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TRANSCRIPT
PRE-FEASIBILITY REPORT
(Proposed Expansion of Inorganic Chemical Manufacturing unit to APIs, API intermediates &
Inorganic chemical Manufacturing Unit with R&D)
of
M/s. Bhagyanagar Chlorides Pvt. Limited Sy. No. 54/1,
Saggonda (V), Gopalapuram (M), West Godavari District, Andhra Pradesh
February 2016
Contents
S. No. Description
Page No.
1.0 Executive Summary 1
1.1 Salient Features of the Project 1
2.0 Introduction 3
2.1 Identification of the Project and project proponent 3
2.2 Brief description of Nature of the Project 3
2.3 Need for the Project and its importance to the country and or region
4
2.4 Demand and Supply Gap 5
2.5 Imports Vs. Indigenous production, Export Possibility, Domestic/Export Markets
5
2.6 Employment Generation due to the proposed expansion project 6
3.0 Project Description 6
3.1 Type of the project 6
3.2 Location 6
3.3 Alternate sites 6
3.4 Size or magnitude of operation 7
3.5 Project description 9
3.6 Raw materials 9
3.7 Resources optimization / recycling and reuse 10
3.8 Availability of water and Energy 10
3.9 Quantity of Wastes Generation and their Management /
Disposal 11
3.9.1 Water requirement and Wastewater generation and their
Management / Disposal 11
3.9.2 Solid Waste Generation, Handling and their Disposal 13
3.10 Schematic flow sheet for EIA procedure 15
4.0 Site Analysis 15
4.1 Connectivity 15
4.2 Land Form, Land use and Land ownership 15
4.3 Topography 15
4.4 Existing Land use pattern 15
4.5 Existing Infrastructure 16
4.6 Soil Classification 16
4.7 Climate data from Secondary sources 16
S. No. Description
Page No.
4.8 Social Infrastructure 16
5.0 Planning 17
5.1 Planning Concept 17
5.2 Population Projection 17
5.3 Land use planning 17
5.4 Assessment of Infrastructure Demand 17
5.5 Amenities/Facilities 18
6.0 Proposed Infrastructure 18
6.1 Industrial Area 18
6.2 Residential Area 18
6.3 Green Belt 18
6.4 Social Infrastructure 18
6.5 Connectivity 18
6.6 Drinking Water management 18
6.7 Sewerage System 19
6.8 Industrial Waste Management 19
6.9 Solid Waste Management 22
6.10 Power Requirement & Supply / Source 22
7.0 Rehabilitation and Resettlement (R&R) Plan 22
8.0 Project Schedule & Cost Estimates 22
8.1 Time Schedule for the project construction 22
8.2 Estimated project cost 22
9.0 Analysis of proposal (Final Recommendations) 23
9.1 Budgetary allocation for Pollution Control Measures 23
List of Tables
Table Title Page No.
1 Coordinates of all Corners of the Project Site 6
2 Permitted (Existing) Products and their Capacities 7
3 Proposed Products, their Capacity and Therapeutic Category 8
4 Permitted and Proposed Products, their quantities and its Status
9
5 Existing Water Requirement, Wastewater Generation and its Treatment 11
6 Proposed Water Balance and segregation and Treatment Method 12
7 Effluent Quantity and Treatment Flow as per segregation 13
8 Solid Waste Generation from the Existing Products 14
9 Solid Waste Generation from the Proposed Products 14
10 Environmental Components Shortest distance from Project Periphery 15
11 Breakup of proposed landuse Pattern 17
12 Maximum Quantity of Process emission for Proposed Products 19
13 Stack Emission Details – Proposed 21
14 Budgetary allocation for pollution Control Measures 24
LIST of Annexures
Annexure No.
Title Page No.
I Certificate of Incorporation 25
II CFE from APPCB vide No. 3335/PCB/ZO-Vsp/Tech/2007 dated 17-08-2007
26
III CFO from APPCB vide order no. 3335/APPCB/ZO-VSP/Tech./2013
dated 24-10-2013
30
IV General location of the Proposed Project 34
V Specific Location of the Proposed Project 35
VI Google map showing the coordinates 36
VII Plant Layout 37
VIII Typical Manufacturing description & Flowchart for proposed products 38
IX Raw Materials required for the manufacture of Proposed products 53
X Hazardous chemicals list 60
XI Ground Water analysis report 61
XII Proposed Effluent Treatment Plant Flow Diagram 62
XIII Schematic Flow Sheet for EIA Procedure 63
XIV Topography Map – 10km radius 65
XV Soil Analysis Report 66
Other Annexure
XVI Seismic Map of India 67
M/s Bhagyanagar Chlorides Pvt. Ltd. Pre-Feasibility Report
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Pre-Feasibility Report for Expansion of Inorganic Chemical Manufacturing unit to APIs, API intermediates & Inorganic chemical
Manufacturing Unit with R&D facility
1.0 Executive Summary
M/s. Bhagyanagar Chlorides Pvt. Ltd. proposes to expand its Inorganic Chemical
manufacturing unit to Active Pharmaceutical Ingredients (APIs), API Intermediates & Inorganic
chemical manufacturing Unit with R&D facility located at Sy. No.: 54/1, Saggonda (V),
Gopalapuram (M), West Godavari District, Andhra Pradesh with a total investment of Rs.
54 Crores including the existing investment of Rs. 14 Crores.
The proposed expansion project falls under the Category ‘A’, project or activity 5(f)
according to the EIA Notification 2006.
1.1 Salient Features of the Project:
• The existing unit was established in 2007 and obtained CFE from APPCB in 2007.
• Proposing expansion in the existing area with extended land from 2.17 Ha to 4.3 Ha.
• The proposed expansion project is to manufacture 10 products with R&D activity on
campaign basis i.e., 2 regular and 3 campaign products at a time with a production capacity
of 15845 TPA (existing 10800 TPA).
• Total Greenbelt area is 1.46 Ha (34%).
• Industry obtained CFE for manufacturing Inorganic Chemicals from APPCB vide order
no. 3335/PCB/ZO-Vsp/Tech/2007 dated 17-08-2007. Latest CFO was issued by APPCB vide
order no. 3335/APPCB/ZO-VSP/Tech./2013-723 dated 24-10-2013 valid upto 31-05-2016.
• This proposed expansion project site is located at an aerial distance of
i. 21 km to NH16 at Kovvur in SE direction which connects to Rajamundry, Chennai in South and Vishakapatnam, Bhubaneshwar, Jharpokharia in NE
ii. Gopavaram village at 1 km in W direction
iii. Kovvur railway station at 23 km in SE direction
iv. Gopalapuram (Mandal Headquarters) at 10 km in SW
v. Eluru (District Headquarters) at 72 km in SW direction
vi. Rajamundry Airport at 23 km in SE direction.
• Total cost of the expansion is Rs. 54 Crores. Total capital cost allocated towards
environmental pollution control measures is Rs. 6.92 crores including existing investment of
Rs. 0.97Crores. Recurring cost after expansion will be about Rs. 6. crores per annum.
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• Total water requirement will be about 250 KLD of which fresh water requirement will be 163
KLD and balance 87 KLD will be recycled water from ETP. Fresh water will be met from
Groundwater from existing Bore wells.
• The proposed power requirement of the plant is 1120 KVA including existing 120 KVA. DG
sets are used as standby during power failure. Diesel of about 220 lit/hr will be used in the
proposed 500 KVA and 2 x 250 KVA DG sets along with existing DG sets of 62.5 KVA & 20
KVA.
• Total 130 employees including existing 60 nos. will be benefitted due to the proposed
expansion project. Out of which direct 110 and indirect 20 employees.
• Coal of about 40 TPD (with 4000 Kcal) / husk of about 50 TPD (with 3000 Kcal)/ Briquettes of
about 40 TPD (with 4000 Kcal) will be used in the proposed 2 x 5 TPH coal/husk/Brickets
(Ground nut Briquettes) fired boilers. Diesel of about 20 lph will be used for Proposed 2 lakh
Kcal./hr Thermic Fluid Heater.
• Industry will provide additional dual scrubbers based on the characteristics of process
emissions. Boilers will be provided with multi-cyclone separator & bag filter to reduce the
particulate emissions into atmosphere.
• The wastewater generated from the plant will be about 99 KLD from process, washing,
utilities, DM regeneration, scrubber, Q.C, R&D and domestic wastewater.
• The effluent will be pumped to the above ground level R.C.C lined tanks for storage and
neutralization then sent to proposed upgraded ETP-ZLD of 120 KLD capacity within the
premises.
• Domestic wastewater will be sent to septic tank and the overflow to ETP - ZLD.
• Hazardous waste will be segregated and collected in the HDPE drums / bags as appropriate
and will be stored in the covered and raised platform with provision of leachate collection
system.
• Solid waste like boiler ash will be sent to cement brick manufacturers.
• Compressors, Boilers and DG sets will be the major noise generating units in the plant. Out
of these, the generator will be functioning at the time of power failure. Built-in acoustic
enclosures provided for D.G. set unit to minimize the noise levels. However the workers in
this area will be provided with ear muffs.
