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PREFEASIBILITY REPORT

Of

Expansion and new project for

Manufacture of Advanced Pharmaceuticals Intermediates

For grant of Environmental Clearance

Schedule - 5(f)

Under category B

By

BEC Chemicals Pvt. Ltd, Plot no. 24, MIDC Dhatav,

Tehsil Roha, District Raigad

Maharashtra, 402 116

Prepared by

GOLDFINCH ENGINEERING SYSTEMS PVT. LTD. THANE

NABET Accredited EIA Consultant

Thane, Maharashtra

July, 2015

INDEXChapter

No.Section CONTENTS Page No.

1 1.0 EXECUTIVE SUMMARY 1-2

2 INTRODUCTION OF THE PROJECT/BACKGROUNDINFORMATION

3-5

2.1 Identification of the project and Project Proponent 3

2.2 Nature of the Project 4

2.3 Need of project with description for region and country 4

2.4 Import vs. indigenous production 4

2.5 Export Possibility 4

2.6 Domestic/Export Markets 4

2.7 Employment Generation due to Project 5

3 PROJECT DESCRIPTION 6-63

3.1 Type of Project 6

3.2 Location of Project 6

3.3 Alternate sites 9

3.4 Size of magnitude of Operation 9

3.5 Project Description 9

3.6 Raw material and Finished Products 55

3.7 Resources optimization 57

3.8 Availability of Resource (Water, Energy/ Power Requirement) 60

3.9 Quantity of Waste to be Generated 63

4 SITE ANALYSIS 64-65

4.1 Connectivity 64

4.2 Land form, Land use, Land ownership 64

4.3 Topography 64

4.4 Existing land use pattern 64

4.5 Existing infrastructure 64

4.6 Soil classification 65

4.7 Climatic data for secondary sources 65

5 PLANNING BRIEF 66-67

5.1 Planning concept 66

5.2 Population Projection 66

5.3 Land use planning 66

5.4 Assessment of infrastructure demand 67

5.5 Amenities/Facilities 67

ChapterNo.

Section CONTENTS Page No.

6 PROPOSED INFRASTRUCTURE 68-76

6.1 Industrial area 68

6.2 Residential area 68

6.3 Green Belt 68

6.4 Social infrastructure 69

6.5 Connectivity 69

6.6 Drinking water management 69

6.7 Sewerage system 69

6.8 Industrial water 69

6.9 Solid waste management 76

6.10 Power Requirement and supply/source 76

7 REHABILITATION AND RESETTLEMENT 77

7.1 Policy to be adopted 77

8 PROJECT SCHEDULE AND COST ESTIMATES 78

8.1 Time schedule for the Project 78

8.2 Estimated project cost (Economic viability of the project) 78

9 ANALYSIS OF PROPOSAL 79-81

9.1 Financial and Social Benefits 79

9.2 Major Emergency 79

9.3 Hazard 80

9.4 Risk 80

9.5 The on-site emergency plan 80

9.6 The off-site emergency plan 80

9.7 Objectives of the emergency plan 80

Annex. I Site Plan 82

Annex. II Letter from Raigad CETP 83

PFR for M/s. BEC Chemicals Pvt. Ltd. Prepared by Goldfinch Engineering Systems Pvt. Ltd.MIDC, Dhatav, Roha, Raigad (M.S.) pg. 1

CHAPTER 01

EXECUTIVE SUMMARY

BEC Chemicals Pvt. Ltd. was founded by Late Mr. M. T. Shah in 1979 and is specialized in manufacturing of

Active pharmaceutical Ingredients (API’s) and Intermediates. The manufacturing unit is 100% Export Oriented

Unit as per Foreign Trade Policy and is recognized as STAR EXPORT house by DGFT (INDIA).

The company’s head office is based in Mumbai (close to the International Airport) and manufacturing unit

situated at MIDC, Dhatav, Roha, District Raigad. The manufacturing unit has been approved by Indian and

European Drug Authorities and is EU-GMP, WHO-GMP and State GMP certified. The company is also ISO

9001:2008, 14001:2004, 18000:2004, OHSAS certified by SGS-UK.BEC Chemicals proposed the expansion of

existing production capacity of Ketoprofen, and 5- amino Salicylic acid and manufacturing of 14 new Active

pharmaceutical Ingredients (API’s) along with by-products of capacity 5580 MT/A in existing manufacturing

facility located at Plot No 24 at MIDC Industrial Area Dhatav, Tehsil Roha, District Raigad, State, Maharashtra-

402 116.

The company’s corporate policy primarily focus on Product Quality, Customer Satisfaction, Patient’s Safety,

Health & Safety Measures, Training, Team Work, Social Responsibilities, monitoring thrive for Continuous

Improvements which has resulted into trust and confidence among our International customers. The company’s

Research and Development centre (situated in Mumbai) has been recognized by the Department of Science and

Technology as DSIR Approved. BEC chemicals undertake contract research and new process development work

for generic APIs under confidentiality agreements. The R&D is well equipped to undertake projects from Lab

scale to Kilo scale, with complete technical package as per CTD format.

BEC Chemicals proposes to increase the production capacity of existing products and also to manufacture new

products(Bulk drug and intermediate) in proposed 2 NEW manufacturing blocks which would be constructed at

Existing Plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116. The new

facility shall meet with the required Environment Health and Safety &c GMP norms.

The EIA Notification no. S. O. 1533 promulgated on 14th September 2006 has covered Synthetic Organic

Chemical Industry as 5 (f) and need prior environmental clearance. It is stated that 5(f) industries located in a

notified industrial area are classified under category B and would be appraised by State Level Expert appraisal

committee/ impact assessment authority. Public hearing is not required for B category of projects.

The proposed addition of 2 new manufacturing blocks will be on existing Plot no. 24 at MIDC Industrial Area,

Dhatav land admeasuring 12220.0 Sq. Meters. Preliminary Layout Plan is attached as Annexure–I. The land is

already in demarcated as “Industrial” in a notified industrial area and is not a prime Agricultural land. Thus there


is no change in the land use status. The city of Roha, Railway line, National highway is at a sufficiently safe

distance. Govt./ MIDC has provided all basic infrastructures like assured electrical power, continuous water

supply with purification from water works having RSF (Rapid Sand Filtration) and disinfection, the internal road

network, external approach road and networking with CHWSTDF (Common Hazardous Waste Storage

Treatment and Disposal Facility). There is no sensitive establishment in the vicinity such as health resort,

hospital, archaeological monuments, sanctuaries, etc. All nearby villages are provided with drinking water from

wells or Government Water Supply Schemes RWS. Hence we do not encroach upon their supply.

There will be no noise nuisance from the facility. Proposed 1 DG sets of 750 KVA will be run occasionally only

during power failure. There will no crushing, pulverizing operations. Labour strength is also limited in this MSI

unit.

Total water requirement (including existing) will be 400 CMD. About 175CMD will be generated as trade

effluent. Sewage effluent quantity will be 24 CMD. Full-fledged effluent treatment plant consisting of primary,

secondary and tertiary treatment is provided for treatment of existing trade effluent and up gradation/expansion

on similar treatment process is proposed. Domestic sewage will be treated in proposed sewage treatment plant of

capacity 30 CMD.

Proposed fresh water consumption will be 230CMD. The water supply is from MIDC. To run the proposed TFH

of 200000 Kcal, consumption of fuel (FO) will be 23.32lit/hr. 160.5lit./hr. of HSD will be used to run the

proposed DG set of capacity 750 KVA for backup power supply during failure of Power supply from MSEDCL.

Safety and occupationally Health will be dealt carefully. A disciplined approach is natural to this industry. EHS

policy is in place. Thus, Trained Staff having knowledge of First Aid and Fire Fighting will be available in every

shift. Safety Officer will be appointed as also the competent person. Wherever; necessary provisions of other

Acts, like Petroleum Act, Explosive Act etc. are required will be obeyed as per requirement. Fire-fighting system

is kept as per norms of Insurance Company.

DMP (Disaster Management Plan) and off-site emergency plan is in place. Accordingly, personal protective

equipment will be given and use will be insisted. Consulting physician has been appointed for the factory.

The existing facility and proposed expansion is located at existing Plot No. 24 at MIDC Industrial Area Dhatav,

Roha Dist: Raigad, State: Maharashtra- 402 116. The site is 125.00 km from Mumbai city and 5 km from Roha

station. The land and infrastructure is made available by MIDC and the raw material is easily available through

the easy transport via road connectivity.

This proposed project will not pose any significant adverse impact on the environment; it will generate

additional employment and revenue. This land is in notified Industrial estate. No Rehabilitation is involved.

There will not be problematic waste materials as all will be utilized.


CHAPTER 02

INTRODUCTION OF THE PROJECT/ BACKGROUND INFORMATION

2.1 Identification of the project and Project Proponent

BEC Chemicals Pvt. Ltd. was founded by Late Mr. M. T. Shah in 1979 and is specialized in manufacturing of

Active pharmaceutical Ingredients (API’s) and Intermediates. The company’s head office is based in Mumbai

(close to the International Airport) and manufacturing unit at Roha.

M/s. BEC Chemicals has proposed 1365 MT/Annum products of API (Bulk drug and intermediate) along with

by-products of capacity 5580 MT/A in. Research and Development forms the backbone of the organization with

state of the art instrumentation facilities. The company has a state of art R&D centre, located close to our Head

Office in Mumbai which was set up in collaboration with IBI Chematur Ltd. in year 2010. Recently the R&D

Centre has been recognized by Department of Science and Technology, INDIA as DSIR approved. We

undertake contract research and new process development work.

The R&D centre is ISO 9001:2008 certified and complies with the requirements of OHSAS and Good

Laboratory practices. The centre is well equipped with sophisticated analytical instruments, process equipments

and can undertake trials from milligrams to kilograms. To facilitate scaling up, the centre has a separate section

for scaling the research work up to pilot scale in 50-100 litres of reaction volume.

The R&D centre's primary focus is to work on Organic Synthesis and developing bio-process technologies

for pharmaceutical product lines. The R&D centre has been set up to facilitate requirements of customers in

terms of process development of new products and to optimize the process technology for existing products

manufactured at BEC Chemicals, in order to achieve higher quality standards and remain competitive.

BEC chemicals R & D team have been successful to recover valuable by-products from waste streams generated

while manufacturing products. After recovery of these by-products from waste streams the pollutants quantity

going to ETP will certainly reduce and treatability will improve sufficiently effectively reducing the treatment

cost.

Industry will provide a full – fledged Effluent Treatment Plant of capacity 200 CMDto treat the effluents

discharged from the manufacturing processes. The treated water from the ETP will be discharged to CETP. The

company has an ambitious plan and clear vision for reaching Global Market taking into consideration, the safety

of the products as well as its personnel.


