility is located in different plots as below
Status Plot no Activities Existing 36A/B Research & Development of new molecules Existing 62&63 Manufacturing and storage of materials Existing 60&65 Manufacturing and storage of materials Existing 64 Utility section, admin and quality control Proposed 83P & 84 For the manufacturing of zinc derivatives
The proposed project is located at Jigani Industrial Area, AnekalTaluk, Bangalore,and Karnataka. The site is located about 40 km away from Bangalore Town and it is in the express highway and the nearest railway station is Anekal railway station (12 km).
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Figure 3.1Project Site
Figure 3.2 10 km Radius around project site
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3.3 Major products of the company
The details of current existing major products are given below:
Triclosan:Triclosan is an antibacterial agent and itis manufactured at plot no. 62, 60 and 65, approximately 1000 mt annually.
Ethyl Hexyl Glycerine : EHG is also used as an antibacterial and it is manufactured at plot no. 64, 60 and 65, approximately 600 mt annually.
Zinc derivatives: Proposed expansion for the manufacturing of Zinc derivatives at plt no. 83P and 84 is approximately 3600 MT annually.
3.4 Details of alternate sites
Since the existing site is only used for the proposed project, the alternate site option is not explored. The environmental setting of the existing site is given in Table 3.1:
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Table 3.1Environmental setting of the existing site
S. No. Particulars Details
1 Plant site latitude 12°46’3.17”N
2 Plant site longitude 77°38’30.55”E
3 Temperature Max. 34 oC, Min. 21.4 oC
4 Present land use Industrial area
5 Nearest Highway Bangalore Chennai road -10 Km N
6 Nearest railway Station Anekal railway – 12 Kms S
7 Nearest Airport Kempegowda, Bangalore - 65 Kms
8 Nearest village Jigani -3 Kms
9 Nearest major city Bangalore - 25 Kms N
10 Nearest river Nil
11 Type of soil Reddish brown clay silt soil
3.5 Size of Operation
In the view of fulfilling market requirement, we are proposing to change the product mix, presently we are manufacturing regularly 9 Nos. products and 3 new products will be included with increase in the production quantity of 3000 MT/annum (existing 1940 + 3000 = 4940 MT/annum).
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3.6 Project Description
Receive Raw Material
Dispensing Raw Material
Raw Materials Charging in Reactor and Reaction monitoring
Centrifuge operation
Material Drying Operation in Dryer
Milling Operation
Sifting Operatio n
Blending Operation
Finished Goods/ Product packing
Finished Goods/ Product Dispatching Process detail (enclosed as Annexure 1)
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3.7 Raw Material Required Raw Materials required with approximate quantity for Proposed Change of Product Mix is given inTable 3.2.
Table 3.2 Raw Material List
S. No. Name of raw material Quantity Proposed (MT/Year)
1. 2,4-DCP 1320 --
2. 2,5-DCNB 1536 --
3. Sulphuric acid 7200 --
4. HCl 1200 --
5. Iron powder 1380 --
6. Hexane 300 --
7. Ethyl Acetate 60 --
8. Methanol 120 --
9. Hexanoic acid 60 --
10. Acetic acid 27.6 --
11. Resorcinol 60 --
12. Mono ethanol Amine 10 --
13. Butyric acid 20 --
14. Di-methylic acrylic acid 60 --
15. Ethyl Hexanol 500 --
16. Piperidine 100 --
17. 2,4-6-aminochloropyridine 100 --
18. Zinc oxide -- 1914
19. Citric acid -- 420
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S. No. Name of raw material Quantity Proposed (MT/Year)
20. Lactic acid -- 3186
21. phosphoric acid -- 384
Raw materials would be obtained by road transportation through different parts of the country such as Chennai, Maharashtra, and Gujarat as well as can be imported also. The finished goods for domestic sales would be by road and for export shall be by air.
3.8 Resource optimization/recycling and reuse
After the reaction is complete the solvents are recovered, tested as per pre-defined specification. The residue from the solvent recovery is sold out by KSPCB approved vendors for disposal. The recovered solvents are collected in drums, labeled and analyzed. Then they are reused (recycled) for the process, mostly for the same product.