Industry has uploaded for Form-I along with draft Terms of Reference (ToR) in MoEF&CC
website, in the process of obtaining ToR for preparation of EIA, in line with issue of Environmental
Clearance. Hence, a technical pre-feasibility report highlighting the expansion project and the
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various operations including waste generation and mitigation measures are prepared & submitted
to the Environmental Appraisal Committee (EAC) for issuing ToR.
2.0 Introduction
2.1 Identification of the Project and Project Proponent
The present unit was originally established in 2007. M/s. Bhagyanagar Chlorides Pvt. Ltd.
ROC copy is enclosed as Annexure-I. Industry proposed to expand its Inorganic Chemical
manufacturing unit to Active Pharmaceutical Ingredients (APIs) and API Intermediates
manufacturing with R&D facility in the total area of 4.30 Ha (incl. existing 2.17 Ha) located at
Saggonda Village, Gopalapuram Mandal, West Godavari, Andhra Pradesh. The proposal is to
obtain Environmental Clearance from the Ministry of Environment, Forests and Climate Change
(MoEF&CC) and Consent for Establishment from APPCB.
• Industry’s first obtained CFE from APPCB vide No. 3335/PCB/ZO-Vsp/Tech/2007 dated
17-08-2007 (Annexure-II).
• Latest CFO was issued by APPCB vide order no. 3335/APPCB/ZO-VSP/Tech./2013 dated
24-10-2013 valid upto 31-05-2016 (Annexure-III).
• Total investment for the proposed project is about Rs.54 Crores including existing investment
of Rs.14 Crores.
• Total production capacity is 15845 TPA (existing 10800 TPA), from 2 Regular and 3 campaign
at a time will be manufactured with R&D activity.
Project Proponent:
The Bhagyanagar Chlorides is promoted by Shri A.V.S. Prasad, Managing Director having
more than 25 years of experience in the same field. His vision and hard work were the key
factors for the growth of the company.
Shri P. Srinivasa Rao, Jt. Managing Director joined the industry in 2007. He has B. Tech
(Mechanical Engg.) from Bangalore University, and has over 31 years of experience in varied
aspects of business including technology transfer, SCM, Business Development and Finance.
2.2 Brief Description of Nature of the Project
The project proponent proposed to expand existing Inorganic Chemical manufacturing unit.
As per EIA Notification 2006, the project is 5 (f) Synthetic Organic Chemical Industry (Bulk Drug
(API) & Intermediates). The products manufactured are used in API formulation industry and the
therapeutic category of the products is Antifungal, Antiulcerative, Antibacterial, Bronchodilator,
Antihypertensive etc., which are applicable for human consumption around the world after
formulation activity.
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The manufacturing process of APIs consists of chemical synthesis and multiple stage of
processing extending to maximum of Ten stages involving different types of chemical reactions.
The entire process operations are operated by various technical, skilled and unskilled persons with
due care to be met various standards prescribed by authorities.
Technology for manufacturing the products listed under proposed expansion is available
from in-house R&D & private consultants and proposes to adopt new technologies and techniques
that are continuously refined in every stage of manufacturing to meet global standards. Industry
will implement the proven technologies in the R&D for the cost effective & environment friendly
practices.
2.3 Need for the Project and its Importance to the Country and or Region
The Indian pharmaceutical industry valued at $16 billion has portrayed tremendous
progress with reference to infrastructure development, technology base creation and a
wide range of production. India has achieved an eminent global position in pharma
sector. The Indian pharmaceuticals market is third largest in terms of volume and thirteen
largest in terms of value, as per a pharmaceuticals sector analysis report by equity master.
The market is dominated majorly by branded generics which constitute nearly 70% to 80%
of the market. The Indian pharmaceutical industry is estimated to grow at 20% compound
annual growth rate (CAGR) over the next five years, as per India Ratings. The domestic
pharma growth rate was 11.9% in October 2015.
It is estimated that by the year 2015, the Indian pharmaceutical industry has the potential to
achieve over Rs.2,00,000 Crore in formulations and bulk drug production. The industry now
produces bulk drugs belonging to all major therapeutic groups requiring complicated
manufacturing process and has also developed Good Manufacturing Practices (GMP)
facilities for the production of different dosage forms.
The pharma industry exports APIs and pharmaceuticals worth over $ 14.9 billion in 2013-
14. It ranks 17th in terms of export value of bulk activities and dosage. Indian exports cover
more than 200 countries including the highly regulated markets of USA, Europe, Japan and
Australia.
At a growth rate of 12% per year, the pharmaceutical industry in India is well set for rapid
expansion. As a result of the expansion, the Indian pharmaceutical and healthcare market
is undergoing a spurt of growth in its coverage, services, and spending in the public and
private sectors.
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2.4 Demand and Supply Gap
The products manufacture by the proponent has demand from China, Japan, Middle East,
Latin American countries and other Asian countries etc. In addition, the products are consumed in
domestic market by Dr. Reddy labs, Mylan etc. It is reported that there is increase in the
consumption of these products by about 5-6% every year. As Indian industries are importing from
neighbouring countries and western countries, indicates the gap in the demand and supply of the
products in the domestic markets.
2.5 Imports vs. Indigenous production, Export Possibility, Domestic/Export Markets
Presently China is dominating in the API (bulk drug) market the world over. India is
importing all major intermediate chemicals required for manufacturing lifesaving drugs i.e., Anti-
Cancer Drugs, Anti ulcerative, etc. We are importing from China – the Third generation Antibiotics
mainly Cephalosporin intermediates that are of very high value. Most of our imports are from
Chinese companies and thus we are losing our valuable foreign reserves to China. As mentioned
above the imports have gone up from $ 2.9 billion in 2011 to about $ 4.6 billion in 2012 on account
of APIs, Pharmaceuticals and fine chemicals. During the same period the imports of formulations
has also doubled. The Chinese, American and European markets play a very vital role in the
supply of these products to our country. This clearly indicates that there is tremendous scope for
developing the indigenous products by reducing the imports and thus saving the foreign exchange
reserves of the country. This potential can be utilized to the fullest extent possible by increasing
the production capacity of the existing industries or by establishing new industries to meet the
market demand of the products.
As it is a well known fact that Indian products are well accepted abroad for its quality and
marketing flexibility. The exports from the Indian companies to other foreign countries such as
Europe, America, Japan and other African countries has been increasing from Rs.8007 in 2005 to
Rs.16565 Crores in 2009. This shows the acceptability of the products produced in India. The
formulations market has shown a tremendous increase in the exports from about Rs.9500 to
Rs.23700 Crores during the same period. However, the basic raw material for formulations is
APIs. Hence, this sector has a tremendous potential of indigenous market as well as export market
and the promotion of such projects will not only help by way of generation of employment but also
by generation of foreign currency reserves for the country. The figures mentioned above are
sourced from BDMA.
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2.6 Employment Generation due to the Proposed Project
The following Table shows the manpower requirement after expansion of the proposed
project:
Type Existing (No. of persons)
Proposed (No. of persons)
Total after Expansion
Direct 60 50 110 Indirect - 20 20 Total 60 70 130
3.0 Project Description
3.1 Type of the project
Proposed expansion project of APIs & API intermediates falls under category ‘A’ as per EIA
Notification 2006 under the item No. 5 (f). There are no interlinked projects.
3.2 Location
The unit is located at 54/1, Saggonda (V), Gopalapuram (M), West Godavari District,
Andhra Pradesh. The proposed project expansion site has coordinates of all corners is presented
in Table 1. The study area represents Rural Environment.
Table 1: Coordinates of all corners of the Project site
Sl. No. Latitude Longitude
1. 17°10'22"N 81°36'12"E 2. 17°10'32"N 81°36'12"E 3. 17°10'32"N 81°36'18"E 4. 17°10'26"N 81°36'18"E
The map showing general location, specific location, Google map showing the Coordinates
and plant layout of the Total Project and existing project is enclosed at Annexures IV, V, VI & VII
respectively.
3.3 Alternate sites
This proposed expansion project is in the existing and additional plant area at Saggonda
village. Hence no alternate sites were considered.
Environmental considerations of this expansion project site.
This expansion site is in existing industry with additional plain land.
> 1 km away from human habitation,
The Andhra Sugars Limited industry is located at 1.4 km in NE which is a major raw material of
Chlorine supplier.
4.2 km (W) away from canal near Rampalem
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5 km (E) away from Godavari river.
There are 5 reserve forests.
• Polavaram RF (Mixed Jungle) 8 km N
• Gopavaram RF (Dense Jungle) 2.5 km SW
• Vinjaram RF (Mixed Jungle) 8.3 km NNW
• Gangolu RF (Dense mixed Jungle) 3.5 km NW
• Karakapadu RF (Mixed Jungle) 9.2 km W
Exist Transportation and Communication network
There are no rare or endangered or endemic or threatened (REET) species of animals or birds.
3.4 Size or magnitude of operation
Project Area: 4.30 Ha. (incl the existing 2.17 Ha)
Production Capacity: 15845 TPA from 5 out of 10 products on regular and campaign basis.