2.2 Nature of the Project

BEC Chemicals proposes to increase the production capacity of existing products and also manufacture new

products(Bulk drug and intermediate) in proposed 2 NEW manufacturing blocks which would be constructed at

existing Plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116. The new

facility shall meet with the required Environment Health and Safety &cGMP norms.

This is an optimum site as it is already existing site. Also it is manageable both from production, pollution

control and quality assurance point of view. All necessary infrastructures for this capacity are conveniently

available.

Company’s corporate policy focuses primarily on Product Quality, Customer Satisfaction and adherence to high

level of Environment protection and Safety. The company has a state of art R&D centre, located close to our

Head Office in Mumbai which was set up in collaboration with IBI Chematur Ltd. in year 2010.

2.3 Need of project with description for region and country

Industrialization in India is increasing at rapid pace and is leading to growth and expansion of various industries

like Pharmaceuticals, agrochemicals etc. M/s BEC Chemicals Pvt. Limited is a global supplier of API (Bulk

drug and intermediate) to the pharmaceutical companies worldwide M/s BEC Chemicals aims to expand its

product portfolio further in order to cater to Domestic & International markets by expanding its production

capacities. These products will serve to cut the supply of imports from foreign countries thus saving currency

and at the same time will earn valuable foreign currency by export of the proposed products. Almost all the

proposed new products are niche and at present very few companies are manufacturing them. This results into

insufficient capabilities in India to cater to Domestic as well as International Markets.

2.4 Imports vs. Indigenous production

The rising demand for API and has also given rise to competition from foreign players. The proposed expansion

will also help check the competition from foreign players

2.5 Export Possibility

The finished goods will be sold in domestic market and would be largely exported to the Regulated International

Market as per demand.

2.6 Domestic/ Export Markets

The finished goods will be sold in domestic market and will be exported to the Regulated International Market as

per demand.


2.7 Employment Generation due to Project

Employment will get generated for administration and production purposes; that will be recruited locally without

any difficulty.

Employment will get generated in market by sales and service for providing products to the industry. Also the

increased capacity will increase the raw material consumption as well as the supporting services and will give

further business to the vendor industry.


CHAPTER 03

PROJECT DISCRIPTION

3.1 Type of Project:

M/s. BEC Chemicals is proposing an expansion by adding 2 NEW manufacturing blocks that will produce

existing and proposed new products (Bulk drug and intermediate) at the existing Plot no. 24 at MIDC Industrial

Area Dhatav, Roha, Dist: Raigad, State: Maharashtra- 402 116.

M/s. BEC Chemicals was initially set up a manufacturing unit with a capacity of 380 MT/Annumalong with by-

products of capacity 5580 MT/A. BEC Chemicals is desirous to propose their Products in this Medium Scale

Industrial (MSI) unit at Plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116.

M/s. BEC Chemicalsnow proposed to produce API (Bulk drug and intermediate) at Plot no. 24 at MIDC

Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116.The proposed production will be 1365 MT/

Annum maxalong with by-products of capacity 5580 MT/A. On screening it is necessary for BEC Chemicals to

approach designated Authority from State Environment Department for Environment Clearance for this unit.

This Pre-feasibility report however, is prepared for forming a framework for EIA study, Scoping and finalizing

the Terms of Reference, as may be required.

The government has an objective to improve economic status of this District and has encouraged MIDC to set up

an Industrial Estate at Dhatav. In order to have a sustainable development, the pollution generation from this

industry is finally made insignificant having taken all the precautions right fromraw material selectionup to low

or no waste generation and conversion.

3.2 Location of Project:

The proposed project is located at plot no. Plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State:

Maharashtra- 402 116. The Geographical Location of this Industry is 18025’ N Latitude and 73009’ E longitude

with an elevation of 12.8 m (42ft) above mean sea level MSL.

This proposed site is in premises MIDC Industrial area, Dhatav which is meant for these types of Industries. This

proposal is for manufacturing of API (Bulk drug and intermediate) at the proposed Plot no. 24 at MIDC

Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116.

MIDC has provided all infrastructure like assured electrical power, continuous purified water supply from water

works having RSF (Rapid Sand Filtration) and disinfection, the internal road network, external approach road,

and networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility) at

MIDC Taloja in vicinity established with support of MIDC and MPCB.


Google Image of the site


Location can be thus justified. A relevant portion of MIDC Map is shown below. The proposed land is on plot

no. 24 admeasuring 12220.0 Sq. Meters.


Land Form:

The project site is situated in MIDC Dhatav. It is a notified industrial area where the land is owned by Maharashtra

Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity.

Land Ownership: Land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the

Company for 99 years.

3.3 Alternate sites:

This is a proposed expansion project for existing and new products, on existing plot. There is ample area

available for expansion and current site is in approved chemical zone of MIDC and is well connected to get raw

material by road / railway and carry on the proposed manufacturing activities.

3.4 Size or Magnitude of Operation:

The maximum proposed capacity is 1365 MT/A and 5580 MT/A of by-products

3.5 Project Description:

List of Products for Environmental Clearance:

Sr.No.

Existing / ConsentedProducts

Added Products Proposed

Product NameQty.,MT/A



1

Ketoprofen& itssalts such asKetoprofenLysinateKetoprofen EthylEsterDex-KetoprofenDex-KetoprofenTrometamol

100

Ketoprofen,Ketoprofen nitrile& itssalts such asKetoprofenLysinateKetoprofen Ethyl EsterDex-KetoprofenDex-KetoprofenTrometamol

300

Ketoprofen& itssalts, such asKetoprofenLysinate,Ketoprofen EthylEster,Dex-Ketoprofen,Dex-KetoprofenTrometamol

400

2 Ketoprofen nitrile 60Ketoprofen nitrile

clubbedin abovecolumn

Ketoprofen nitrileclubbed

inabove

Column


3

5-Amino SalicylicAcid/Mesalamine/Mesalazine(Aniline & SalicylicAcid & CNBARoute)

220

5-Amino SalicylicAcid/Mesalamine/Mesalazine(Aniline & SalicylicAcid & CNBA Route)

50

5-Amino SalicylicAcid/Mesalamine/Mesalazine(Aniline &Salicylic Acid &CNBA Route)

270

NEW PRODUCTS

4Flurbiprofenand itssalts

25Flurbiprofenandits salts

25

5 Pentoxyphylline 80 Pentoxyphylline 806 Valproic Acid 50 Valproic Acid 50

7 Sodium Valproate 120SodiumValproate

120

8 Divalproex Sodium 50DivalproexSodium

50

9 Ibuprofen Lysinate 25IbuprofenLysinate

25

10 Alminoprofen 10 Alminoprofen 10

11 Fenofibrate 25 Fenofibrate 25

12 Meloxicam 25 Meloxicam 25

13 Aspirin Lysinate 25AspirinLysinate

25

142-Ethoxy-5-FluroUracil

202-Ethoxy-5-Fluro Uracil

20

15Thioctic Acid (LipoicAcid)

45Thioctic Acid(Lipoic Acid)

45

16 Acetylcystein 45 Acetylcystein 45

173-(1-cyanoethyl)

benzoic acid crude150

3-(1-cyanoethyl)benzoic acidcrude

150

Total380 985

1365


BY-PRODUCTS

Sr.No.

Byproducts Assay / PurityProposed quantity of By-

products(in MT/A)

1 Aluminium Chloride Solution 35% ± 5% 1650

2 Hydrochloric Acid Solution 30% ± 5% 450

3 Recovered Aniline 90% ± 5% 150

4 Sodium sulphide solution 20% ± 5% 310

5 Acetic Acid solution 30% ± 5% 2720

6 Mix Solvents 80% ± 5% 300

Total 5580


Process Flow Details

BRIEF MANUFACTURING PROCESS

KETOPROFENNITRILE

Step I – (CEBA to CEBA Chloride)

3, (1, Cyanoethyl) Benzoic Acid (CEBA) is chlorinated with Thionyl chloride in the presence of benzene at a

temperature of around 80 to 820C. After completion of reaction, benzene is distilled to get CEBA Chloride

(CEBA chloride step is not isolated).

(CEBA chloride to Ketoprofennitrile)

CEBA chloride is then reacted with benzene in presence of aluminium chloride again at a temperature of around80 to 820C to get Ketoprofennitrile crude. The Ketoprofennitrile crude is then dissolved in Isopropyl alcoholafter heating at about 600C and then precipitated by chilling the mass at around 0 to 50C to give pureKetoprofennitrile.

Sr. No. INPUT Qty.in kgs OUTPUT Qty.in kgs

1 Ceba 500 Thionylchloride+benzene(rec.) 780

2 Benzene 875Aluminum chloride solution alongwith HCL 2400

3 Thionyl chloride 375 Organic layer water washing 2000

4 Benzene 1945 Sodium bicarbonate washing 4000

5 Aluminium chloride 813 Crude Distillation Residue 12

6 Hydro chloric acid 113 Ketoprofennitrile Finished product 625

7 Water for quenching 2000 IPA recovered 725

8 Water for ist washing 2000 Benzene 2520

9 Sodium bicarbonate 42 Solvent Evaporation loss 190

10WATER FOR Sod. Bicarbonatewashing 2000 Mother Liquor Evaporation loss 174

11 WATER FOR iindWASHING 2000

12 IPA 763

13Caustic Lye 7.5% (scrubbersolution) 4500 Scrubber Solution 4500

14 Water for Hcl scrubbing 1000 Water from Hcl scrubbing 1000

15 Water jet Ejector 2000 Water jet Ejector output 2000

Total 20926 Total 20926


Flow Diagram

STEP-I: FROM CEBA TO KETOPROFENNITRILE

Drying and pulverzing

Reaction of CEBA chloride

Distillation

CEBA Chloride

(In-situ)

Ketoprofennitrile

Quenching

3, (1, Cyanoethyl) Benzoic Acid (CEBA)

Benzene

Benzene

Aluminium Chloride

Reaction of Ketoprofennitrile

WaterHCl

Crude Ketoprofennitrile

Separation, Distillation

Distillation

Distilled Ketoprofennitrile

Crystallized Ketoprofennitrile

Ketoprofennitrile Wet

Crystallization

Crystallization and washing

Dimethyl formamideThionyl Chloride

Isopropyl alcohol

Ketoprofennitrile pure

Sodium bicarbonate

Benzene + Thionyl Chloride

AlCl3Solution (about 35-40%)

1stWater Wash

NaHCO3 solution washing

2nd Water wash

Scrubber 107

Scrubber 108(HCl about30%)


Brief Manufacturing Process

Ketoprofen:

Step I – (CEBA to CEBA Chloride)

3, (1, Cyanoethyl) Benzoic Acid (CEBA) is chlorinated with Thionyl chloride in the presence of benzene at a

temperature of around 80 to 820C. After completion of reaction, benzene is distilled to get CEBA Chloride

(CEBA chloride step is not isolated).