3.9 Power and fuels
The existing power requirement is 500 kWh and with the proposed expansion additional power required is 600 kWh. This is a combination of HT and LT loads. The power required will be sourced from BESCOM.
As the existing boiler (heater) is adequate for the revamp conditions, the fuel oil and fuel gas requirements will not vary when compared to the existing conditions. There are three DG sets are used as an alternate source of power if required for the existing sites, while proposed expansion site will also equipped with a dedicated DG set for the site. The details of power and fuel requirements are given in table 3.3:
Table 3.3 Power and fuel requirement
Details Capacity Source Existing After ProposedExpansion Power Requirement 500kwh 600kwh BESCOM
Diesel Requirements Approx.5000 Approx. 6000 lit/Month HP lit/Month Fuel oil 18 Kl/Month 20 Kl/Month Furnace Oil
3.10 Manpower
The total manpower of existing facility is 262 nos. The additional manpower requirement due to the proposed expansion is 30 nos. Thus the total manpower after proposed expansion will be 292 nos.
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Plant facilities runs on all three shifts with a staggered weekly off. The manpower requirement includes both technical and non-technical personnel are given in the below Table 3.4.
Table 3.4 Manpower Requirement
Permanent Contractual Total Details (Nos) (Nos) (Nos) Existing 224 38 262 Additional 20 10 30 Total 244 48 292
3.11 WATER REQUIREMENT
The total water requirement for the existing unit is 165 KLD. Additional water requirement due to the new facility is 35 KLD, thus the water requirement after the proposed expansion will be 200 KLD. Water is sourced from KIADB and private water suppliers. The detailed water usage break up is given Table 3.5.
Table 3.5 Water requirement
Proposed Proposed water Existing Additional S. No Water requirement Total Break-up (KLD) (KLD) (KLD) (KLD) Fresh Treated 1 Process 60 20 80 20 60 2 Washing 5 1 6 1.2 4.8 3 Boiler Feed 60 1 61 21 40 4 Chiller 5 0.5 5.5 5.5 0 5 Domestic 10 2.5 12.5 12.5 0 6 Other utilities 10 3 13 13 0 7 Green belt 15 7 22 22 0 Total 165 35 200 95.2 104.8
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3.12 Utilities
Table 3.6shows the list of utilities in the project:
Table 3.6 List of Utilities
S. No. Utility Existing Flow rate Flow rate after proposed project 1 VHP Steam 2.7 MT / hr 3.7 MT / hr
2 MP Steam 1 MT / hr 1.5 MT / hr
3 LP Steam 1.7 MT / hr 2.2 MT / hr
4 Nitrogen 10 Nm3 / hr 12 Nm3 / hr
5 Cooling Water 500m3 / hr 700m3 / hr
6 Service Water Intermittent Requirement Intermittent Requirement Boiler Feed 7 Intermittent Requirement Intermittent Requirement Water 8 Plant Air Intermittent Requirement Intermittent Requirement Electrical 9 500 kWh 600 kWh Power
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3.13 Liquid waste management Table 3.7 Liquid waste detail
Existing 92 KLD Proposed 110 KLD including existing will be treated at ETP.
ETP, STP & MEE Scheme
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3.14 Air pollution control measures 1. The discharge of emissions from the additional air pollution source from the premises of the KOPL is passes through the air pollution control equipment (Scrubbers/Chimney) and discharged through stack/chimney. 2. Ambient Air quality of the premises conforms to the national ambient air quality standards specified in environmental (protection) rules. 3. Emissions are analyzed on monthly basis Below are the details of control of air pollution at the sites:
Air pollutants controls Plot no. Plot No. Details Plot no. 36 Plot no. 62/63 83P/84 60/64/65 (Proposed) Chimney 1 1 1 1 Scrubber 1 2 2 --
3.15 Hazardous and solid waste management The hazardous wastes generated from Plant (Table 3.8) are collected, stored and disposed through authorized disposal cum recycle facilities as per the authorization from PCB and the unit
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has agreements with all waste disposal facilities for the same. There is no internal disposal facility available within the site.The Authorization Letter from KSPCB is enclosed as Annexure 5. The hazardous waste generated from the existing manufacturing unit, is Benzofuranand this is being sent toVasavdatta Cement for co-processing,approved CPCB facility which is located in Gulberga, Karnataka.