Products: The permitted and proposed products along with its production capacities are
presented in Tables 2 and 3 respectively.
Table 2: Permitted (Existing) and their Capacities
SI. No. Product Existing Products
Quantity Regular Product (kg/day) (TPA) 1. Aluminum Chloride anhydrous 30000 10800
By products 1. Hydro Chloric Acid 83.3 Liters 30 KL 2. Sodium Hypo Solution 83.3 Liters 30 KL
Source: M/s. Bhagyanagar Chlorides Pvt. Ltd.
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Table 3: Proposed Products, their Capacity and Therapeutic Category
Sl. No.
Product name Quantity (Kg/day)
Quantity (TPA)
Therapeutic Category / Intermediate /
Chemical
Regular Products
1. Aluminum Chloride anhydrous 30000 10800 Inorganic raw material
2. Benzo Trichloride 6666.67 2400 Raw Material for Acetyl Chloride &
Chloro acetyl chloride
Campaign Products
3. Fluconazole 333.33 120 Antifungal
4. Pantoprazole Sodium 233.33 84 Antiulcerative
5. Ciprofloxacin Hydrochloride 666.67 240 Antibacterial
6. Salbutamol Sulfate 333.33 120 Bronchodilator
7. Ramipril 300 108 Antihypertensive
8. N,N-Diethyl cyanoacetamide 200 72 Entacapone intermediate
9. Acetyl chloride 3333.33 1200 Raw material for APIs
10. Chloro acetyl chloride 3333.33 1200 Raw material for APIs
Production (Maximum 5 Products at a time)
44000 15840
R&D 13.88 5
Total Production with R&D (Maximum 5 Products at a time)
44013.88 15845
Source: M/s. Bhagyanagar Chlorides Pvt. Ltd.
List of By-products
SI. No. Name of the By-Product Quantity
(KL/day) Quantity (KL/A) Name of the Product
1. Hydro Chloric Acid (25%) 9 3240 KL
Benzotrichloride, Chloro acetyl chloride,
Salbutamol Sulfate Fluconozole
Aluminum Chloride anhydrous
2 Sodium Hypo Solution 83.3 Liters 30 KL Aluminum Chloride anhydrous
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Table 4: Permitted and Proposed Products, their quantities and its Status
Sl. No.
Product name Permitted
(TPA) Proposed
(TPA)
Total After Expansion
(TPA) Status
Regular Products
1. Aluminum Chloride anhydrous 10800 -- 10800 Existing
2. Benzo Trichloride -- 2400 2400 New
Campaign Products 3. Fluconazole -- 60 60 New
4. Pantoprazole Sodium -- 36 36 New
5. Ciprofloxacin Hydrochloride -- 120 120 New
6. Salbutamol Sulfate -- 60 60 New
7. Ramipril -- 60 60 New
8. N,N-Diethyl cyanoacetamide -- 36 36 New
9. Acetyl chloride -- 1200 1200 New
10. Chloro acetyl chloride -- 1200 1200 New
3.5 Project Description with Process Details
The manufacturing process of APIs consists of chemical synthesis extending to maximum
of 10 stages of processing involving different types of chemical reactions. Typical process
description with process details is enclosed at Annexure-VIII. These drugs are mainly used for
human Medication after Formulation activity for various diseases. Industry will implement the
proven technologies in the R&D for the cost effective & environment friendly practices. The plant
layout showing existing and proposed components of the project is enclosed at Annexure-VII.
3.6 Raw Materials
The raw materials required for the manufacture of proposed products are the chemicals
and the fuel.
• The APIs & API Intermediates manufacturing involve the use of various chemicals and
organic solvents either directly as reactant or for extraction of a product of interest from the
reaction mixture.
• Coal / Husk / Briquettes consumption will be 40 / 50 / 40 TPD for the proposed 2 x 5 TPH
coal/husk/Briquettes fired boilers.
• About 240 lit/hr diesel will be used at full operation load in the proposed 500 KVA and
2 x 250 KVA DG sets along with existing DG sets of 62.5 KVA & 20 KVA DG sets. and 2
lakh Kcal/hr Thermic fluid heater.
• The total power requirement of the proposed plant is 1120 KVA including existing 120 KVA.
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• Mode of transportation of all raw materials and finished products from the project site is by
road to local markets and by road / rail / sea if exported.
The chemicals (raw materials) required for the manufacture of proposed products is
presented at Annexure – IX and Hazardous chemicals list is presented at Annexure – X.
3.7 Resources Optimization / Recycling and Reuse
R&D facility in the unit is taking all efforts to recycle the wastes / reuse wherever possible.
However, R&D is a continuous process, where improvements in the processes adopted by the
industry, waste minimization etc. will be worked out as the project progresses. Following are some
of the recycle options proposed by the industry.
Industry is proposing for Zero liquid discharge plant to reuse all treated effluents as makeup
water for utilities like Cooling Tower. This will reduce the fresh water consumption.
Industry is proposing dedicated reactors for few products there by reducing the reactor
washings.
All solvents are recovered to the extent possible and reused in the process.
Organic residue and spent carbon will be sent to Authorized Cement industries to burn in
Cement Kiln as an alternate fuel.
Boiler ash will be sent to Cement Brick manufacturing units.
Waste / Used oil will be sent to Authorized Waste / Used oil Reprocessing units.
Container & container liners of hazardous chemicals, Polythene / HDPE Bags, broken plastic
drums shall be disposed of to outside agencies after complete detoxification.
Spent catalyst will be sent back to supplies
Waste Lead acid batteries will be sent back to suppliers on buy back basis.
Optimum utilization of solar energy.
Recycling and reuse of by-products, solvents generated during the process will also be
planned properly thereby implementing the clean manufacturing techniques.
3.8 Availability of Water and Energy
The total fresh water requirement is about 163 KLD which will be met from Groundwater
from existing bore wells. The proposal is to minimize the effect on the level of water table by
practicing reuse / recycling of the treated water wherever possible thereby reducing the fresh
water requirement. Water analysis report of the raw water at project is enclosed as
Annexure – XI.
The total power requirement will be met from Andhra Pradesh State Power Distribution
Corporation Limited (APSPDCL). Coal and Diesel will be procured from the distribution sources
closer to the project site.
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3.9 Quantity of Wastes Generation and their Management/ Disposal
3.9.1 Water requirement and Wastewater Generation and their Management/ Disposal
The permitted, proposed water requirement and wastewater generation with its proposed
treatment is presented in Tables 5 & 6 respectively. The sources of wastewater generation are
from the process, floor & reactor washes, utilities, Q.C, R&D, scrubber and plant domestic waste.
Total proposed wastewater will be 99 KLD, which will be segregated into HTDS/HCOD &
LTDS/LCOD and collected by gravity into a collection tank separately. This individual effluent will
be pumped to the above ground level R.C.C lined tanks for storage and neutralization then sent to
ETP-ZLD. The effluents segregated quantity, characteristics and treatment flow is briefly
presented in Table 7.
Table 5: Existing Water Requirement, Wastewater Generation and its Treatment
Description Water
Requirement (KLD)
Wastewater Generation
(KLD) Treatment Method
Process & Washings 0.5 0
Gardening / Irrigation 4 0
Domestic 2 2 Septic tank followed by soak pit.
Total 6.5 2
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Table 6: Proposed Water Balance, Segregation and Treatment Method
Description Input (KLD) Output (KLD)
Fresh Water
Recycled Water
Evaporation / Handling Loss
Total Wastewater
Segregation type of Wastewater
Process (5 products at a time)
44 -- 0 44 (46.5 Tons) HTDS/HCOD
Washings (reactor, centrifuges, nutch filters, containers, floor, etc.,)
10 - -- 10 LTDS/LCOD
Boiler (2 x 5 TPH)
57 (24 %
Makeup) 0
38 (16% loss)
8 (3% Blow
down) Utilities
(LTDS/LCOD)
11 (5 % - MEE
Steam condensate)
Cooling Tower 1500 TR
3 87 82.5 7.5
(Bleed)
DM Regeneration 5 -- - 5 HTDS / LCOD
Scrubber 12 - 9 3 HTDS / LCOD
Q.C and R&D 5 -- - 5 LTDS/LCOD
Domestic (130 nos @50 lpcd) 7 -- 1.5 5.5 LTDS/LCOD
Greenbelt (4 acres @ 5 KL/acre)
20 -- 20 - --
Total
163 87 151 99
Reuse: Stripper condensate 0.5 KLD; Moisture in salt and ETP sludge is 2 KLD, Water loss in ETP 9.5 KLD (Total water loss is 12 KLD = 12 %)
250 250
Note: 44 KLD is 46.5 Tons consists of 43.95 KLD liquid effluent and 2.6 Tons of salts (Max. on
various combinations) as per material balance.