(CEBA chloride to Ketoprofennitrile)

CEBA chloride is then reacted with benzene in presence of aluminium chloride again at a temperature of around80 to 820C to get Ketoprofennitrile crude. The Ketoprofennitrile crude is then dissolved in Isopropyl alcoholafter heating at about 600C and then precipitated by chilling the mass at around 0 to 50C to give pureKetoprofennitrile.

Step II – (Ketoprofennitrile to Ketoprofen)

Ketoprofennitrile is hydrolyzed with water and Sodium Hydroxide at a temperature of around 100 to 1050C to

give Sodium salt of Ketoprofen. Ketoprofen Sodium salt on acidification gives Ketoprofen (crude).

Ketoprofen (crude) is then purified by dissolving in dilute acetic acid at about 70 to 800C, treating with

Activated charcoal, filtering and cooling gradually to about 200C and finally washing the centrifuged material

with Purified water.

It is then dried at 40 to 450C for 24 hours till the loss on drying is less than 0.5%. It is then blended, pulverized to

the required particle size, and packed in double polyethylene bags, independently sealed, which are placed in 50

kg HDPE drums appropriately labeled as per customer requirements.


1 Ceba 250 Thionylchloride+benzene(rec.) 390

2 Benzene 437.5Aluminum chloride solution alongwith HCL 1200

3 Thionyl chloride 187.5 Organic layer water washing 1000

4 Benzene 972.5 Sodium bicarbonate washing 2000

5 Aluminium chloride 406.5 Crude Distillation Residue 6

6 Hydro chloric acid 56.5 Ketoprofennitrile Finished product 312.5

7 Water for quenching 1000 IPA recovered 362.5

8 Water for ist washing 1000 Benzene 1260

9 Sodium bicarbonate 21 Solvent Evaporation loss 95

10WATER FOR Sod. Bicarbonatewashing 1000 Mother Liquor Evaporation loss 87

11 WATER FOR IInd WASHING 1000

12 IPA 381.5

13 Caustic Lye 7.5% (scrubber solution) 2250 Scrubber Solution 2250

14 Water for Hcl scrubbing 500 Water from Hcl scrubbing 500

15 Water jet Ejector 1000 Water jet Ejector output 1000


16 Ketoprofen Nitrile 225 Liq.Ammonia(3%) 500

17 Caustic Soda lye 120 Toluene 1370

18 Sulphuric Acid 155 Activate charcoal/Hyflo supper cell 10

19 Toluene 1400 Aqueous layer 1850

20 Water 3600 ML of Acetic Acid(25-30%) 2000

21 Acetic acid 660 Product cake washing 1800

22 Water for washing 1800 Finished Product 225

23 Hyflo Supper cell 3 Solvent Evaporation loss 70

24 Activate charcoal 3 Mother Liquor Evaporation loss 1791

25 Water 750

26 Water for regeneration for DM plant 1000

27 water Equipment cleaning 3000 Water Equipment cleaning 3000

28 Water for scrubber 1000 Scrubbed Ammonia 1100

29 Water Floor cleaning 200 Water Floor cleaning 200



Flow Diagram

STEP-I: FROM CEBA TO KETOPROFENNITRILE

Drying and pulverzing

Reaction of CEBA chloride

Distillation

CEBA Chloride

(In-situ)

Ketoprofennitrile

Quenching

3, (1, Cyanoethyl) Benzoic Acid (CEBA)

Benzene

Benzene

Aluminium Chloride

Reaction of Ketoprofennitrile

Water: -5578.5kg(1stwaterwash:-975kg, NaHCO3 solutionwash: - 975kg, 2nd water wash: -975kg)HCl

Crude Ketoprofennitrile

Separation, Distillation

Distillation

Distilled Ketoprofennitrile

Crystallized Ketoprofennitrile

Ketoprofennitrile Wet

Crystallization

Crystallization and washing

Dimethyl formamideThionyl Chloride

Isopropyl alcohol

Ketoprofennitrile pure

Sodium bicarbonate

Benzene + Thionyl Chloride

AlCl3Solution (about 35-40%):- Byproduct

1stWater Wash

NaHCO3 solution washing

2nd Water wash

Scrubber 107

Scrubber-108(HCl about30%) :- Byproduct


STEP-II: FLOW DIAGRAM FROM KETOPROFENNITRILE TO KETOPROFEN

Crude Ketoprofen (Molten Mass)

Filtration

Hydrolysis

Toluene Washing &Acidification

Separation of Toluene layer

& Toluene distillation

Purification

Crystallization & separation

of Ketoprofen wet mass

Drying

H2SO4

Toluene

Acetic acid

Purified Water

Ketoprofen nitrile

Water

NaOH Flakes / Lye

Pulverization

Ketoprofen

Wet Mass Granulation

Filtrate to ETP (Washing ML)

Acetic Acid (30% ± 5%): -Byproduct

Water for washing


BRIEF MANUFACTURING PROCESS OF KETOPROFEN LYSINATE

1) A solution of ketoprofen in IPA is treated with 50% D,L-Lysine solution at 10°C for 4-5 hrs results in

precipitation of ketoprofenlycinate salt

2) Ketoprofenlysionate is filtered, washed with chilled IPA and is dried in oven at 55 -60°C to get pure

ketoprofenlysinate

Note: - The key raw material for KetoprofenLysinate is Ketoprofen. The details of raw materials, PFD

and Byproducts generation forketoprofen is given on page no. 12 to 15


1 Isopropyl Alcohol 620 IPA ML 700

2 Ketoprofen 62 Residue after distillation 10

3 50 % DL Lysine 72 Finished Product 100

4 IPA Washing 125 Charcoal 10

5 Charcoal 10 Hyflo 6

6 Hyflo 6 Solvent Evaporation loss 30

Mother Liquor Evaporation loss 39




BRIEF MANUFACTURING PROCESS OF DEX - KETOPROFEN

1) The process consists of preparation of diastereoisomer salt of Ketoprofen with n-octyl-d-glucamine.

2) Dexketoprofen [(S) - Ketoprofen] is liberated from its diastereoisomer salt.

Note: - The key raw material for Dex-Ketoprofen is Ketoprofen. The details of raw materials, PFD and

Byproducts generation forketoprofen is given on page no. 12 to 15


1 Ketoprofen 100 Methanol Ethyl Acetate ML 1000

2 NODG 140 Toluene 1900

3 Methanol 550 Aqueous ML 550

4 Ethyl Acetate 550 Ethyl Acetate Methanol Acetone Mixture 300

5 Toluene 2000 Finished Product 30

6 Water 600

7 Sodium Hydroxide 7.5 Residue from solvent distillation 4

Solvent Evaporation loss 113.5


Total 3947.5 Total 3947.5


BRIEF MANUFACTURING PROCESS OF DEX - KETOPROFEN TROMETAMOL

1) The process consists of preparation of diastereoisomer salt of Ketoprofen with n-octyl-d-glucamine.

2) Dexketoprofen [(S) - Ketoprofen] is liberated from its diastereoisomer salt.

3) Dexketoprofen is then reacted with Tromethamine to form addition compound in Methanol-Acetone as

solvent.

4) DexketoprofenTromethamine is isolated and dried.


1 Ketoprofen 100 Methanol Ethyl Acetate ML 1000

2 NODG 140 Toluene 1900

3 Methanol 550 Aqueous ML 550

4 Ethyl Acetate 550Ethyl Acetate Methanol AcetoneMixture 300


6 Water 600

7 Sodium Hydroxide 7.5

8 Acetone Methanol Mixture 80

9 Ethyl Acetate 290 Residue from solvent distillation 6

10 Triss Buffer 11 Solvent Evaporation loss 280

Mother Liquor Evaporation loss 252.5

Water Floor cleaning 100 Water Floor cleaning 100


Note: - The key raw material for Dex-KetoprofenTromatomol is Ketoprofen. The details of raw

materials, PFD and Byproducts generation forketoprofen is given on page no. 12 to 15


BRIEF DESCRIPTION OF MANUFACTURING PROCESS FOR,5 AMINO SALICYLIC ACID

Step M-1:

Aniline is diazotised in the presence of Hydrochloric Acid (HCl) and Sodium Nitrite (NaNO2) to get diazonium

Chloride. This is further coupled with salicylic acid to yield azo salt, which is used in Step M-2.

Step M-2:

Azo - salt from Step M-1 is reacted with Sodium Sulphide (Na2S) &Sulphur under reflux. Aniline recovery is

done and reaction completion is monitored. After reaction completion, reaction mass is acidified with Sulphuric

Acid (H2SO4) to yield 5- Amino Salicylic Acid Crude.

Step M-3

So, formed crude product is dissolved in Sulphuric Acid and converted into 5 ASA Sulphate

Step M-4

So, formed 5ASA Sulphate is purified by dissolving in acidified water and precipitated by Liquor Ammonia

(NH3). The resultant Mesalazine drug substance is washed with Purified water, dried in oven at about 70 to 800C

till the loss on drying is less than 0.5%. It is then pulverized and packed in double polyethylene bags,

independently sealed, which are packed in 25 kg/50 Kg Drums appropriately labeled as per customer

requirements.

Sr. No. INPUT Qty.in kgs OUTPUT Qty.in kgs1 Aniline 132 5-ASA Finished Product 1502 Hydro chloric Acid 341 Aniline Recovered 65

3 Sodium Nitrite 104Activatecharcoal+Hyflo+Insolubles(Wet) 150

4 Salicylic Acid 200 ML + Washings + Scrubber Solution 135005 Caustic Soda Lye 2956 Sodium Sulphide 2417 Sulphur 52 Mother Liquor Evaporation loss 16088 Sulpuric Acid (50%) 2009 Sulphuric Acid (50%) 16611 Hyflo Super cell 512 Activate charcoal 613 Sodium hydro sulphite 114 Sulphuric Acid CP grade 6016 Activate charcoal 1517 Hyflo Super cell 518 Liquor Ammonia 15019 Water Required for Process 10500

20Water Required for Washing &Scrubber 3000Total 15473 Total 15473


BRIEF DESCRIPTION OF MANUFACTURING PROCESS FOR FENOFIBRATE

Fenofibric acid is charged into Isopropyl alcohol and Thionyl chloride is added slowly at higher temperature and

refluxed. The reaction mass is treated with potassium carbonate solution, aqueous layer is separated and

discarded. Once again the organic layer is treated with potassium carbonate solution, the aqueous layer is

separated and discarded. Activate charcoal is added into organic layer and filtered. The clear filtrate is then

added to water and maintained. The crystallized material is centrifuged, washed with water and dried.