Hazardous waste will be properly disposed as per the Hazardous waste Management rule 2008 and amendment in 2016.
Table 3.8 Hazardous waste
Hazardous Quantity Waste waste Total Method of handling Category Existing Additional Generated Proposed
Collected in leak proof containers and 1.5 0.8 2.3 5.1 Used Oil disposed only to KSPCB registered KLD KLD KLD authorized re-processor
28.2 Spent catalysts 1 MTD 0 1 MTD Sent to authorized dealer
28.3 Spent carbon 0 10 MT 10 MT Co-incineration in cement industries.
Process residue 1012.5 1012.5 Stored in secure manner and handed over to 28.1 0 and waste MTA MTA KSPCB authorized incinerator
1230 600 1830 33.1 MS Drums Nos /A Nos/A Nos/A Stored in secure manner and handed over to HDPE Used 650 300 950 KSPCB authorized recycler 34.1 Liners Nos/A Nos/A Nos/A ETP Sludge/Chemical 22.5 10.5 33 Stored in secure manner and handed over to 35.3 sludge from MTA MTA MTA KSPCB authorized TSDF clarifier and evaporator
The Municipal Solid Waste generated from the site is collected and transported to recyclers, municipal yards and landfills depending on the type of waste. The details are given below in table 3.9:
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Table 3.9 Municipal Solid Waste details
Kg/Day Type Disposal Method Existing Proposed Organic 57.6 64.8 Local Municipal bins Inorganic 62.4 70.2 Sent to KSPCB Authorized recyclers Total 120 135
Method of Handling Quantity (T/Year) Nature of S. No Collection & Solid Waste Total Treatment Disposal Existing Additional Storage Proposed Paper / Card Separate 1 2 0 2 NIL Burnt in boiler Board storage area Disposal in land Dust Bin Separate filling through 2 12 4 16 NIL collections storage area Authorized vendors Dry leaves Separate 3 1 0.2 1.2 NIL burnt in boiler Grass storage area sold as scrap to Separate 4 Metal scrap 12 3 15 NIL vendors under storage area agreement Wooden Separate 5 12 1 13 NIL burnt in boiler scrap storage area
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4. SITE ANALYSIS
4.1 Connectivity The proposed site on the NH – 4 and is connected to Bangalore –Chennai (NH 7) road just 10.0 Km away from the Factory entrance.
Nearest railway station is Anekal: 12.0 km and
Kempegowda International Airport: 65
4.2 Landform, Landuse, Landownership The Plant is located at plot nos.: 36/60/62/63/64/65 and 83P/84, Village, Industrial areaTaluk,Anekal District-Bangalore, Karnataka. The layout plan of Bangalore Units is enclosed in section no. 3.2, while proposed plant layout is enclosed as Annexure 11.
4.3 Topography
Bangalore has two unique Topography terrains—North Bangalore Taluk and the South Bangalore taluk. The North Bangalore taluk is a relatively more level plateau and lies between an average of 839 to 962 meters above sea level. The middle of the taluk has a prominent ridge running NNE- SSW. The highest point in the city, Doddabettahalli, (962m) is on this ridge. There are gentle slopes and valleys on either side of this ridge. The low-lying area is marked by a series of water tanks varying in size from a small pond to those of considerable extent, but all fairly shallow.
The topography of Bangalore is flat except for a central ridge running NNE-SSW. The highest point is Doddabettahalli, which is 962 m (3,156 ft) and lies on this ridge. No major rivers run through the city, though the Arkavathi and South Pennar cross paths at the Nandi Hills, 60 km (37 mi.) to the north. River Vrishabhavathi, a minor tributary of the Arkavathi, arises within the city at Basavanagudi and flows through the city. The rivers Arkavathi and Vrishabhavathi together carry much of Bangalore's sewage. A sewerage system, constructed in 1922, covers 215 km² (133 mi²) of the city and connects with five sewage treatment centers located in the periphery of Bangalore.[5]
The South Bangalore taluk has an uneven landscape with intermingling hills and valleys. The southern and western portions of the city consist of a topology of granite and gneissic masses. The eastern portion is a plane, with rare minor undulations.