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Table 7: Effluent Treatment Flow for as per Segregation
Effluent Characteristics
Quantity (KLD) Treatment Flow
Process, DM & Scrubber
HTDS/HCOD & (HTDS)
HTDS > 5000 mg/l HCOD > 5000 mg/l
52
Collection Equalization Neutralization Settling Holding Steam stripper MEE along with HTDS effluent Condensate to ETP (biological treatment) Concentrate to ATFD
ATFD Condensate to ETP (Biological Treatment) along with domestic wastewater (septic tank overflow) Pressure Sand Filter Activated Carbon Filter R.O R.O rejects to MEE.
R.O Permeate & MEE Condensate to cooling tower
ATFD Salts to TSDF and stripped solvents to SPCB authorized cement industries
Washings, Boiler, Cooling Tower, QC &
R&D LTDS / LCOD
LTDS < 5000 mg/l LCOD < 5000 mg/l
41.5 Collection Equalization Neutralization ETP (Biological Treatment) along with MEE Condensate
Domestic 5.5 Septic tank Overflow to ETP (Biological Treatment)
Proposing 120 KLD Effluent Treatment Plant system and flow chart is enclosed as
Annexure-XII. All the treatment tanks etc., will be constructed / installed above the ground with
water proof lining. This individual effluent will be pumped to the above ground level R.C.C lined
tanks for storage and neutralization then sent to ETP-ZLD.
ETP – ZLD facility consists of primary (equalization and neutralization), secondary (stripper
with MEE, ATFD & biological) and tertiary treatment (PSF, ACF & R.O) will be provided. Domestic
wastewater will be sent to septic tank and the overflow to ETP (biological treatment). Concentrate
from MEE system will be sent to ATFD and the salts from the evaporation system will be collected
and sent to TSDF for safe disposal.
3.9.2 Hazardous / Solid Waste Generation, Handling and their Disposal
Hazardous/ Solid waste will be segregated, detoxified and collected in the HDPE Drums /
Bags and will be stored in the covered and raised platform with Leachate collection system. The
existing and proposed solid waste and other waste generated, handling and disposal method from
the various stages of manufacturing plant is presented in the Table 8 & 9 respectively. Spillages
such as wastewater / solid wastes / raw material are possible and the risk of this would be limited
to within the premises of the manufacturing facility. A precautionary measure like spillage control
management is practiced in the industry.
M/s Bhagyanagar Chlorides Pvt. Ltd. Pre-Feasibility Report
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Table 8: Permitted Hazardous Waste Generation from the Existing Products
Sl. No. Source Permitted
Quantity (kg/day) Disposal Option
1. Used oil/ Waste lubricant oil 100 LPA Sent to Authorized Reprocessors/
Recyclers
Table 9: Proposed Hazardous / Solid Waste Generation from the Proposed Products
Sl. No. Source
*Proposed Quantity
(TPD) Handling Method Disposal
1. Organic residue 2.02
HDPE Drums
Sent to SPCB Authorized Cement industries / TSDF
2. Spent Carbon 0.12
3. Distillation Bottom Residue (1% of spent solvents)
0.4
4. Inorganic & Evaporation salt (Process) 3.13
HDPE Bags 5. Evaporation salt (Non-Process) 0.5
6. ETP Sludge with 50% moisture 0.6
7. Boiler Ash 16 Stored in covered area
Sold to Cement Brick Manufacturers
Other Hazardous Waste generation from the Plant
8.
a) Detoxified Container / Liners drums b) HDPE Carboys c) Fiber Drums d) PP Bags
300 Nos./ month
100
Kg/month
Designated covered area
Disposed to SPCB Authorized agencies after
complete detoxification
9. Spent solvents (with moisture) (solvents 35.5+water 1.5)
37 KLD Stored in Drums / Tanks
Recovery within the premises duly sending the residue to
Authorized agencies
10. Recovered Solvents from spent solvents 32 KLD
Stored in Drums / Tanks
Reuse in process / Send to authorized recyclers
11. Spent Mixed solvents (3.5 from SRS + 1 from ETP)
4.5 KLD Stored in Drums / Tanks
Sent to SPCB Authorized agencies
12. Waste oils & Grease 1.5 KL/A Stored in Drums
Sent to SPCB Authorized agencies for reprocessing /
recycling.
13. Used Lead acid Batteries
50 Nos. / annum
Designated covered area
Sent to suppliers on buy-back basis.
14. Misc. Waste (spill control waste) 12 TPA Stored in
Drums TSDF
15. Spent Catalyst (Raney Nickel) 24 TPA Stored in
Drums Sold to suppliers on buy-back
basis / auth. reprocessers. 16. Spent Piperazine HCl 1405 TPA * Solid waste quantities maximum on 5 products at a point of time
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3.10 Schematic Flow Sheet for EIA Procedure
The schematic flow sheet for EIA procedure is depicted as Annexure -.XIII.
4.0 Site Analysis
4.1 Connectivity
The proposed expansion project site is connected to NH16 at Kovvur in SE direction at a
distance of 21 km aerial distance, which connects to Rajamundry, Chennai in South and
Vishakapatnam, Bhubaneshwar, Jharpokharia in NE. Approach road also connecting to NH 42 at
Chityala which connect to Khammam in West and Kovvur in SE. Gopavaram village at 1 km (W);
The Andhra Sugars Limited (Major Raw material supplier) is at 1.4 km NE, Gopalapuram (Mandal
Headquarters) at 10 km (SW); Eluru (District Headquarters) at 72 km (S); Kovvur railway station at
23 km (SE) and Rajamundry Airport at 23 km (SE).
4.2 Land Form, Land use and Land Ownership
Total land is 4.30 Ha. is in possession of Project Proponent.
4.3 Topography
The Topography map with a 10 km radius is enclosed as Annexure-XIV.
4.4 Existing Land Use Pattern
The existing and proposed land use pattern of project area (core area) 4.3 Ha. Industrial
land and shortest distance of environmental components in buffer area from the project periphery
is given in Table 10.
Table 10: Environmental Components Shortest distance from Project Periphery
S. No.
Particulars Details (Distance & Direction w.r.t. site)
1. Water bodies • Canal near Rampalem – 4.2 km (W) • Godavari river – 5 km (E) • Pond near Kommy gudem – 6.3 km (N) • Pond near Bhimolu– 4.8 km (SW) • Canal near Bhimolu – 3.4 km (S) • Kovvada Kalva (Canal) - 4.3 km (N)
2. Reserve Forests No high quality or scarce resources are present in the buffer zone. Following Reserved forest blocks are present such as • Polavaram RF (Mixed Jungle) 8 km N • Gopavaram RF (Dense Jungle) 2.5 km SW • Vinjaram RF (Mixed Jungle) 8.3 km NNW • Gangolu RF (Dense mixed Jungle) 3.5 km NW • Karakapadu RF (Mixed Jungle) 9.2 km W
3. National Parks/ Wild Life Sanctuaries/ Eco
Nil
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sensitive areas 4. Agricultural land Adjacent 5. Non-Agricultural land Adjacent 6. Habitation Gopavaram Village
4.5 Existing Infrastructure
Internal CC roads, approach road connecting to NH16 at Kovvur in SE direction at a
distance of 21 km aerial distance, which connects to Rajamundry, Chennai in South and
Vishakapatnam, Bhubaneshwar, Jharpokharia in NE. Approach road also connecting to NH 42 at
Chityala which connect to Khammam in West and Kovvur in SE. Transportation facilities, water
supply, Power supply, Occupation Health Centre, Conference hall, Telecommunication facility etc.,
are available.
4.6 Soil Classification
The soil in the project site is Red and in the study area is mostly red in colour, containing
32.56% sand, 34.58% silt and 32.86% clay . The soil analysis report of the project site is enclosed
as Annexure-XV.
4.7 Climate Data from Secondary Sources
The tropical climate conditions with extreme hot summer and cold winter prevail in this
district. April to June are the hottest months with high temperature in May. The monsoon usually
breaks in the middle of June and brings good rains upto middle of October. The normal rainfall of
this district is 1077 mm. (Source: District Hand Book)
The climate of the district is moderate and characterized by tropical rainy climate with
aggressive summer. The period from December to middle of February is generally the season of
fine weather. The summer season is from March to May. This is followed by monsoon period from
June to September, the post monsoon from October to December and the winter season from
January to February.
4.8 Social Infrastructure
National Highway no. 16 (Chennai – Bhubaneshwar) is at 21 km (SE), road network,
transportation facilities, power supply, fire station and other basic amenities such as
telecommunication facility, education centre, hospitals, community halls are available at
Gopalapuram at 10 km (SW).
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5.0 Planning
5.1 Planning Concept
Type of Industry: The proposed expansion project is of Inorganic Chemical manufacturing unit to
APIs, API intermediates & Inorganic chemical Manufacturing Unit with R&D facility.
Facilities: Industry proposed for expansion at existing and additional land and facilities required
for the project will be provided as per requirement.
Transportation: Transportation of raw material and final products is done via roads as the
proposed project is well connected with roads, rail and airways.
Town and Country Planning Classification: This is existing industry land and additional land is
private land, converted to industrial use and is in possession of project proponent.
5.2 Population Projection
There is a scope for increase in the population from the proposed expansion project.