1 IPA 47.5

2 Fenofibric acid 15

3 Thionyl Chloride 7.5

4 Potassium carbonate 9

5 Water for potassium carbonate 30 Aqueous layer 35

6 Potassium carbonate 7.5

7 Water for potassium carbonate 25 Aqueous layer 25

8 Hyflo Supper cell 0.5

9 Activate charcoal 0.75 Spent charcoal & hello 1.25

10 IPA for Hyflo bed preparation 9.5

11 IPA for carbon slurry 2.5 Solvent Evaporation loss 25

12 IPA for filter washing 15.12 Mother Liquor Evaporation loss 13.62

13 Water for dilution 300 Centrifuge ML with 25 % IPA 355

14 Water for CF washing 350 Washing ML 350

Finish product 15



BRIEF DESCRIPTION OF MANUFACTURING PROCESS:

PRODUCT NAME: MELOXICAM BP/EP/USP

Methyl Benzothiazine Isopropyl Ester and 2-Amino,5-Methyl Thiazole are condensed in Xylene to get

Meloxicam Crude. Meloxicam crude is the purified by acetic acid to get Meloxicam pure.


1 Xylene 500 Distilled Xylene 425

2 2-AMT 25

3 MBI 50

4 Xylene for washing of centrifuge 18 Xylene ML 80

5 Acetic Acid 110 Acetic acid ML 95

6 Water for centrifuge washing 300 Water washing ML 300

7 Methanol for purification 250

8 C. soda flakes 6.2 Solvent Evaporation loss 45

9 Water for caustic dissolution 7 Mother Liquor Evaporation loss 52.15

10 Activate charcoal 1.2

11 Hyflo 1 Waste carbon &Hyflo 2.25

12 Methanol for hello bed preparation 10

13 Methanol for filter bed washing 37 Acetic acid & methanol ML 325

14 Acetic acid for pH 37

15 Methanol for CF washing 17

Finished Product 45



BRIEF MANUFACTURING PROCESS OF KETOPROFEN ETHYL ESTER

1) Acid catalyzed esterification of Ketoprofen obtained from Ketoprofennitrile with ethanol yields Ketoprofen

ethyl ester

2) Subsequent downstream processing by bicarbonate wash water eash and charcoalization yields Ketoprofen

ethyl ester pure


1 Ketoprofennitrile 100 Water Washing 990

2 Sodium Hydroxide 54 Water From Azeotropic Distillation 3

3 Water 1700 Aqueous Alkaline ML 750

4 Toluene 1000 Toluene 900

5 Ethanol 60 Finished Product 115

6 Sodium bicarbonate 5

7 Hyflo 3 Hyflo 3

8 Activate Carbon 5 Activate Carbon 5

9 Sulphuric Acid 50 Solvent Evaporation loss 80



Note: - The key raw material forKetoprofenEthyle Ester is Ketoprofennitrile. The details of raw

materials, PFD and Byproducts generation for Ketoprofennitrile is given on page no. 10 to 11


BRIEF MANUFACTURING PROCESS OF IBUPROFEN LYSINATE

1) A solution of ibuprofen in IPA is treated with 50% D, L-Lysine solution at 10°C for 4-5 hrs results in

precipitation of ibuprofen lysinate salt

2) Ibuprofen lysinate is filtered, washed with chilled IPA and is dried in oven at 55 -60°C to get pure ibuprofen

lysinate.


1 Isopropyl Alcohol 880 IPA ML 1000

2 Ibuprofen 55 Residue after distillation 15

3 50 % DL Lysine 88 Finished Product 100

4 IPA Washing 220

5 Charcoal 10 Charcoal 10

6 Hyflo 6 Hyflo 6

Solvent Evaporation loss 75




BRIEF MANUFACTURING PROCESS OF ASPIRIN LYSINATE

1) A solution of Aspirin in IPA is treated with 50% D,L-Lysine solution at 10°C for 4-5 hrs results in

precipitation of aspirin lysinate salt

2) Aspirin lysinate is filtered, washed with chilled IPA and is dried in oven at 55 -60°C to get pure aspirin

lysinate


1 IPA 1250 IPA ML 1150

2 50 % DL Lysine 100 Residue after distillation 6

3 Aspirin 100 Finished Product 140


5 Hyflo 6 Hyflo 6





Brief Manufacturing Process for Pentoxyphylline

1. Base catalyzed condensation of Theobromine& 6-chlorohexanone in DMF as solvent yields pentoxyphylline2. Purification in methanol yields pentoxyphylline pure


1 Dimethyl Formamide (DMF ) 3450 Finished Product 1050

2 Theobromine 900 DMF Recovery 3300

3 6-Chlorohexanone 761 Methanol recovery 2100

4 Potassium Carbonate 530 Potassium Chloride 530

5 Activate charcoal 8 Spent Carbon 8

6 Methanol 2870 Solvent Evaporation loss 770




BRIEF MANUFACTURING PROCESS OF ALMINOPROFEN

1) The Alkylation of 2-(4-aminophenyl) propionate with 2-methylallyl chloride by means of pyridine in

refluxing ethanol gives 2-[4-(2-methylallylamino) phenyl] propionate.

2) 2-[4-(2-methylallylamino) phenyl] propionate is finally hydrolyzed with NaOH in refluxing methanol to

yield Alminoprofen


1 2-methyl alllyl chloride 100 Recovered Ethanol 425

2 Pyridine 87 Recovered Methanol 400

3 Ethanol 500 Finished Product 210


5 Hyflo 6 Hyflo 6

6 Dil. HCL 450 Solvent Evaporation loss 175

7 Propionate Compound 180 Mother Liquor Evaporation loss 652

8 Sodium Hydroxide 45

9 Methanol 500




Brief Manufacturing Process for Flurbiprofen sodium

1. 2-bromopropionic acid on treatment with Sodium Methoxide yields sodium bromopropionate2. Grignard reaction between 4-bromo-2-fluorobiphenyl & sodium bromopropionate followed by acidic

treatment gives Flurbiprofen , which is purified by crystallization followed by treatment with caustic lye toyield Flurbiprofen sodium pure


1 Tetrahydrofuran (THF) 910 Finished Product 160

2 Magnesium Metal Turning 25 THF Recovery 820

3 Acetone 50 Acetone Recovery 45

4 4-Bromo-2 floor biphenyl (BFL) 245 Toluene Recovery 1200

5 Toluene 1300 Special denature Spirit Recovery 620

6 2-Bromo Sodium Propionate 172 Methanol Recovery 45

7 Potassium Carbonate 152 Effluent for treatment 3810

8 Sulphuric Acid 60 Solvent Evaporation loss 70

9 Hydrochloric Acid 300 Mother Liquor Evaporation loss 49

10 Special denature Spirit 650

11 Caustic Soda 65

12 Methanol 50

13 DM Water for batch 600

14 DM Water for Sulphuric 300

15 DM Water for Potassium Carbonate 360

16 Sodium Flurbiprofen 160

17 Petroleum Ether 2100

18 HCL 300 Petroleum Ether Recovery 2020

19 Activate Carbon 8 Spent Carbon for sale 8

20 DM Water for Process 1000 Side Chain 260

21 2-Bromo Propionic Acid 250 Toluene Recovery 1450

22 Sodium Methoxide 25% 280 THF Recovery 180

23 Toluene 1500 Methanol Recovery 300

24 THF 200

Water Floor cleaning 100 Water Floor cleaning 100



BRIEF MANUFACTURING PROCESS OF 2-ETHOXY-5-FLUOROURACIL

1) Stage I

Formylfluoroacetate ethyl ester sodium salt is prepared from ethyl fluoroacetate and ethyl formate using sodium

ethylate as base

2) Stage II

O-ethyl isoureasulphate is preapared from urea and diethyl sulphate

3) Stage II

Condensation of Formylfluoroacetate ethyl ester sodium salt and o-ethyl isoureasulphate gives 2-Ethyoxy-5-

Flurouracil

Sr.No. INPUT Qty.in kgs OUTPUT Qty.in kgs


2 Sodium Ethylate 60 Toluene Recovery 300

3 Ethyl formate 132 Charcoal 6

4 Ethyl fluoroacetate 76.5 Effluent for treatment 1200

5 Urea 86 Solvent Evaporation loss 400

6 Diethyl Sulphate 115 Mother Liquor Evaporation loss 409.5

7 Sodium Methylate 200

8 Water 1300

9 Hydrochloric acid 55

10 Charcoal 6



BRIEF MANUFACTURING PROCESS OF VALPROIC ACID

1) Base catalysed alkylation of Diethyl Malonate with n-Propyl Bromide using Sodium tertiary Butoxide

affording Diethyl-2,2-di-propyl malonate.

2) Diethyl-2,2-dipropyl malonate on hydrolysis & decarboxylation using Sodium Hydroxide &

70%Methane Sulphonic Acid respectively affords crude 2,2-Di-n-propyl-acetic acid(Valproic Acid).

3) Valproicacid(crude) on purification by vacuum distillation yields, Valproic Acid pure.


1 Ethanol 1000ETHANOL + PROPHYLBROMIDE 900

2 SODIUM METAL 72 TOLUENE 1400

3 TOLUENE 1550 SODIUM BROMIDE Aqueous 850

4 SULPURIC ACID 62 ML 2400

5 SODIUM CLORIDE 75 Residue from Toluene Distillation 7

6 N PROPYL BROMIDE 360Residue from high vacuumdistillation 6

7 DIETHYL MALONATE 200 Finished Product 125

8 Water for Reactor Washing 200 Water Washing 200

9 Water Washing 2400 Solvent Evaporation loss 20




BRIEF MANUFACTURING PROCESS OF SODIUM VALPROATE

1) Base catalysed alkylation of Diethyl Malonate with n-Propyl Bromide using Sodium tertiary Butoxide

affording Diethyl-2, 2-di-propyl malonate.

2) Diethyl-2, 2-dipropyl malonate on hydrolysis & decarboxylation using Sodium Hydroxide &

70%Methane Sulphonic Acid respectively affords crude 2, 2-Di-n-propyl-acetic acid (Valproic Acid).

3) Valproic acid (crude) on purification by vacuum distillation yields, Valproic Acid pure.

4) Valproic Acid (pure) is converted to its Sodium salt by treatment with Sodium Hydroxide in

Cyclohexane


1 Ethanol 1000 Ethanol + prophyl bromide 900

2 Sodium metal 72 Toluene 1400

3 Toluene 1550 Sodium bromide aqueous 900

4 Sulpuric acid 62 Ml 2400

5 Sodium cloride 75 Residue from Toluene Distillation 7

6 N propyl bromide 360Residue from high vacuumdistillation 6

7 Diethyl malonate 200 Finished Product 135


9 Water Washing 2400

10 Cyclohexane 800 Cyclohexane Recovered 725

11 Sodium Hydroxide 34 Residue after Cyclohexane recovery 3

12 Activated Charcoal 5 Charcoal Residue 5





BRIEF MANUFACTURING PROCESS OF DIVALPROEX SODIUM

1) Base catalyzed alkylation of Diethyl Malonate with n-Propyl Bromide using Sodium tertiary butoxide

affording Diethyl-2, 2-di-propyl malonate.