There are no major rivers flowing through the city. However, rivers Arkavathi and Kaveri merge within the proximity of Nandi Hills, which lie 60 km north of Bangalore. River Vrishabhavati, a tributary of Arkavathi, flows for a small stretch in the Bangalore North taluk and carries a bulk of the city's sewerage. The city has a handful of freshwater lakes and water tanks such as Madivala tank, Hebbal tank, Ulsoor lake and Sankey Tank. Groundwater occurs in silty to sandy layers of alluvialsediments and jointed quartzite.
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The rock types prevalent in the district belong to the Saugar, Charnokite and Peninsular Gneissic Complex (PGC) groups. The PGC is the dominant group of rocks and covers two-thirds of the area and includes granites, gneissis and migmatites. The soils in Bangalore vary from red laterite to clayey soils
Topomap: Annexure 13 (5 km radius map) and Annexure 14 (10 km radius map).
4.4 Existing Land use pattern The present land use is in the industrial zone. The details of sensitive areas from the site boundary are given in Table 4.1. The site does not fall within the CRZ area
Table 4.1 Details of sensitive areas
S. Areas Proposed project location No boundary 1 Areas protected under international conventions, Bannerghatta National Park – national or local legislation for their ecological, 7.7 Km landscape, cultural or other related value. Ragihalli Forest – 6.5 Km 2 Areas which are important or sensitive for ecological Hennagara Lake – 1.5 Km reasons – Wetlands, Watercourses or other water bodies, Kammasandra Lake – 7.8 Km coastal zone, biospheres, mountains, forests Hebbagodi Lake – 7.5 Km Ramakrishnapura Lake – 5.8 Km Chandapura Lake – 7.6 Km Masur lake – 7.7Km Settahali Lake -8.4 Km Bommandhlli – 4.77 K Thirumagondana Halli- 8.4 Km Ragihalli Forest – 7.1 Km 3 Areas used by protected, important or sensitive species Bannerghatta National Park – 7.7 of flora or fauna for breeding, nesting, foraging, resting, Km over wintering, migration 4 Inland, coastal, marine or underground waters Hennagara Lake – 1.5 Km Kammasandra Lake – 7.8 Km Hebbagodi Lake – 7.5 Km Ramakrishnapura Lake – 5.8 Km Chandapura Lake – 7.6 Km Masur lake – 7.7Km Bommandhlli – 4.77 Km Thirumagondana Halli- 8.4 Km Settahali Lake -8.4 Km 5 State, National boundaries Karnataka – Tamil Nadu Border – 12 Km 6 Routes or facilities used by the public for access to Bannerghatta - Anekal Road –
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recreation or other tourist, pilgrim areas 3.5 Km 7 Defence installations Nil 8 Densely populated or built-up area Bommasandra village – 8.2 Km Doddathoguru– 9.3 Km Electronic City-8.7 Km 9 Areas occupied by sensitive man-made land uses Hospitals (hospitals, schools, places of worship, community YK hospital – 1.5 Km facilities) Suhas Hospital – 1.36 Km Vijayashree Hospital – 1.32 Km Narayana Hrudayalaya - 10.0 Km Sparsh Hospital – 12.0 Km
Educational Institutions: Govt. School Jigani -5.3 Km International Institute of Information Technology- 8.9 Km Vivekananda Kendra Vidyalaya - 2.0 Km Government School Hennagra- 4.3 Km Worship Places: Sri Lakshmi Narashimha Swami Temple -8.91 Km Jigani Masjid – 2.3 Km 10 Areas containing important, high quality or scarce Hennagara Lake – 1.5 Km resources, (groundwater resources, surface resources, Kammasandra Lake – 7.8 Km forestry, agriculture, fisheries, tourism, minerals) Hebbagodi Lake – 7.5 Km Ramakrishnapura Lake – 5.8 Km Chandapura Lake – 7.6 Km Masur lake – 7.7Km Bommandhlli – 4.77 Km Thirumagondana Halli- 8.4 Km Settahal Lake -8.4 Km 11 Areas susceptible to natural hazard which could cause The site falls in Seismic Zone – the project to present environmental problems, II (Low Risk) as per seismic (earthquakes, subsidence, landslides, erosion or extreme zoning Map of India or adverse climatic conditions)