Skilled workers prefer to stay in the nearby locations to avoid travelling from long distances. Local
Non-technical villagers will be preferred for the unskilled jobs such as gardening, movement of
materials, etc. Local / Non local educated youth will be employed as semi-skilled workers and
training will be provided. Hence, there is a possibility of increase in population of the skilled and
semi-skilled. However, on the whole there is a possibility of little increase in population of the area.
5.3 Land use Planning
The expansion unit has been proposed in the existing and additional land. Land use
pattern of the Project area is given in Table 11.
Table 11: Break up of proposed land use pattern
S. No.
Purpose
Existing Area
Proposed Area Total Area
% Sq.m Sq.m Sq.m 1. Built up area 1775.5 4682.92 6458.42 15.01 2. Roads 560 5380.46 5940.46 13.81 3. Green belt 10000 4642.47 14642.47 34.05 4. Open area
7909 8067.4 15661.29 36.4
5. Truck Parking Area 315.11 0.73
Total 20244.5 22773.25 43017.75 100
5.4 Assessment of Infrastructure Demand
On assessment of infrastructure demand near the project area Hospital with Ambulance
facility and Fire station is requirement for the nearby villages of project area.
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5.5 Amenities/Facilities
Industry will continue to provide and upgrade the following amenities / facilities in the
proposed expansion project.
• Canteen • Potable drinking water • Training block • Laying of Black top / Concrete internal roads • Fire hydrant facility • Eye/body wash showers • First Aid kits at all prominent places. • Head nurse for emergency medication. • Rest Room for employees • Seating facilities for those employees who do their work standing and ergonomically
designed sitting facilities for those who do their work sitting • Pre-employment and routine medical examinations and the necessary follow up actions • Communication systems like Phone, Internet with safety measures, etc. • Security system at the entrance etc.
6.0 Proposed Infrastructure
6.1 Industrial Area
Additional production blocks, administration facilities, utility area, ETP area are been
proposed in the expansion area.
6.2 Residential Area :
There will be no residential area within the project site.
6.3 Greenbelt
The expansion unit has been proposed in existing with extension area about 4.30 Ha i.e.,
43017.75 sq.m. Out of which about 1.46 Ha i.e.14642.47 sq.m is allocated for Greenbelt area
which is equivalent to 34% of the total area.
6.4 Social Infrastructure
As a Corporate / Entrepreneur Social Responsibility (ESR), Industry will contribute for
development of village social infrastructure.
6.5 Connectivity
There is no change in connectivity compare to existing facility.
6.6 Drinking Water Management
Potable drinking water will continue to be provided to all employees. The source of drinking
water is Groundwater.
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6.7 Sewerage System
Sewage will be generated from the Canteen and Toilets, which will be collected into
sewage collection tank through pipelines and septic tank respectively. Overflow of these tanks will
be sent to ETP – ZLD system which needs to be upgraded to meet the expansion project demand.
6.8 Industrial Waste Management
Existing storage system needs to enhance to meet the expansion project demand. The
management of these wastes is to be handled very sensitively and by adopting proper segregation
techniques.
Liquid Waste Management: The liquid wastes from the various industrial activities will continue to
be segregated and send to ETP-ZLD.
Process Emissions Management:
Manufacturing of APIs and API intermediates will result in gaseous emissions. Maximum
Process emissions from proposed products are given in Table 12 respectively. Proposed gaseous
emissions will be scrubbed in two stage scrubbers with water or other liquid based on the
characteristics of gases.
Table 12: Maximum Quantity of Process Emission for Proposed Products
Sl. No.
Process Emission
Maximum Quantity on various combinations
(kg/day) Treatment Method
1. HCl 2686.5 Scrubber with water / caustic sol.
2. NH3 7.17 Scrubbed by using Chilled water
3. H2 23.77 Diffused with flame arrestor
4. CO2 252.73 Dispersed into atmosphere
5. SO2 49 Scrubber using caustic sol.
6. N2 6.67 Dispersed into atmosphere
Fugitive emissions Management:
Solvents used in the APIs & API intermediates manufacturing process will be stored in drums and bulk quantities will be stored in underground/ above ground storage tanks.
Solvents are handled in closed conditions thereby reducing the losses in the form of evaporation.
Proper earthing will be provided to all the electrical equipment and the joints / connections wherever solvent handling is done.
Reactor and solvent handling pump will have mechanical seals to prevent leakage.
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The industry will take measures for reduction of fugitive emissions and for further reduction industry will provide vent condensers to the tanks.
Chilled brine circulation will be carried out to condensate the solvent vapour and to the receivers of the solvent vapors which ensures the maximum recovery.
Solvent vapours from the Centrifuge and Catch pots will be connect to vent condensers.
The height of the solvent receiver tank vent is above production block roof level and the diameter is 20 mm.
Flame proof fitting / equipments / pumps / lighting will be used wherever solvents are used. The solvent storage tanks will be provided with breather valve to prevent losses.
Combination Solvent
Input
Solvent Loss in Effluent
Solvent Loss in
Org. residue
Solvent Loss
(Handling)
Solvent Recovery
Solvent Recovery
(KLD) (KLD) (KLD) (KLD) (KLD) (%) 1 37.6 0.13 0.9 1.75 35.3 94 2 25.5 0.16 0.29 1.34 23.71 93 3 35.9 0.15 0.43 1.76 33.63 94
Maximum on various combination 37.6 0.16 0.43 1.76 35.3 94
Emissions from Utilities Management:
Boilers and DG sets are the two main sources contributing to emissions from the plant. The
proposed coal/ husk/ Briquettes fired boilers will be used for 2 x 5 TPH Boilers. Diesel will be used
for 2 lakh Kcal./hr TFH and Proposed 2 x250 KVA and 500 KVA DG Sets, existing 20 KVA & 62.5
KVA. DG Sets will be used as standby power during power failures. The emissions from the boiler
are given in Table 13.
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Table 13: Stack Emission Details
Source Stack Height
(m)
Diameter (m)
Temperature
( oC)
Flue Gas Flow rate
(m3/hr)
Exit Gas Velocity (m/sec)
PM SO2 NOx
kg/hr
Proposed Boilers
5 TPH 30 0.62 150 13104 12.88 0.747 7.47 5.22
5 TPH 30 0.62 150 13104 12.88 0.747 7.47 5.22
Proposed Diesel fired thermic fuel heater
2 lakh Kcal/hr
TFH 30 0.3 150 867.61 3.4 0.004 0.087 0.093
Proposed D.G sets
500 KVA 9 0.3 150 2822.4 11.10 0.031 0.625 0.671
250 KVA 8 0.2 150 1411.2 12.48 0.015 0.312 0.335
250 KVA 8 0.2 150 1411.2 12.48 0.015 0.312 0.335
Existing D.G sets 62.5 KVA 6 0.08 150 352.8 19.54 0.003 0.078 0.083
20 KVA 5 0.06 150 111.6 11.10 0.001 0.025 0.026
The various measures proposed to minimize the pollution from the boiler are as follows:
Multi-cyclone separator followed by Bag filter will be installed to control the particulate (PM)
emissions within statutory limit of 115 mg/Nm3. To facilitate wider dispersion of pollutants,
30m height stack each will be installed.
The NOx emissions from the boilers will be controlled by controlling combustion measures,
which will be approached by way of low NOx burners or by air stagging in boiler. The NOx
emissions will be restricted to below 500 mg/Nm3.
Stacks will be provided to proposed D.G sets as per CPCB / SPCB Guidelines.
Fugitive dust will be controlled by adopting dust extraction and dust suppression measures
and development of greenbelt along the periphery of the proposed Boiler area.
Noise Management:
• Compressors, Boilers and DG sets will be the major noise generating units in the plant.
• The noise levels of the DG sets will be well within the limits as these will be installed with
acoustic enclosures. Workers will always be provided with ear muffs.
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• All the equipment in the plant would be designed to have a total noise level not exceeding
85-90 dB(A) as per the requirement of OSHA (Occupational Safety and Health
Administration) standards.
6.9 Hazardous / Solid Waste Management
• Solid waste mainly segregated into process organic residues, inorganic salts, boiler ash
spent mixed unrecoverable solvents and spent carbon.
• The organic residues, Spent carbon & Spent mixed unrecoverable solvents can be
disposed off to Cement plants as recommended by CPCB for use as alternate fuels either
in the solid or liquid form.
• Boiler ash will be sold to brick manufacturers.
• Inorganic salts are to be sent for landfill at HWMP – TSDF.
Solid waste will be segregated, stored and disposed as mentioned in the Table 8
6.10 Power Requirement & Supply / Source
Power supply of 1120 KVA will be drawn from the nearby sub-station of APPDC. D.G. set
will be used as alternate arrangement in case of failure in power supply. Proposed 2 x 250 KVA &
500 KVA D.G. sets in addition to the existing 62.5 KVA and 20 KVA DG sets.
7.0 Rehabilitation and Resettlement (R&R) Plan
The proposed additional land is plain land adjacent to the existing land and is in
possession of project proponent. Therefore Rehabilitation and Resettlement plan is not applicable
to this expansion project site. The nearest habitation is away from 1 km away from the project site.