2) Diethyl-2, 2-dipropyl malonate on hydrolysis & decarboxylation using Sodium Hydroxide & 70%

Methane sulphonic Acid respectively affords crude 2, 2-Di-n-propyl-acetic acid (Valproic Acid).

3) Valproicacid(crude) on purification by vacuum distillation yields, Valproic Acid pure.

4) ValproicAcid(pure) is converted to its Divalproex Sodium salt by treatment with half equivalent of

Sodium Hydroxide in Cyclohexane.


1 Ethanol 1000 Ethanol + prophyl bromide 900

2 Sodium metal 72 Toluene 1400

3 Toluene 1550 Sodium bromide aqueous 900

4 Sulpuric acid 62 Ml 2400

5 Sodium cloride 75 Residue from Toluene Distillation 7

6 N PROPYL BROMIDE 360Residue from high vacuumdistillation 6

7 DIETHYL MALONATE 200 Finished Product 130


9 Water Washing 2400

10 Cyclohexane 800 Cyclohexane Recovered 725

11 Sodium Hydroxide 17 Residue after Cyclohexane recovery 2

12 Activated Charcoal 5 Charcoal Residue 5





BRIEF MANUFACTURING PROCESS OF LIPOIC ACID

1. The Treatment of ethyl-6,8-dichlorooctanoate with sulfur and sodium sulfide in boiling ethyl alcohol yields

cyclic sulfide

2. Basic hydrolysis of the methyl ester group of the cyclic sulfur gives alpha lipoic acid


1 Ethyl-6,8-dioctanoate 90 Finished Product 41

2 Ethanol 160 Toluene Recovery 300

3 Conc. HCl 4.5 Water 550

4 Toluene 350 Cyclohexane + Ethyl Acetate Mixture 400

5 Water 600 Spent Carbon 9

6 Sodium Sulphide 56.5 Solvent Evaporation loss 250

7 Sulphur 11.8 Mother Liquor Evaporation loss 228.77

8 TBAB 0.37

9 Potassium Hydroxide 23.6

10 Sodium Chloride 30

11 Ethyl Acetate 33

12 Cyclohexane 410

13 Activate charcoal 9


Total 1853.77 Total 1853.77


BRIEF MANUFACTURING PROCESS OF ACETYLCYSTEINE

Base catalyzed condensation of L-cysteine hydrochloride monohydrate with acetyl chloride yields acetyl

cysteine, which is purified to give crystalline product.


1L-Cysteine Hydrochloridemonohydrate 35 Finished Product 38

2 Sodium Hydroxide 14.6 IPA water Mixture 300

3 Water 225 Spent Carbon 3

4 acetyl chloride 16 Solvent Evaporation loss 38

5 Conc. HCL 16 Mother Liquor Evaporation loss 30.6

6 IPA 100

7 Carbon 3




BRIEF MANUFACTURING PROCESS OF 3-(1-cyanoethyl) benzoic acid crude (CEBA)

1) Methylation of 3-cyanomethyl benzoic acid methyl ester with Di-methyl carbonate and catalyst gives 3-

(1-cyanoethyl)benzoic acid methyl ester

2) The reaction mass of 3-(1-cyanoethyl)benzoic acid methyl ester is then distilled and hydrolyzed to

obtain 3-(1-cyanoethyl)benzoic acid crude

3) The Crude 3-(1-cyanoethyl)benzoic acid crude is purified in methanol, filtered and treated with charcoal

to get pure 3-(1-cyanoethyl)benzoic acid (CEBA)


13-cyanomethyl benzoic acid methylester 175 Finished Product 160

2 Di-methyl carbonate 110

3 Mixture of Earth metals 25 Spent Carbon 5

4 NaOH lye (Caustic soda Lye) 100 Solvent Evaporation loss 130

5 Methanol 875 Mother Liquor Evaporation loss 200

6 Activated Carbon 5 Mother Liquor to ETP 1795

7 Water 1000



3.6 Raw Material requirement:

Raw Materials:

The basic raw material for this key product capacity are submitted herein below and for the details are given for

all reactants, solvents and work up support chemicals.

Source for Raw Material Procurement: Raw Material is easily available in the local market; some of the raw

materials will be procured from the International Market.

Mode of Transport of Raw Materials: Few of the raw materials will be transported locally and few will be

imported from the International Market.

Storage at the site: Raw Materials will be stored in storage yard at the project site. Location of storage yard is

demarcated in Layout Plan.

LIST OF RAW MATERIAL AND QUANTITY

Sr.No.

Name of Raw Material Category Quantity in Kg/D Solid/Liquid

1. Cyano Ethyl Benzoic Acid (CEBA) Reactant 500 Solid2. Benzene Reactant 2820 Liquid3. Thionyl Chloride Reactant 382.5 Liquid4. Aluminium Chloride Reactant 813 Solid5. Hydrochloric acid Reactant 1799.5 Liquid6. Sodium Bicarbonate Reactant 47 Solid7. Isopropyl Alcohol (IPA) Solvent 4032.62 Liquid8. Caustic lye Reactant 5577 Liquid9. Ketoprofen Nitrile Reactant 325 Solid10. Sulfuric Acid Reactant 1177 Liquid11. Toluene Solvent 14550 Liquid12. Acetic acid Reactant 1207 Liquid13. HyfloSupercel Filter-aid 41.5 Solid

14. Activated CarbonDecolorizingagent 114.95

Solid

15. Ketoprofen Reactant 162 Solid16. 50% DL lysine Reactant 260 Liquid17. N-Octyl-D-glucamine (NODG) Reactant 280 Solid18. Methanol Solvent 4874 Liquid19. Ethyl Acetate Solvent 1423 Liquid20. Sodium Hydroxide Reactant 179.6 Solid21. tris(hydroxymethyl)aminomethane) Buffer Tris Buffer Reactant 11 Solid22. Aniline Reactant 132 Liquid23. Sodium nitrite Reactant 104 Solid24. Salicyclic acid Reactant 200 Solid25. Sodium sulphate Reactant 297.5 Solid26. Sulphur Reactant 63.8 Solid27. Sodium Hydro Sulphite Reactant 1 Solid

28. Liquor AmmoniaAcidscavenger 304

Liquid

29. Fenofibric Acid Reactant 15 Solid30. Potassium carbonate Reactant 698.5 Solid


31. Xylene Solvent 518 Liquid32. 2-amino-5-methylthiazole (2 AMT) Reactant 25 Solid33. methyl benzothiazine isopropyl ester (MBI) Reactant 50 Solid34. Caustic Soda Flakes Reactant 6.2 Solid35. Ethanol Solvent 3720 Liquid36. Ibuprofen Reactant 55 Solid37. Aspirin Reactant 100 Solid38. 2 Chloro 5 Nitro Benzoic acid Reactant 300 Solid39. Raney nickel Catalyst 21 Solid40. Thioglycolic acid Reactant 7 Solid41. Dimethyl formamide Solvent 3450 Liquid42. Theobromine Reactant 900 Solid43. 6 Chlorohexanone Reactant 761 Liquid44. 2 methyl allyl chloride Reactant 100 Liquid45. Pyridine Solvent 87 Liquid46. Propionate compound Reactant 180 Solid47. Tetrahydofuran Solvent 1110 Liquid48. Magnesium metal turning Reactant 25 Solid49. Acetone Solvent 90 Liquid50. 4 -Bromo 2 fluro- biphenyl Reactant 245 Solid51. 2 Bromo sodium propionate Reactant 172 Solid52. Special denatured spirit Solvent 650 Liquid53. Petroleum ether Solvent 2100 Liquid54. 2 bromo Propionic acid Reactant 250 Liquid55. Sodium Methoxide Reactant 480 Liquid56. Sodium ethylate Reactant 60 Liquid57. Ethyl formate Reactant 132 Liquid58. Ethyl fluoroacetate Reactant 76.5 Liquid59. Urea Reactant 86 Solid60. Diethyl sulphate Reactant 115 Liquid61. Sodium metal Reactant 216 Solid62. Sodium Chloride Reactant 255 Solid63. N propyl bromide Reactant 1080 Liquid64. Diethyl malonate Reactant 600 Liquid65. Cyclohexane Solvent 2010 Liquid66. Ethyl 6,8 dioctanoate Reactant 90 Liquid

67. Tetra Butyl Ammonium Bromide (TBAB)

Phasetransfercatalyst 0.37

Solid

68. Potassium hydroxide Reactant 23.6 Solid69. L Cysteine Hydrochloride monohydrate Reactant 35 Solid70. Acetyl chloride Reactant 16 Liquid


3.7 Resource Optimization:

M/s. BEC Chemicalsisdesirous to propose in this sector with 1365 MT/Annum product-size.

Particulars Details

1. Plot Area, sq. m 12220.0

2. Proposed Built-up Area, sq. m 4532.00

3Total Water requirement, CMD 400

4. Effluent Qty.(Trade + sewage) 24+175

5. Fuel (FO//COAL/Briquette )

HSD

165/300/550

160.5 lit/hr

6. TFH 200000kcal

Stack for TFH 16.4 m

7. Stack, m (For Scrubbers) 15-20 m

8. Stack, m (DG set 750 KVA) 5.5 m above enclosure

9. Work Force Approx. 300 nos.

10. Trade Effluent Treatment Upgrade to 150 CMD – Treated effluent to CETP

11. Domestic Effluent Treatment Well-designed septic tank followed by collection pit shall be

proposed. The outlet of collection pit will go to ETP for further

treatment

12. Hazardous waste Refer Table Below

Sr.No. Hazardous Wastes Category Quantity Method of Disposal

1. ETP Sludge 34.3 1790 kg/day CHWTSDF

2. Mixed Carbon&Hyflow

(Process)

28.2 600 kg/day CHWTSDF

3. Distillation Residue 20.3 70 kg/day CHWTSDF

4. Mixed Catalyst 28.2 60 kg/day CHWTSDF

5. Spent Carbon from ETP 28.2 350kg/day CHWTSDF

6. Disposal of barrelscontainers used forhandling of hazardouswaste chemicals

33.3 1. Poly Bags : 54 kg/day

2. Carboys: 235 no./day

3. Fiber Drums: 30 no./day

4. Centrifuge Bags: 2kg/day

5. PF Bags: 0.4 kg/day

Sent to MPCB ApprovedVendor



CHWTSDF

CHWTSDF


13. List of Products

Sr.No.

