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 Pre-Feasibility Report Page 1 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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 Pre-Feasibility Report Page 2 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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 Pre-Feasibility Report Page 3 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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 Pre-Feasibility Report Page 4 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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. Pre-Feasibility Report Page 5 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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. Pre-Feasibility Report Page 6 of 70 Proposed Manufacturing Of Synthetic Organic Chemicals 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).