8.0 Project Schedule & Cost Estimates
8.1 Time Schedule for the project construction
The timelines for commencement of proposed construction activity will be from
December 2016 as it is expected that the expansion project will be in a position to obtain
Environmental Clearance & Consent for Establishment for the project. In 2017-18 the commercial
production is expected to be commenced.
8.2 Estimated project cost
Overall estimated cost involved in the total project (existing and proposed) like land,
building, plant & machinery is Rs. 54 Crores including existing Rs. 14 Crores. Total capital cost
allocated towards environmental pollution control measures is Rs. 5.95 Crores and the Recurring
cost will be about Rs. 6 crores per annum.
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9.0 Analysis of proposal (Final Recommendations)
• The proposed expansion project will result in growth of surrounding area by generating direct
and indirect employment to local people. Around 130 members will be benefitted due to the
expansion project (incl. existing 60 nos.).
• Under the Corporate Social Responsibility the Industry will continue to develop a policy of
developing the villages in the vicinity by identifying the requirements.
• No adverse effect on environment is envisaged as proper mitigation measures will be taken
up.
• Industry will strengthen the existing Safety, Health & Environment Department and also
continue to engage recognized laboratories to carry out all necessary monitoring parameters
for its activities.
• The segregated (HTDS / LTDS) wastewater will regularly analyzed before and after
treatment in ETP-ZLD.
• Qualified staff will be appointed for the purpose of Operation and Maintenance of the
pollution control facilities.
• Stand-by facilities will be provided to all the pumps so as to ensure fail proof treatment,
handling and disposal.
•
9.1 Budgetary allocation for Pollution Control Measures
The management will set aside adequate funds in its budget to fully meet the stated
objectives of the environmental policy. The existing and proposed capital equipment for
environmental management include effluent treatment plants, pipelines and channels for
wastewater discharge, greenbelt development, environment laboratory, fire, occupational health
etc., The break-up of budgetary allocation for various control measures is presented in Table 14.
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Table 14: Budgetary allocation for Pollution Control Measures
S. No. Description
Existing cost (in lakhs)
Proposed cost (in lakhs)
Capital Capital *Recurring
Air Pollution Control
1. Multicyclone& Bag filter with Stacks 2 30
10 2. Scrubbers 50 50 3. Vent condensers 50 Water Pollution Control
3. ETP Civil works, Steam stripper, MEE, ATFD, R.O. and mechanical equipment
5 250 300
Noise Pollution Control
4. Silencers / acoustic enclosures 1 10 5
Solid Waste Management
5. Covered Platform with leachate collection system 5 10 170
6. Greenbelt Development 5 5 5
7. Occupation Health and Safety 4 10 10
8. Fire Management 10 60 5
9. Dyke walls and Storm water drains 5 20 5
10. Environmental Laboratory 5 50 10 11. Misc. 5 50 80
Total 97 595 600 *Recurring cost includes manpower, consumables, maintenance, energy charges per
annum
ANNEXURES
Annexure -I
25
Annexure-II
26
Annexure-II
Annexure-II
Annexure-II
27
Annexure-II
28
Annexure-IIAnnexure-III
29
Annexure-III
30
Annexure-III
31
Annexure-III
32
Annexure-III
33
Go
pal
apu
ram
Man
dal
, W
est
Go
dav
ari D
istr
ict
An
dh
ra P
rad
esh
Sta
te
Pro
ject
Sit
e
Ind
ia
Gen
eral
Lo
cati
on
Map
Annexure-IV
34
Sp
ecif
ic L
oca
tio
n (
Ro
ute
Map
)
Pro
ject
Sit
e
Vill
age
Bhag
yana
gar C
hlor
ides
Pvt
. Ltd
Annexure-V
35
Go
og
le m
ap S
ho
win
g P
roje
ct S
ite
Co
ord
inat
es
Pro
ject
Sit
e C
oo
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ates
Sl.
No
. L
atit
ud
e L
on
git
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e
1.
17°1
0'22
"N
81°3
6'12
"E
2.
17°1
0'32
"N
81°3
6'12
"E
3.
17°1
0'32
"N
81°3
6'18
"E
4.
17°1
0'26
"N
81°3
6'18
"E
Annexure-VI
36
Annexure-VII
37
Flow Chart
Aluminium Chlorine Process Emissions
Aluminum Chloride Anhydrous
Description :
Aluminium is heated to its melting temperature and maintained in a pool. Chlorine in gaseous form is fed intoAluminum pool in the reactor. Aluminum Chloride Anhydrous vapors are formed and collected in to an air-cooled condensor, where the Aluminum Chloride Anhydrous vapors sublime to form crystalline power. This isfurther collected in bins and sent for grading and packing.
PRODUCT : Aluminum Chloride Anhydrous
Stage I
Annexure-VIII
38
Flow Chart
Toluene Chlorine gas
Benzo trichloride
Stage-1 : Chlorine gas is passed into boiling toulene in the presence of chlorine chlorinated activating light, amixture of different product is obtained. The principle product being substitued with chlorine molecule. This is acontinuous process.
Description :
Recovery and Reuse Process Emissions-Recovery
PRODUCT : Benzo trichloride
Stage I
Annexure-VIII
39
Flow Chart
1,3-Difluoro benzeneChloroacetyl Chloride Sol.Recovery4-Amino-1,2,4-Triazole Evaporation LossIsopropyl Alcohol EffluentHydrochloric Acid (35%) Organic ResidueSodium Nitrite Process EmissionsAmmonia (25%) soln.Water
Stage-1TMSI Sol.Recovery1,2,4-Triazole Evaporation LossPotassium Hydroxide EffluentMethylene Dichloride Organic ResidueWater
Fluconazole (Crude)Hydrochloric Acid (35%) EffluentAmmonia (25%) soln Spent CarbonCarbonHyflowWater
Stage-1 : 1,3-Difluro Benzene reacts with Chloroacetyl Chloride and condence with 4-Amino-1,2,4-Triazole inpresence of Sodium Nitrite in Isopropyl Alcohol solvent media to get Stage-1(2,4-Difluoro-1H-1YL-1,2,4-Triazole Acetophenone).
PRODUCT : Fluconazole
Fluconazole
Description :
Stage-2 : Stage-1 Compound is reacted with TMSI and condence with 1,2,4-Triazole in presence ofPotassium Hydroxide in Methylene Dichloride solvent media to get crude Fluconazole.
Stage-3 : Crude Fluconazole disolved in water and Hydrochloric Acid charge carbon and filter pH adjust withAmmonia solution to get Final Product of Fluconazole Pharma.
Stage I
Stage II
Stage III
Annexure-VIII
40
Stage-5 : Stage-4 Compound is reacted with Sodium Methoxide in presence of Methanol to get Stage-5Compound.
Stage-6 : Stage-5 Compound is reacted with Acetic Anhydride to get Stage-6 Compound.
Stage-7 : Stage-6 Compound is reacted with Sodium Hydroxide in presence of Methylene Dichloride to getStage-7 Compound.
Stage-8 : Stage-7 Compound is reacted with Thionyl Chloride in presence of Toluene and Acetone to getStage-8 Compound.
Stage-9 : Stage-8 Compound is reacted with (5-Difluoromethoxy)-2-mercapto Benzimidazole and SodiumHydroxide in presence of Toluene to get Stage-9 Compound.
Stage-10 : Stage-9 Compound is reacted with Sodium Hypochlorite and Sodium Hydroxide in presence ofAcetone and Toluene solvent media to get Pantoprazole Sodium.
Stage-2 : Stage-1 Compound is reacted with Ammonium Carbonate in presence of Toluene to get Stage-2Compound.
Stage-3 : Stage-2 Compound is reacted with Phosphorus Oxychloride in presence of Ethylene Dichloride toget (Stage-3) Compound
Description :
Stage-1 : Maltol is reacted with Diemthyl Sulfate in presence of Potassium Carbonate in Acetone solventmedia to get (Stage-1) Compound.
Stage-4 : Stage-3 Compound is reacted with Hydrogen Peroxide in presence of Methylene Dichloride and n-Hexane to get Stage-4 Compound.