Existing / Consented Products Added Products Proposed




1

Ketoprofen& its saltssuch as

KetoprofenLysinate

Ketoprofen Ethyl Ester

Dex-Ketoprofen

Dex-KetoprofenTrometamol

100

Ketoprofen, Ketoprofennitrile &

its salts such as

KetoprofenLysinate

Ketoprofen Ethyl Ester

Dex-Ketoprofen


300

Ketoprofen Ketoprofennitrile & its salts, suchas KetoprofenLysinate,

Ketoprofen Ethyl Ester,

Dex-Ketoprofen,


400

2 Ketoprofen nitrile 60 Ketoprofen nitrileClubbedin abovecolumn

Ketoprofen nitrileClubbedin abovecolumn

3


220


50


270

NEW PRODUCTS

4Flurbiprofenand itssalts

25Flurbiprofenandits salts

25

5 Pentoxyphylline 80 Pentoxyphylline 80

6 Valproic Acid 50 Valproic Acid 50


7 Sodium Valproate 120SodiumValproate

120

8 Divalproex Sodium 50DivalproexSodium

50

9 Ibuprofen Lysinate 25IbuprofenLysinate

25

10 Alminoprofen 10 Alminoprofen 10

11 Fenofibrate 25 Fenofibrate 25

12 Meloxicam 25 Meloxicam 25

13 Aspirin Lysinate 25 Aspirin Lysinate 25

142-Ethoxy-5-FluroUracil

202-Ethoxy-5-Fluro Uracil

20

15Thioctic Acid (LipoicAcid)

45Thioctic Acid(Lipoic Acid)

45

16 Acetylcystein 45 Acetylcystein 45

173-(1-cyanoethyl)

benzoic acid crude150

3-(1-cyanoethyl)benzoic acidcrude

150

Total380

985 1365

BY-PRODUCTS

Sr.No.

Byproducts Assay / PurityProposed quantity of By-

products (in MT/A)

1 Aluminium Chloride Solution 35% ± 5% 1650

2 Hydrochloric Acid Solution 30% ± 5% 450

3 Recovered Aniline 90% ± 5% 150

4 Sodium sulphide solution 20% ± 5% 310

5 Acetic Acid solution 30% ± 5% 2720

8 Mix Solvents 80% ± 5% 300

Total 5580


14.Disposal of barrels/ containers used for

Handling for Hazardous waste / Chemicals

Sale after decontamination

15. Max Power requirement 1700 KW

16. Investment 30.00 cr

3.8 Availability of Resources (Water, Energy/Power requirement):

Power: The total need for this proposed project is 1700 kw The required power connection is available fromMSEDCL who will fulfil the need for new unit power.

Existing Connected Load: 542 kW

Proposed Max. Demand: 1700 4kw

Existing Sanctioned Load: 542Kw

Power Supply: (From MSEDCL)

Proposed power requirement: 1700 4kw

DG Sets:

Number and capacity of DG Sets to be used (Proposed)

Capacity Qty. Fuel type Qty.

750 KVA 1 HSD 160.5 lit/hr at Full load.

Details of non-conventional renewable energy proposed to be used:

1) Design and construction of building considering maximum use of natural light and ventilation.

2) In future we are planning to use solar power for toilet and street lights.

Water:The fresh water requirement will be about 400 CMD for domestic, greenery, and process, cooling and

boiler feed purpose. The source of water is from MIDC.

Manpower: The manpower required for administration and production purposes will be recruited locally

without any difficulty.

Steam Requirement: Steam requirement for the unit, can be met by using boiler of adequate capacity.

Fuel for Boiler: Furnace oilor coal or briquette shall be proposed as a fuel.

Material Storage: The BEC Chemicals will keep its efforts to see if any other mode of process comes up or if

outsourcing can be done to minimize the load. Measures may be adopted as

1. Procuring pure raw material and analyzing them before accepting.

2. To reduce inventory by adopting JIT (just in time) procurement.


3. Designing the tank roofs to avoid VOC (Volatile Organic Carbon)

4. To go by predictive maintenance rather than preventive or emergency maintenance.

5. Good housekeeping and machine keeping for enhancing the efficiency.

3.9 Quantity of waste anticipated:

Water and waste water

The BEC Chemicals proposed to add a 1365 MT/Amanufacturing of API (Bulk drug and intermediate) along

with by-products of capacity 5580 MT/A at the existing Plot no. 24 at MIDC Industrial Area Dhatav, Dist:

Raigad, State: Maharashtra- 402 116. The details regarding pollution control of water, waste water, air and solid

wastes are as follows:

Water & Waste water: The source of water supply is MIDC.


Water Balance:

PurposeWater Requirement

M3/day

Water Losses

M3/day

Effluent

M3/day

Exis. Prop. Total Exis. Prop Total Exis. Prop. Total

i) Domestic 14 16 30 6 0 6 8 16 24

ii) Industrial

processing

1. Process

(Production)

2. Washings

3. Scrubbers

4. Ejectors

5. DM

116 104 220 83 12 95 33 92 125

iii) Cooling

water

makeup(Evapor

ation and blow

down)

15 85 100

13

Evapn/

windage

77

Evapn/

windage

90 2 8 10

iv) Boiler

Feed (40% Due

to steam splash

& blow down

loss-60 %

condensate is

recycled)

15 25 40

--

considered

in

requirement

--

considered

in

requirement

--

considered

in

requirement

15 25 40

v) Gardening

10 0 10 10 0 10 0 0 0

TOTAL 170 230 400 112 89 201 58 141 199


3.9 Quantity of Waste to be Generated:

Solid Waste

The main solid waste from this factory will be (a) non-hazardous solid waste from office, garden leaves and (b)

hazardous waste from process and bio sludge.

Non-hazardous Solid Waste: - Will be segregated and disposed through sale/ recycle/ corporation.

a) Non-Hazardous Waste:

There is no addition to non-hazardous waste

b) Hazardous Waste:



2.

Mixed Carbon

&Hyflow

(Process)





6.

Disposal of barrels

containers used for

handling of hazardous

waste chemicals

33.3

1. Poly Bags : 54 kg/day



4. Centrifuge Bags: 2

kg/day


Sent to MPCB Approved

Vendor


Vendor


Vendor

CHWTSDF

CHWTSDF


CHAPTER 04

SITE ANALYSIS

4.1 Connectivity:

This proposed project is located at plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State:

Maharashtra-402 116. The project site in MIDCDhatav,Roha is well connected. The site is in Roha, within 15

minutes of Roha station, 125 km from the Mumbai, by road. Train connections are available from Mumbai and

Thane, located 5 km away from the factory. Air connections to all domestic and international destinations are

available from Mumbai airport, about 125 km away by road.

4.2 Land form, Land use and Land ownership:

The project site is situated in MIDC Dhatav. It is a notified industrial area where the land is owned by Maharashtra

Industrial Development Corporation (MIDC) and leased to the Company. The land is meant for industrial activity.

The proposed land has area of 12220.0 m2.

Land Ownership: The land is owned by Maharashtra Industrial Development Corporation (MIDC) and leased to the

Company for 99 years.

4.3 Topography:

The Geographical location of this industry is 18025’ N Latitude and 73009’ E at an altitude of approximately 12.8

m (42 ft.) above mean sea level (MSL).

4.4 Existing land use pattern:

Proposed site falls under the Industrial MIDC. The land is reserved for Industrial use. River Kundalika is

sufficiently away from project site.

4.5 Existing Infrastructure:

Existing Infrastructure:

The land is in a recognized MIDC industrial area. All infrastructures are available

At distance of 7-8 km from Mumbai –Goa highway

Rail Network is easily accessible from Roha Station, just 5 km away

Air travel is readily available from Mumbai airport.

Water is available from MIDC


Electricity is available from MSEDCL

There is a CETP in Dhatav MIDC, Roha, and a hazardous waste management service MWML CHWTSDF in

Taloja. The company is a member of both of these.

4.6 Soil Classification:

There is sandy loam to clay in texture, yellowish in colour and under laid with murum derived from the basic

rock basalt.

4.7 Climate data from secondary sources:

The climate, if proposed area is characterized by hot summer and general dryness throughout the year except the

south west monsoon season. The year may be divided into three seasons. The winter or cold season is from

December to February, summer or hot season from March to May. The south west monsoon season is from June

to September, while October and November constitute the post monsoon season. The annual average rainfall of

the area is 3038.2 mm, month of May is the generally the hottest month of the year with average temperature in

between 32 to 370 C. In cold season the area is sometimes affected by the cold waves over north India and the

minimum temperature may drop to 14 to 170 C. The air is generally dry except during the south west monsoon

season, when the relative humidity is high.

Climate classification: Project site features a semiarid climate.

Temperature: Annual temperature in Roha ranges from 17-330 C, with the most comfortable time to visit in the

winter October to February.

Rainfall: Most of the rainfall occurs in the monsoon season from June to September. Average annual rainfall is

3038.2 mm.


CHAPTER 05

PLANNING BRIEF

5.1 Planning Concept:

MIDC Industrial area, Dhatav provides many basic facilities like uninterrupted water supply, power and

road network & solids disposal facility if feasible. When various sites were seen, this site appeared to be

environmentally best as also from the business angle and therefore this option was finally adopted. This

site is inside the campus of the MIDC and means safe transportation, less need of Utilities, less

constructing buildings and roads, less fuel, less water with optimization of infrastructure.

Dhatav MIDC has provided all infrastructure like assured electrical power, continuous water supply with

purification from water works like disinfection, the internal road network, external approach road, and

networking with CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal Facility),

MWML at Taloja in vicinity established with support of MIDC and MPCB.

All nearby villages are provided with drinking water from wells or Government Water Supply Schemes

RWS. Hence we do not encroach upon their supply.

5.2 Population Projection:

Roha city has a population of 34,345 as per census 2011. It has more than 7,563 households of Maratha,

Muslim, Buddhist, and also includes SC, ST, OBC and open categories community. The village has

basically an agrarian economy and industrial workers and farming is the main occupation of the villagers.

The local self-Government vests with a Grampanchayat having an elected body of headed by a Sarpanch.

Population growth is being increased at alarming rate with their basic requirements. Amongst, Medicine

is one of the basic need, which is very essential for everyone to live happy life. So to fulfil their future

basic need of Medicine for social community there is a necessity to promote R & D Centre in each

industrial sector. There will be in ratio of population increase in similar way their need also increases so

to fulfil their needs we are going to set up a proposed unit which again generates employment.

5.3 Land use planning:

The proposed project is in notified MIDC Industrial area, this is not a prime Agricultural Land. The land-

use is already as “industrial”. Thus there is no change in the status.


5.4 Assessment of Infrastructure Demand (Physical and Social):

M/s. BEC Chemicals Pvt. Ltd proposed expansion and new product of API (Bulk drug and

intermediate)at the Plot no. 24 at MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra-

402116. There will be demand of physical infrastructure and social infrastructure.

5.5 Amenities/ Facilities:

M/s. BEC Chemicals Pvt. Ltd proposed project for expansion and new products, The M/s. BEC

Chemicals proposed manufacturing of API (Bulk drug and intermediate) at the proposed Plot no. 24 at

MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402 116. Many basic facilities like

uninterrupted water supply, Power and Road Network & solids disposal facility if feasible. This site is

inside the campus of the MIDC and means safe transportation, less need of utilities, less constructing

buildings and roads, less fuel, less water with optimization of infrastructure and networking with

CHWSTDF (Common Hazardous Waste Storage Treatment and Disposal facility), MWML, Taloja in

vicinity established with support of MIDC and MPCB.