4.5. Existing Infrastructure: a. Land
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The Plant facilities are spread over 20234Sqm KIADB Land which is completely fortified and protected on all four sides by boundary walls. b. Buildings
Total built up area is divided into various sections like Production Blocks, Engineering, Warehouses, Administration, Canteen, Toilets etc. There is adequate space & provision for operations. c. Plant Machinery & Utilities
The Plant Facilities have been designed and set up with the objective to carry out almost all chemical reactions and processes. Details of plant and machinery and utility equipments used for the production are as below: i.Process Equipments: . Reactors : 50 . Centrifuges :7 . VTDs : 03 . Air Jet Mill: 01 . Multi Mill:01 . Sifter : 04 . Blender : 02 ii. Machinery / Utility Equipments; . Boilers: 3 . Cooling towers :5 . DG sets : 05 . Brine chilling plant:02 . Air compressors:04 . HVAC system: 2 . Vacuum pumps: 10 . Scrubbers: 05 iii. Safety Equipments: . Fire Hydrant System : 03 . Fire Extinguishers: 400 . Fire Alarm System : 03 . Eye wash fountain / Safety Showers : 5 . Emergency PPE cupboards : 5 . Wind Sack : 4 . Compressed Air Foam System (CAFS) : 1
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. FM-200 (Automatic fire extinguishers) : 100 . AFT (Advanced Fire Technology) : 5
The site is well connected by road to NH 7 (Bangalore- Chennai). The list of the few existing industries within 10 km from the site is given in Table 4.2.
Table 4.2 Existing infrastructure within 10 Km radius from the site
S. No. Name Distance from site (km)
1 Mallik Engineering 1.73
2 J’Pan Tubular Components 0.98
3 OTIS 1.77
Kirloskar Toyota textile machinery Pvt. 4 1.9 Ltd.
5 Hikal Ltd. 0.35
6 Aron Universal Ltd. 1.21
7 HCL Technologies 2.2
8 Cipla Limited 2.19
9 Mylan Limited 1.85
10 Syngene International-(Biocon park) 4.84
11 Microlabs 2.84
12 Acebright 0.98
4.6. Soil Classification:
The top soil is reddish brown clay silt soil. The soil classification is Laterite soils and is mainly found in Anekal Taluk.
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4.7. Climatic data from secondary sources:
Normal annual rainfall of Bangalore urban district is 831mm. During the year 2005, Bangalore urban district received actual rainfall of 1342.7 mm in 69 rainy days. Of the total rainfall, contribution from southwestern monsoon is 54.18% and 26.53% is from northeastern monsoon. In addition to this, Pre-monsoon showers contribute significant rainfall of 18.53%. The annual average maximum temperature ranges from 23.9 to 30.4°C and minimum temperature ranges from 19.6 to 23.9°C. The annual average humidity is 65.5°C. The annual average wind speed is 4.5km/h.
4.8. Social Infrastructure available:
The social infrastructure facilities available near the site are given in Table 4.3
Table 4.3 Project surrounding features
S. No. Name Km Directions Schools and Colleges 1 Govt. School Jigani 5.38 N 2 International Institute of Information Technology 8.99 NE NE 3 Vivekananda Kendra Vidyalaya 2.00 W 4 Government School Hennagra 4.34 NE Religious Places
1 Sri Lakshmi Narashimha Swami Temple 8.91 NW 2 Jigani Masjid 2.31 N Hospitals
1 YK hospital 1.50 N 2 Suhas Hospital 1.36 N 3 Vijayashree Hospital 1.32 N
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5 PLANNING BRIEF
5.1. Planning concept
The city of Bangalore is easily accessible along the link road and further along the National highway. The peripheral ring road of BDA is accessible from NH- 7. Nearest railway station is Anekal: 12.0 km and Kempegowda International Airport: 65 Km.
5.2. Population Projection
262 temporary and permanent employees at existing site and 30 additional manpower is projected.