PRODUCT : Pantoprazole Sodium
Annexure-VIII
41
Flow Chart
Maltol Sol.RecoveryDimethyl Sulfate Evaporation LossPotassium carbonate Organic ResidueAcetone Inorganic Solid Waste
Process Emissions
Stage-1 Sol.RecoveryAmmonium Carbonate Evaporation LossWater EffluentToluene Organic Residue
Process Emissions
Stage-2 Sol.RecoveryPhosphorus Oxychloride Evaporation LossWater EffluentSodium Hydroxide Organic ResidueEthylene Dichloride
Stage-3Hydrogen peroxide (50%) Sol.RecoveryAcetic acid Evaporation LossSodium hydroxide EffluentWater Organic ResidueMethylene Dichloriden-Hexane
Stage-4 Sol.RecoverySodium Methoxide Evaporation LossMethanol Organic Residue
Inorganic Solid Waste
PRODUCT : Pantoprazole Sodium
Stage I
Stage II
Stage III
Stage IV
Stage V
Annexure-VIII
42
Stage-5 Sol.RecoveryAcetic Anhydride Evaporation Loss
Organic Residue
Stage-6 Sol.RecoverySodium Hydroxide Evaporation LossMethylene Dichloride EffluentWater Organic Residue
Stage-7 Sol.RecoveryThionyl Chloride Evaporation LossToluene Organic ResidueAcetone Process Emissions
Stage-8Sol.Recovery
Evaporation LossSodium Hydroxide EffluentWater Organic ResidueToluene
Stage-9Sodium Hypochlorite (4%) Sol.RecoveryAcetone Evaporation LossCarbon EffluentSodium Hydroxide Organic ResidueToluene Spent CarbonWater
PRODUCT : Pantoprazole Sodium
Pantoprazole Sodium
5-Difluoromethoxy-2-mercapto benzimidazole
Stage VI
Stage VII
StageVIII
Stage IX
Stage X
Annexure-VIII
43
PRODUCT : Ciprofloxacin Hydrochloride
Description :
Stage-1 : Toluene was used as a solvent. Initially, Toluene was taken in the reactor (M.C.0.1 below), (take allsafety precautions before charging SH, Nitrogen blanketing is maintained (purging) through out up to complexmaintenance), to which sodium hydride added at RT, after that Dimethyl Carbonate addn, these mixture was
heated to 55oC. Acetophenone solution (acp+toluene) addition overall period of 4hrs at 60-65oC. after that
maintained another 4 hrs, the reaction mass was checked for completion of reaction. Then cooled to 15-20o
Acetic Acid was added within 2hrs at 15-20oC & maintained 30 minutes at 20oC.After that complex added
slowly at 20-30oC with in 2 hrs and maintained 10hrs at 30-35oC.the reaction mass was checked for completionof reaction. The reaction mass filtered to separate salt & organic layer. These organic layer taken and cooled to
0-5oC. The added CPA at 0-5oC and maintained 4 hrs completion of the reaction was checked. The solvent
removed upto70%. Then cooled to 5 to -2oC, centrifuge the mass & washed with chilled toluene.
Stage-3 : Methanol was used as a solvent. Initially solvent was taken into the reactor, piperazine and Q-Acid
material added. Then heated to 120-125oC.Reaction mass was maintained 15hrs at 125-130oc. Completion ofthe reaction mass checked. Then Base pure ml's (as a water input) was added to the mass and distill out thesolvent completely. Adjust the pH was neutral (6.9 to 7.2) by using hydrochloric acid and centrifuge the materialand washed with hot water.
Stage-2 : Initially, toluene was charged into the reactor & added stage-I material, heated up to reflux andremove water Azeotropically. Then CS flakes were added lot wise, collected water completely. Then the masswas maintained 2 hrs and the mass was checked for completion of reaction. Then solvent toluene can be
removed completely. After that water & C.S.lye charge & heated to 80-95oC. Maintained 4 hrs and checkedthe mass for completion of reaction. Hydrochloric acid was used to adjust pH 3-3.5 of reaction mass. Thencentrifuged the mass collect the material of Q-Acid.
After that water charged into the reactor and added that material. Then adjust the pH up to 4.2 to 4.5 by usingacetic acid, added carbon, EDTA, hyflo maintained 30 minutes filtered and collect the clear filtrate and adjust
pH neutral (6.9 to 7.2) by using ammonia solution at 55 to 60oC. Then centrifuge the mass at 55-60oC andwashed with hot water. Collect the material.
Stage-4 : Initially, required quantity of Methanol was taken in the reactor at RT and added stage-3 material.
Then adjust pH 2 to 2.5 by using cp HCl. Heated the reaction mass to 60-65oC. Maintained 3 hrs with in 60-
65oC. Then the mass was cooled to 10-15oC, maintained 1 hr at 10-15oC. The mass was centrifuded toseparate Methanol ml's and technical grade of Ciproflaxacin Hydrochloride.
Annexure-VIII
44
Flow Chart
2,4-Dichloro-5-Fluoro AcetophenoneDimethyl Carbonate Sol.RecvoerySodium Hydride (60%) Evaporation LossDimethyl Sulfate EffluentDimethylformamide Organic ResidueCyclopropyl amine Inorganic Solid WasteAcetic acid Process EmissionsTolueneWaterHydrochloric Acid (35%)
Stage-1Sodium Hydroxide Sol.RecoveryHydrochloric Acid (35%) Evaporation LossWater EffluentToluene Organic Residue
Stage-2PiperazineHydrochloric Acid (35%)Acetic acid Sol.RecvoeryAmmonium Hydroxide (25%) Evaporation LossCarbon Send to Auth. PartyEDTA Spent CarbonHyfloWaterMethanol
Ciprofloxacin Base Pure (470 + 370) Sol.RecoveryHydrochloric acid (35%) Evaporation LossMethanol EffluentWater Organic Residue
PRODUCT : Ciprofloxacin Hydrochloride
Ciprofloxacin Hydrochloride
Stage III
Stage IV
Stage I
Stage II
Annexure-VIII
45
Description :
PRODUCT : Salbutamol Sulfate
Stage-3 : Stage-2 Compound is oxidised with Selenium Dioxide in presence of 1,4-Dioxane to gove oxidesedcompound. It is further condenced with tert-Butylamine in presence of Methanol solvent media to give Stage-3Compound.
Stage-4 : Stage-3 Compound is reduction with Sodium Borohydride in presence of Lithium Bromide in Diglymeand Ethylene Dichloride solvent media to give Stage-4 Compound.
Stage-5 : Stage-4 Compound under goes deprotenation with Hydrogen in presence of Raney Nickel catalyst innitrogenic condition in Methanol solvent media to give Salbutamol base. It is further salt formation with Sulfuricacid to give Salbutamol Sulfate.
Stage-2 : Stage-1 Compound is condenced with Benzylchloride in presence of Potassium Carbonate,Dimethylsulfoxide, TEBAC and Methanol solvent media to give Stage-2 Compound.
Stage-1 : Methyl Salicylate is acylated with Acetyl Chloride in presence of Aluminum Chloride and EthyleneDichloride solvent media to Stage-1 Compound.
Annexure-VIII
46
Flow Chart
Methyl SalicylateAcetyl ChlorideAluminum Chloride Sol.RecoverySodium Bicarbonate Evaporation LossEthylene Dichloride EffluentIce Process EmissionsHydrochloric Acid (10%)Water
Stage-1DimethylsulfoxidePotassium Carbonate Sol.RecoveryBenzylchloride Evaporation LossTEBAC EffluentMethanol Process EmissionsWater
Stage-2 Byproduct1,4-Dioxane Sol.RecoverySelenium Dioxide Evaporation Losstert-Butylamine Organic ResidueMethanol
Stage-3DiglymeSodium Borohydride Sol.RecoveryLithium Bromide Evaporation LossAcetic Acid EffluentSodium Hydroxide Organic ResidueEDTA Spent CarbonEthylene DichlorideCarbonWater
Stage-4Methanol Sol.RecoveryRaney Nickel Evaporation LossHydrogen Organic ResidueNitrogen Process EmissionsSulfuric Acid
Salbutamol Sulfate
PRODUCT : Salbutamol Sulfate
Stage I
Stage II
Stage III
Stage IV
Stage V
Annexure-VIII
47
Stage-6 : 2-Azabicyclo-(3,3,0)-octane-3-Carboxylic acid benzyl ester reacts with ECPP Alanine in presenceof Toluene and Acetone gives Ramipril Benzyl ester.
Stage-7 : Ramipril Benzyl ester on hydrogenation with Hydrogen on Palladium Carbon in presence ofMethanol gives Ramipril.
Stage-2 : Methyl-β-chloro-α-acetamido propionate reacts with Cyclopentanone in presence of PotassiumCarbonate and Toluene gives 1-Acetylamino-2-(2-oxocyclopentyl) propionic acid methyl ester.
Stage-3 : 1-Acetylamino-2-(2-oxocyclopentyl) propionic acid methyl ester cyclises in presence ofHydrochloric acid and water give 2-Azabicyclo-(3,3,0)-octene-3-Carboxylic acid.
Stage-4 : 2-Azabicyclo-(3,3,0)-octene-3-Carboxylic acid on hydrogenation with Hydrogen on Palladiumcarbon in presence of Methanol gives 2-Azabicyclo-(3,3,0)-octane-3-Carboxylic acid.
Stage-5 : 2-Azabicyclo-(3,3,0)-octane-3-Carboxylic acid reacts with Benzylalcohol in presence of Sulfuricacid and Toluene gives 2-Azabicyclo-(3,3,0)-octane-3-Carboxylic acid benzyl ester.
Stage-1 : L-Serine methylester.HCl reacts with Acetic Anhydride in presence of Potassium Carbonate,Hydrochloric acid and Toluene gives Methyl-β-chloro-α-acetamido propionate.