--0--


CHAPTER 06

PROPOSED INFRASTRUCTURE

6.1 Industrial area:

M/s. BEC Chemicals Pvt. Ltd proposed new and expansion projectby 1365 MT/Annum and by products

of 5580MT/Annummanufacturing of API (Bulk drug and intermediate)at the proposed Plot no. 24 at

MIDC Industrial Area Dhatav, Dist: Raigad, State: Maharashtra- 402116.

6.2 Residential Area:

In BEC Chemicals Pvt. Ltd. there is no any residential area has been proposed

6.3 Green Belt:

The project is built on an MIDC plot with total area of 12220.0.m2 and green belt area 1094.98.m2. In and

around the industry, plantation is already started. A number of Banyan,BadamandAshoka trees along with

some garden variety shrubs are already existed at the site. As per MIDC norms, 5 tree per 100 m2of green belt

area needs to be planted, and therefore additional 86trees will be planted at the site.

Sr. No. Common Name Scientific Name No. of Trees

1 Neem Azaderachtaindica 10

2 Shirish Albizzialebbeck 6

3 Phanas Artocarpusheterophyllus 6

4 Cadamba Neolamarckiacadamba 6

5 Bibba Semecarpusanacardium 6

6 Taman Lagerstroemia flos-reginae 8

7 Kala Shirish Albizziaamara 6

8 Nandruk Ficusretusa 6

9 Son Chafa Micheliachampaca 6

10 Satwin Alstoniascholaris 6

11 Kate Sawar Bobaxceiba 10

12 Sita Ashok Saracaasoka 10

Total 86


6.4 Social Infrastructure:

The basic amenities within the study area include primary schools, dispensaries, water supply, electric

supply, public telephones, hotels, banks, post offices, petrol pumps, bus services, technical training

institute and entertainment etc.

6.5 Connectivity:

The proposed site is at Plot no. 24 at MIDC Industrial Area Dhatav, The site is 125 km from Mumbai city

and 5 km. from Roha railway station. The land and infrastructure is made available by MIDC and the raw

materials are easily available through easy transport via road connectivity. Proposed project site is

125kmaway from Mumbai Airport.

6.6 Drinking Water Management:

The source of water supply is MIDC.

6.7 Sewage System:

The sewage will be treated in STP having capacity 30 CMD

6.8 Industrial Waste Management:

Water and Waste water:

Design Data & Performance projection

Sr. No. Parametersmg/l except

pH

Inlet EffluentCharacteristics

Outlet EffluentCharacteristics

Effluent dischargestandards(MPCB)

1 pH 2-12 7-8 5.5 -9.0

2 TSS 1000-1200 80-100 <100

3 COD 10000-12000 175-200 <250

4 BOD 5000-6000 50-75 <100

5 O&G 80-100 5-6 <10

All values are in mg/L except pH and Flow


THE PROCESS DETAILS:

The industry already has an Effluent Treatment plant which is designed to treat 100 m3 / day of

wastewater. The existing ETP will then be upgraded to treat 200 m3/day. The process scheme will remain

the same which is at present consisting of primary, secondary and tertiary.

PRIMARY TREATMENT:

The streams will be collected after screening in the underground sump where floating solids are trapped.

The screened solids/floating particles are manually skimmed out and collected in a drum for disposal. The

effluent is then routed by pump to the oil and grease trap for trapping oils by virtue of its immiscibility.

The oil floats on the surface and is skimmed out by using oil skimmer and is collected in drums for

disposal. The effluent devoid of oils flows to the equalization and neutralization tank for equalizing the

organic and hydraulic load. Provision of acid/ alkali dosing for neutralization of effluent will be made

near the tank. The neutralizing agents will be dosed from the respective dosing tanks. The content of

equalization tank is mixed with help of coarse diffused aeration system. The equalized and neutralized

effluent will be then passed to flash mixer for primary clarification.

Alum will be dosed as coagulant in the flash mixer provided with agitator. The coagulated mass will flow

to primary settling tank for settlement of solids. The primary settling tank will be constructed with the

hopper bottom for effective removal of solids. The settled solids will be drained to the sludge collection

tank. The sludge from sludge tank is then pumped to the filter press for dewatering.

SECONDARY TREATMENT - BIOLOGICAL TREATMENT

The biological treatment (2 stages of Activated Sludge Treatment) will consist of following units;

The supernatant from the primary settling tank will flow to the aeration tanks one after the other(2 nos.)

for the aerobic treatment. Activated sludge treatment works on the principle of development of microbial

culture in the aeration tank. Each bacterium is constituted of C, H, N, O and P. Bacteria assimilate all

carbonaceous matter. The oxygen required for the bacterial growth will be supplied through the diffused

aeration system. This system is energy saving and effective as compared to surface aerator.

The mixed liquor suspended solids (MLSS) will continue to grow. The mixed liquor from the bioreactors

will overflow to the respective secondary settling tanks where the sludge will settle down and will be

recycled to the respective bioreactor to maintain the MLSS concentration. The clean treated effluent will

overflow to the intermediate sump.


TERTIARY TREATMENT

Tertiary treatment include following units;

The biologically treated effluent will flow to intermediate sump from where it is pumped to pressure sand

filter for removing any fine solids which have escaped settlement. The Filtered water will be passed

through the Activate charcoal Filter for polishing and removing any refractory organics. The tertiary

treated effluent will be disposed to CETP for further treatment.

Note: The below given volumes and capacities are after up gradation.

Sr.No.

Name of Treatment Unit CapacityReqd

Status Qty., Nos MOC

Existingunits

Capacity

Newunits

Capacity

TotalCapacity

Existing New Total

1. Screening Chamber 3 M3 3 M3 --- 3 M3 1 --- 1 RCC

2. Oil & grease Trap 15 M3 7.5 M3 7.5 M3 15 M3 1 1 2 RCC

3. Equalization/ NeutralizationTanks

120 M3 60 M3 60 M3 120 M3 1 1 2 RCC

4. Flash Mixer 1 M3 1.0 M3 --- 1.0 M3 1 --- 1 RCC

5. Primary Settling Tank 20 M3 20 M3 Tubesettler inExisting

20 M3 1 --- 1 RCC

6. 1st Stage Bioreactor 1400 M3 700 M3 700 M3 1400 M3 1 1 2 RCC

7. 1st Stage SecondaryClarifier

32 M3 30 M3 Tubesettler inExisting

30 M3 1 --- 1 RCC

8. 2ndStage Bioreactor 200 M3 100 M3 100 M3 200 M3 1 1 2 RCC

9. 2nd Stage SecondaryClarifier

32 M3 32 M3 --- 32 M3 1 --- 1 RCC

10. Intermediate tank 15 M3 15 M3 --- 15 M3 1 --- 1 RCC

11. Sludge Thickener 5 M3 5 M3 --- 5 M3 1 --- 1 RCC

12. Treated Water tank 10 M3 10 M3 --- 10 M3 1 --- 1 RCC

13. Filter Press shed 6 MX6M 6 MX6M --- 6 MX6M 1 --- 1 RCC

14. MCC Room & Laboratory 6 MX6M 6 MX6M --- 6 MX6M 1 --- 1 RCC

15. Foundations Suitable --- --- --- Lot --- Lot RCC


B) MECHANICAL EQUIPMENT:

Sr.

No.

Description Size /

Capacity


Existing New Total Existing New Total

1 Belt Skimmer 3 lph ---

3 lph 3 lph 1

--- 1

Elasto

mer

2 Mixer For Equalization

Tank

5 H.P 5 H.P

each

--- 5 H.P

each

2 --- 2 CI

3 Coarse Bubble Diffusers

/Agitators

2.0 M

Long

Agitators Will be

replaced

by

Diffusers

--- 2 12 12 CI

4 Alkali/Acid Dosing Tanks 1000 Lit 1000 ltrs --- 1000 ltrs 2 --- 2 HDPE

5 Alkali Dosing pump 100 LPH 100 LPH --- 100 LPH 2 --- 2 SS

6 Alkali Dosing Agitator 0.5 H.P 0.5 H.P --- 0.5 H.P 1 --- 1 SS

7 Flash mixer feed pump 10 M3/hr 10 M3/hr --- 10 M3/hr 2 --- 2 CI

8 Flash Mixer Agitator 0.5 H.P 0.5 H.P --- 0.5 H.P 1 --- 1 SS

9 Alum Dosing Tank for Flash

mixer

1750 Lit 1000 ltr

each

--- 2000 ltr 2 --- 2 HDPE

10 Alum Dosing Tank for

Secondary System

3500 Lit 2000 Lit

each

--- 4000 ltr 2 --- 2 HDPE

11 Alum Dosing Agitators for

primary

1.5 H.P

each

1.5 H.P

each

--- 1.5 H.P

each

2 --- 2 SS

12 Alum Dosing Agitators for

primary

1.5 H.P

each

1.5 H.P

each

--- 1.5 H.P

each

2 --- 2

13 Alum Dosing Pump for

Flash mixer

0 – 200

LPH

0 – 200

LPH

--- 0 – 200

LPH

2 --- 2 PP

14 Alum Dosing Pump for

Secondary System

0 – 400

LPH

0 – 400

LPH

--- 0 – 400

LPH

2 --- 2 PP

15 Urea Dosing Tank 1000 Lit 1000 Lit --- 1000 Lit 1 --- 1 HDPE

16 DAP Dosing Tank 500 Lit 500 Lit --- 500 Lit 1 --- 1 HDPE


17 Air Blower For 1st

Stage

Bioreactor

1500 M3

/ hr

700 M3 /

hr each

700M3/hr

each

1500

M3/hr

2 1 3 CI

18 Air Blower For 2st

Stage

Bioreactor

200 m3 /

hr

220

M3/hr

each

--- 220

M3/hr

each

2 --- 2 CI

19 Fine Bubble Diffused

Aeration System For 1st

Stage Bioreactor

64mm

DiaX2mL

140 nos.

64mm

DiaX2mL

64mm

DiaX2mL

64mm

DiaX2mL

70 70 140 Silicon

20 Fine Bubble Diffused

Aeration System For 2st

Stage Bioreactor

64mm

DiaX2mL

20 nos.