5.3. Land use planning
The total land area is 40445.33 Sq. Mt (9.99 Acres). The area details of the facility are given below Table 5.1:
Table 5.1 Area details of the facility
Area S. No. Facility Sq. mt Acres % 1 Production Block-1 6479.56 1.60 16.02
2 Production Block-2 12962.36 3.20 32.05
Production Block-3 400.00 0.10 0.99
General Utility, General Warehouse, QC, R&D, 3 5038.16 1.24 12.46 Conference Hall & Office area
4 Cooling Tower 178.83 0.04 0.44 5 Security 36.97 0.01 0.09 6 EHS Office and OHC 42.97 0.01 0.11 7 ETP 2138.16 0.53 5.29 8 Drum Storage yard 1701.25 0.42 4.21 9 Underground Solvent Storage yard 800.63 0.20 1.98
10 Scrap yard 1300.63 0.32 3.22
11 Furnace Oil Storage yard 277.79 0.07 0.69
Engg Office, Engg Stores, QA Office, Canteen, 12 358.83 0.09 0.89 Change room and DG
13 Road Area 1200.00 0.30 2.97
14 Green belt area 5529.19 1.37 13.67 15 Vacant Land 2000.00 0.49 4.94 Total 40445.33 9.99 100 .00
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5.4. Assessment of Infrastructure Demand
The facility is within the KIABD industrial area and the proposed project is only a expansion of existing facility.
5.5. Amenities/Facilities
The existing site is having Canteen facility for employees, Occupational Health Center (OHC) and assembly points etc.
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6 PROPOSED INFRASTRUCTURE 6.1. Industrial Area:
The total land area is 40445.33 Sq. Mt (9.99 Acres). The area details of the facility are given below Table 5.1:
6.2. Residential Area
Not Applicable.
6.3. Green belt
The total land area is 40445.33 Sq. Mt (9.99 Acres) and the greenbelt area will be 5529.19 Sq. Mt (1.37 Acres, 13.67%).
6.4. Social Infrastructure
KIADB Industrial Area.
6.5. Connectivity
Site is well connected by an asphalted road which further connects to Bangalore –Chennai (NH 7) road just 10.0 Km away from the Factory entrance.
Nearest railway station is Anekal: 12.0 km and
Kempegowda International Airport: 65
6.6. Drinking Water Management
Drinking water facility is available and water is purchased from KIADB or local suppliers, which is treated using the existing water treatment facility for drinking water.
6.7. Sewerage system
The quantity and quality of wastewater in the plant is controlled by following measures:
Sewage water is collected from the plant and treated using STP and used for the gardening at the site.
6.8. Industrial waste management a. Air Environment: i. Sources: Reactors, Distillation process Boilers
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Fugitive vapours from reactors, centrifuges and at discharges of vessel contents, etc. D.G. sets ii. Mitigative measures: 1. All reactors are connected to scrubber with a stack attached. 2. The vapours have been collected through exhaust system consisting of hood, duct which are connected to scrubbers. 3. Stack of 6m ARL are provided to D.G. sets. 4. Boilers are connected with chimney 5. Use of PPE’s b. Noise Environment: i. Sources: Generators Reactors Compressors ii. Mitigative measures: 1. Acoustic barriers or shields to the machineries. 2. Vibration free foundations for machineries 3. Acoustical walls and roofs to the building where such machineries are installed. 4. Segregation of machineries having high noise level in isolated buildings. 5. Proper maintenance of machineries especially oiling and greasing of bearing and gears etc. 6. Avoiding vibration of machineries with proper design of machineries such as speed, balancing etc. 7. Use of personnel protective such as earmuff and ear fug for persons working in such locations. 8. Plantation of green trees around the factory building and premises to control the intensity of noise to the surrounding area. 9. Use of PPE’s 10. c. Water Environment: i. Sources: Process water Cooling tower blow down Washing Softner Regeneration Domestic waste water
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ii. Mitigative measures: 1. Effluents from the plant is been stored and neutralized in a collection tank and then sent to Effluent Treatment Plant 2. Domestic water will be treated in Septic tank followed by soak pit. 3. Recycle of process water including steam condensate and reuse of treated wastewater in the plant 4. Control of water taps, washings, leakages from pump glands and flanged joints. 5. Overflow of vessels is strictly avoided 6. Floor cleaning with water will be replaced with dry cleaning. d. Solid & Hazardous waste: i. Sources: Used oil Spent solvents Distillation residue Process residue Off specification products Discarded containers (Ex. Barrels, Carboys & liners) ii. Mitigative measures:
1. Used oil shall be collected in leak proof containers & disposed to Central Pollution Control Board / Karnataka State Pollution Control Board registered authorized recyclers. 2. Spent solvents will be stored in a secured manner and handed over to Karnataka State Pollution Control Board authorized recyclers. 3. Distillation residue will be stored in a secured manner and handed over to Karnataka State Pollution Control Board authorized incinerators. 4. Process residues will be stored in a secured manner and handed over to Karnataka State Pollution Control Board authorized incinerators. 5. Off specification products will be stored in a secured manner and handed over to KSPCB authorized incinerator. 6. Discarded containers will be stored in a secured manner and handed over to Karnataka State Pollution Control Board authorized recycler after washing.