64mm

DiaX2mL

64mm

DiaX2mL

64mm

DiaX2mL

20 --- 20 Silicon

21 1st

Stage & 2nd

Sludge

Recycle pump

10 m3/hr 10 m3/hr --- 10 m3/hr 4 --- 4 CI

22 PSF feed pump 10 m3/hr 10 m3/hr --- 10 m3/hr 2 --- 2 CI

23 Pressure Sand Filter 1.1 m dia

X 2 m

Height

1.1 m dia

X 2 m

Height

--- 1.1 m dia

X 2 m

Height

1 --- 1 MS-

Epoxy

24 Activate charcoal Filter 1.8 m dia

X 1.5 m

Height

1.8 m dia

X 1.5 m

Height

--- 1.8 m dia

X 1.5 m

Height

2 --- 2 MS-

Epoxy

25 Polyelectrolyte Dosing Tank 4375 Lit 2500 lts

each

--- 2500 lts

each

2 --- 2 HDPE

26 Polyelectrolyte Dosing

Agitator

2.0 H.P

each

2.0 HP --- 2.0 HP

each

2 --- 2 SS

27 Polyelectrolyte Dosing

pump

0 – 400

LPH

0 – 400

LPH

--- 0 – 400

LPH

2 --- 2 SS

28 Filter Press feed pump 5 m3/hr 3 Nos. SS

29 Filter Press To

Handle

1000 kgs

of wet

sludge/

batch

To

Handle

1000 kgs

of wet

sludge/

batch

To

Handle

1000 kgs

of wet

sludge /

batch

To

Handle

1000 kgs

of wet

sludge /

batch

1 1 2 PP

30 Motor Control Center &

Electricals

Suitable Suitable Suitable Suitable 1 --- 1 ---

31 Interconnecting piping Suitable Suitable Suitable Suitable Lot Lot Lot HDPE


C) Instruments:

Sr.

No.

Description Size/

Capacity


Existing New Total Existing New Total

1 Magnetic Flow meter Suitable 2 Nos. --- 2 Nos. 2 Nos. --- 2 Nos. PP

2 PH Indicator 0-14 pH 2 Nos. --- 2 Nos. 2 Nos. --- 2 Nos. PP

3 Pressure gauge Dial Size Lot --- --- --- --- --- SS

4 Level Switch For

Equalization tank

- 2 Nos. --- 2 Nos. 2 Nos. --- 2 Nos. SS

5 Level Switch For

Intermediate tank

- 1 No. --- 1 No. 1 No. --- 1 No. SS


Effluent Treatment Plant (Proposed):


6.9 SOLID WASTE

The main solid waste from this factory will be (a) non-hazardous solid waste from office, garden leavesand (b) hazardous waste from process and bio sludge.

a) Non-Hazardous Waste

There will be no addition to non-hazardous waste

b) Hazardous Waste:



2. Mixed Carbon&Hyflow(Process)





6. Disposal of barrelscontainers used forhandling of hazardouswaste chemicals

33.3 1. Poly Bags : 54 kg/day



4. Centrifuge Bags: 2 kg/day





CHWTSDF

CHWTSDF

6.10 Power requirement and supply/Source

The total need for this proposed project is 1084 kW. The required power connection is available fromMSEDCL who will fulfil the need for new unit power.

Connected Load: 542 kW

Max. Demand: 1700 KW

Power Supply: (From MSEDCL)

Proposed power requirement: 1700 KW

D.G. Set: Proposed 1 750 KVA of DG set . 160.5 lit/h HSD will be require as a fuel.


CHAPTER 07

REHABILITATION AND RESETTLEMENT (R & R PLAN)

7.1 Policy to be adopt:

This project does not require acquisition of land and the infrastructure. Hence, there is no any kind of

activity of Rehabilitation and resettlement carried out over it.


CHAPTER 08

PROJECT SCHEDULE & COST ESTIMATES

8.1 Time schedule of the project:

BEC Chemicals Pvt. Ltd. has ability to complete their construction within 6-8 months and likely to be

completion the project for operation purpose.

8.2 Estimated proposed project cost (Economic viability of the project)

Estimated proposed project cost is approximately 30 Cr which is economically viable.

Estimated proposed capital cost of the project (Including cost for land, building, plant and machinery

separately)

Break Up:

Sr. No. Particulars Cost in Crores

1. Land Existing

2. Building/ premises 5.00

3. ETP, Plant & Machinery and

equipment’s

25.00

Total Cost 30


CHAPTER 09

ANALYSIS OF PROPOSAL

9.1 Financial and social Benefits

This project will benefit the local area by direct and indirect employment. This will directly improve the local

economy and the benefits to the state and country particularly from direct and indirect taxes, and increase in

GDP. The project will also contribute to exports thereby fuelling GDP growth and increasing foreign

exchange earnings.

M/s. BEC Chemicals Pvt. Ltd. is a new and expansion project proposed to manufacturing of API (Bulk

drug and intermediate)This proposed project does not pose any significant adverse impact on the

environment but will generate additional employment and also produce bulk drugs & its intermediates,

specialty chemicals, R & D Products with export potential or increase in foreign exchange reserves for

the country.

This helps financially for nation and social community also.

Hence, M/s. BEC Chemicals Pvt. Ltd. requests SEAC to recommend Environmental Clearance for

this proposed new project.

9.2 Emergency

An emergency could be defined as any situation which presents a threat to safety of persons and or

property, or environment. It may require outside help to bring the situation under control.

A major emergency occurring at work is one that may affect several departments within it and or may

cause serious injuries, loss of life, extensive damage to property or serious disruption outside the work. It

will require the use of outside resource to handle it effectively.

Usually the result of a malfunction of the normal operating procedures, which may also be precipitated by

the intervention of an outside agency, such as a severe storm, floods, crashed aircraft, earthquake etc.

Emergency due to operating conditions such as uncontrolled reaction, spark leading to small fire, slow

gas leak, failure of power, water, air, steam, cooling media, scrubbing media etc. These can be locally

handled by plant personnel alone without outside help. Hence,it is not considered as major emergency.

Operating instructions in the Safety Manual shall cover this area, though the on-site emergency plan is

also helpful.


9.3 Hazard

Hazard is a physical situation which may cause human injury, damage to property or the environment or

some combination of these criteria.

9.4 Risk

Risk is the likelihood of an undesired event i.e. accident, injury or death occurring within a specified

period or under specified circumstances. It may be either a frequency or a probability depending on the

circumstances.

9.5 The On-Site Emergency Plan

The On-site Emergency Plan deals with measures to prevent and control emergencies affecting person’s

property & the environment inside the premises.

It is mandatory for the manufacturer to provide the necessary information on the nature, extent and likely

effects of such incidents.

9.6 The Off-Site Emergency Plan

The Off-Site emergency plan deals with measures to prevent and control emergencies affecting general

public and the environment outside the premises.

The manufacturer has to provide the necessary information on the nature, extent and likely effects of such

incidents.

9.7 Objectives of the Emergency Plan

An emergency may not always be prevented but it can be controlled within limits and its effect can be

minimized by using the best resources available at the time.

Emergency planning is a management function and it is not being considered in isolation. Management

must evaluate the activities, operations and processes carried out within the works before starting to plan

an emergency operation.

A check is made to ensure that all required steps have already been taken which are included in

emergency planning.

Considering our number of employees, materials and processes, availability of resources, location of site,

size and complexity of the works, we have prepared this emergency plan.


In the text of our emergency plan, we have included the clear instructions as to what role is to be played

and by whom, without overlap or confusion for all concerned staff member.

The objectives of the Emergency Planning are as under:

(a) To define and to assess emergencies, including risk and environmental impact assessment

(b) To prevent the emergency turning into a disaster.

(c) To safeguard employee’s and people in vicinity.

(d) To minimize damage to property or/and the environment.

(e) To inform employee, the general public and the authorities about the hazards/risks assessed,

safeguards provided residual risk if any and the role to be played by them in the event of emergency.

(f) To be ready for 'Mutual Aid' if need is arises to help neighbouring unit. Normal jurisdiction of an OEP

is the own premises only, but looking to the time factory in arriving the external help of off-site plan

agency, the jurisdiction must be extended outside to the extent possible in case of emergency occurring

outside.

(g) To inform authorities and mutual aid centres to come for help.

(h) To effect rescue and treatment of causalities.

(i) Identify and list in case of any death.

(j) To inform and help relatives.

(k) To secure the safe rehabilitation of affected areas and to restore normalcy at the earliest.

(l) To provide authoritative information to the news media.

(m) To preserve records, equipment’s etc. and to organize investigation into the cause of the emergency

and preventive measures to stop its recurrences.

(n) To ensure safety of the works before personnel re-enter and resume work.

(o) To work out a plan with all provisions to handle emergencies and to provide for emergency

preparedness and the periodical rehearsal of the plan.


Annexure – I

Site Layout Plan

RIA - CETP CO - OPERATIVE SOCIETY LIMITED

(Regn. No. RGD/RHAfGNU(O)904/94 dtd 7.9.94) RlRC Bldg., Plot No. 6, M.I.D.C. Dhatav, Roha - Raigad - 402 116.

Tel. : 021 94 - 263599, Fax : 264594

Bec Chemicals Private Limited, Plot No. 24, MlDC Indl. Area, Roha.

Sub: Capacity booking in CETP.

Dear Sir,

This refers to your letter dated 1.07.2015.

We hereby state that your unit at plot no. 24 has booked capacity o f 300 m3/day water consumption in the present CETP set up.

We have received your request for additional capacity booking o f 100 m3/day water consumption. This issue will be discussed and reviewed in Executive Committee.

Ref. : BEC/ROHA/ADM/l 5- 161 5 5 Date : 01/07/2015

To, The Chairman / Secretary RIA-CETP Co-Operative Society Limited R.I.R.C. Bldg, Plot No.6, M.I.D.C., Dhatav,

. Roha-Raigad-402 1 16

Subiect : Booking for additional water capacity

Dear Sir,

We BEC Chemicals Pvt. Ltd., is member of CETP and our existing booked capacity of water consumption is 300CMlday. However, in view of upcoming projects there are probable chances of increase in additional 100 CMIday water consumption.

Therefore, please book our additional capacity of 100 CMIday, so that it will. become 400 CMlday in totality and let us know our additional contribution considering capacity enhancement and operational charges..of CETP.

' Kindly issue us the certificate for total booked water corisumption/day.

Thanking You,

Yours Faithfully, For, BEC Chemicals Pvt. Ltd.

A- P.B. Girase o \ - i5q * \ c-

General Manager- Works

CIN No. 028932MH1458PTC011230 Head Office:- 5-86) IBI House, Andheri, Kurla Road, Marol Naka, Chimat Padas

Andheri (East) Mumbai No. 400 059, India. Tel :- 02228505152

BEC Chemicals Pvt. Ltd. Plot No. 24. MIDC. Dhatav.Roha. District - Raiqad.Maharashtra - 4021 16. India

T: +91-2194-263551152 1 F: +91-2194-263613 1 E: info@ becchemicals.com I W: www.becchemicals.com

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