6.9. Solid waste management
Solid wastes generated will be stored and disposed as detailed in the Table 6.2.
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Table 6.2 Solid waste
Kg/Day Type Disposal Method Existing Proposed Organic 57.6 64.8 Local Municipal bins Inorganic 62.4 70.2 Sent to KSPCB Authorized recyclers Total 120 135
6.10. Power Requirements and Supply/ Source
Existing
The power required for the project is sourced from BESCOM. DG sets will act as the standby facilities and will be utilized in case of power failures. The details of power requirement and backup power facilities are given below
Capacity Details Total Source Existing Additional Proposed Power Requirement 500+250 400 1150 BESCOM (kw) =750 Back-up 640+250+125 400 1415 DG sets (KVA) =1015 Diesel Requirements Approx. Approx. Approx. HP (KL/Month) 12 5 17 Fuel oil 15 5 20 BPCL (KL/Month) Solid Fuel/Briquette 18 3.6 21.6 Local supplier (T/D)
Boiler: Furnace oil/Briquette fired boiler 1 No having capacity of 3TPH. Additional requirement due to proposed expansion is 0.6 TPH. Furnace oil source is BPCL.
7 REHABILITATION AND RESETTLEMENT (R & R) PLAN 7.1. Policy to be adopted (Central/ State)
Not applicable as proposed project only an expansion within the existing unit of KIADB industrial area.
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8 PROJECT SCHEDULE AND COST ESTIMATE
8.1. Likely date of start of construction and likely date of completion
No construction work.
8.2. Estimated project cost
The budget for proposed expansion for the manufacturing of zinc salts (Such as Zinc Citrate, Zinc Phosphate and Zinc Lactate) is approximately 8 crores. Proposed products are safe for the environment as there is no harmful chemicals shall be used for the manufacturing of the products.
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9 ANALYSIS OF PROPOSAL
9.1. Financial and social benefits
Annual Turnover: 215 cr
Annual profit: 30 cr
Dividend to share holders: 25%
Social Benefit:
Employment to local community: 40%
CSR benefit to local community:
1). Promoting education-Donated utensils for midday meal, steel almirah, box rack, painting on walls for Govt primary school, vadarapalya, jigani.
2). Animal welfare- Adopted 2 Tigress at Mysore Zoo.
3). Promoting education- Shortlisted 15 students for scholarship.
4). Providing safe drinking water-Installing RO machine to Higher primary school, Kaushike Village at Hassan.
Green belt benefits to the environment.-Done plantation at new plot, Harpanhally plot and nearby schools at Jigani.
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10 CONCLUSION •
Since the proposed project is an expansion within the existing site of the • industrial area, there will not be any change in land use. Zero liquid discharge concept is followed and the treated waste water will be • reused for gardening, chiller, boiler feed and process. • Rain water harvesting system is adapted. • Organic waste converter for solid waste management is in force. There will be positive impact on social conditions in and around the site due to • the proposed assignment. The marginal impact due to the proposed assignment will be fully mitigated by the Environmental Management Plan (EMP).
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