Description :
PRODUCT : Ramipril
Annexure-VIII
48
Flow ChartL-Serine methylester.HCl Sol.RecoveryAcetic Anhydride Evaporation LossToluene EffluentPotassium Carbonate Organic ResidueHydrochloric Acid (35%) Process EmissionsWater
Stage-1 Sol.RecoveryCyclopentanone Evaporation LossToluene EffluentPotassium Carbonate Organic ResidueWater Process Emissions
Stage-2 Sol.RecoveryHydrochloric Acid (35%) Evaporation LossXylene EffluentWater Organic Residue
Stage-3 Sol.RecoveryPalladium Carbon Evaporation LossMethanol EffluentHiflo Organic ResidueHydrogen Spent CarbonWater Process Emissions
Stage-4Benzylalcohol Sol.RecoverySulfuric Acid Evaporation LossToluene EffluentWater
Stage-5ECPP Alanine Sol.RecoveryPara Toluene sulfonic acid Evaporation LossToluene EffluentAcetone Organic ResidueWater
Stage-6 Sol.RecoveryPalladium Carbon Evaporation LossMethanol EffluentHiflo Organic ResidueHydrogen Spent CarbonWater Process Emissions
PRODUCT : Ramipril
Ramipril
Stage I
Stage II
Stage III
Stage IV
Stage V
Stage VI
Stage VII
Annexure-VIII
49
Flow Chart
Ethyl cyanoacetate Sol.RecoveryDiethylamine Evaporation LossWater Effluent
Process Emissions
N,N-Diethyl cyanoacetamide
PRODUCT : N,N-Diethyl cyanoacetamide
Description :
Stage-1 : Ethyl cyanoacetate is condensed with Diethylamine in water media to gives N,N-Diethylcyanoacetamide compound.
Stage I
Annexure-VIII
50
Flow Chart
Acetyl chloride Recovery and Reuse Benzo trichloride Effluent Caustic Organic Residuewater
Acetyl chloride
Description :
Stage-1 : Acetic anhydride reacts with Benzo trichloride in presence of Caustic to form Acetyl chloride
PRODUCT : Acetyl chloride
Stage I
Annexure-VIII
51
Flow Chart
Chloro acetic acid Recovery and Reuse Benzo trichloride Organic ResidueWater for Serabbing Process Emissions-Recovery
Chloroacetyl chloride
Description :
Stage-1 : Chloro acetic acid reacts Benzo trichloride to form Chloroacetyl chloride
PRODUCT : Chloroacetyl chloride
Stage I
Annexure-VIII
52
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgAluminium = 202.2 6066Chlorine = 803 24090
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgToluene = 543 3147.83Chlorine gas = 1259 7298.55
PRODUCT : Aluminum Chloride AnhydrousLIST OF RAW MATERIALS
PRODUCT : Benzo trichlorideLIST OF RAW MATERIALS
Annexure-IX
53
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg Kg1,2,4-Triazole = 76 63.31,3-Difluoro benzene = 110 91.74-Amino-1,2,4-Triazole = 90 75.0Ammonia (25%) soln = 298 248.3Carbon = 20 16.7Chloroacetyl Chloride = 110 91.7Hydrochloric Acid (35%) = 457 380.8Hyflow = 8 6.7Isopropyl Alcohol = 1310 1091.7Methylene Dichloride = 730 608.3Potassium Hydroxide = 88 73.3Sodium Nitrite = 76 63.3TMSI = 190 158.3
PRODUCT : FluconazoleLIST OF RAW MATERIALS
Annexure-IX
54
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg Kg5-Difluoromethoxy-2-mercapto benzimidazole = 70 70Acetic acid = 40 40Acetic Anhydride = 40 40Acetone = 1650 1650Ammonium Carbonate = 65 65Carbon = 10 10Dimethyl Sulfate = 45 45Ethylene Dichloride = 360 360Hydrogen peroxide (50%) = 40 40Maltol = 85 85Methanol = 415 415Methylene Dichloride = 715 715n-Hexane = 400 400Phosphorus Oxychloride = 35 35Potassium carbonate = 55 55Sodium Hydroxide = 84 84Sodium Hypochlorite (4%) = 507.5 508Sodium Methoxide = 23 23Thionyl Chloride = 39 39Toluene = 2405 2405
PRODUCT : Pantoprazole SodiumLIST OF RAW MATERIALS
Annexure-IX
55
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg Kg2,4-Dichloro-5-Fluoro Acetophenone = 380.5 253.7Acetic acid = 218 145.3Ammonium Hydroxide (25%) = 250 166.7Carbon = 16 10.7Cyclopropyl amine = 105 70.0Dimethyl Carbonate = 322.5 215.0Dimethylformamide = 183 122.0Dimethyl Sulfate = 316 210.7EDTA = 1 0.7Hydrochloric Acid (35%) = 697 464.7Hyflo = 4.5 3.0Methanol = 1897.5 1265.0Piperazine = 327.5 218.3Sodium Hydride (60%) = 146.5 97.7Sodium Hydroxide = 177 118.0Toluene = 3550 2366.7
PRODUCT : Ciprofloxacin HydrochlorideLIST OF RAW MATERIALS
Annexure-IX
56
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg Kg1,4-Dioxane = 465 1550Acetic Acid = 30 100Acetyl Chloride = 40 133.3Aluminum Chloride = 40 133.3Benzylchloride = 62 206.7Carbon = 6 20.0Diglyme = 167 556.7Dimethylsulfoxide = 10 33.3EDTA = 4 13.3Ethylene Dichloride = 766 2553.3Hydrochloric Acid (10%) = 200 666.7Hydrogen = 1.8 6Lithium Bromide = 27 90Methanol = 829 2763.3Methyl Salicylate = 62 206.7Nitrogen = 1 3.3Potassium Carbonate = 37.5 125Raney Nickel = 10 33.3Selenium Dioxide = 53 176.7Sodium Bicarbonate = 10 33.3Sodium Borohydride = 19 63.3Sodium Hydroxide = 25 83.3Sulfuric Acid = 10 33.3TEBAC = 2.5 8.3tert-Butylamine = 29 96.7
PRODUCT : Salbutamol SulfateLIST OF RAW MATERIALS
Annexure-IX
57
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgAcetic Anhydride = 40 66.7Acetone = 265 441.7Benzylalcohol = 112 186.7Cyclopentanone = 31 51.7ECPP Alanine = 77 128.3Hiflo = 4 6.7Hydrochloric Acid (35%) = 51 85Hydrogen = 3 5.0L-Serine methylester.HCl = 60 100Methanol = 525 875.0Palladium Carbon = 3 5.0Para Toluene sulfonic acid = 5 8.3Potassium Carbonate = 60 100Sulfuric Acid = 1 1.7Toluene = 1800 3000Xylene = 300 500
PRODUCT : RamiprilLIST OF RAW MATERIALS
Annexure-IX
58
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgDiethylamine = 168 258.5Ethyl cyanoacetate = 70 107.7
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgChloro acetic acid = 930 3100.00Benzo trichloride = 1925 6416.67
Raw Material
Consumption of Raw Material /
Batch of Product
Daily Consumption of
Raw Material
Kg KgAcetyl chloride = 750 2500.00Benzo trichloride 1450 4833.33Caustic = 145 483.33
PRODUCT : N,N-Diethyl cyanoacetamideLIST OF RAW MATERIALS
PRODUCT : Acetyl ChlorideLIST OF RAW MATERIALS
PRODUCT : Chloroacetyl ChlorideLIST OF RAW MATERIALS
Annexure-IX
59
LIST OF HAZARDOUS RAW MATERIALS
Raw Material
1,4-DioxaneAcetic acidAcetic AnhydrideAcetoneAcetyl chlorideAluminium Aluminum ChlorideAmmonia (25%) solnAmmonium Hydroxide (25%)ChlorineChloroacetyl ChlorideDiethylamineDimethyl SulfateEthylene DichlorideHydrochloric Acid (10%)Hydrochloric Acid (35%)HydrogenHydrogen peroxide (50%)Isopropyl Alcoholn-HexaneNitrogenPhosphorus OxychlorideSulfuric AcidThionyl ChlorideToluene
Annexure-X
60
Annexure-XI
61
Colle
ctio
n cu
m
Equa
lizat
ion
Tank
Solv
ents
for R
ecov
ery
/ PC
B Au
th. P
arty
(w
ith m
oist
ure)
Co
nden
ser
Hold
ing
Tank
Neu
tral
i-za
tion
Aera
tion
Ta
nk
Stor
age
Tank
Du
al
med
ia
filte
r
Steam Stripper
ATFD
Pre
aera
tion
ta
nk
Condenser R.
O. S
yste
m
Prod
uct w
ater
to
Util
ities
ACF
HTDS
/ H
COD
Efflu
ent i
nlet
Stor
age
Tank
MEE System
Cond
ensa
te
Cond
ensa
te
Pre aeration tank
Filtrate
Slud
ge D
ecan
ter/
SD
BS a
nd d
ried
sludg
e to
TSD
F Sl
udge
Dec
ante
r/
SDBS
and
drie
d slu
dge
to T
SDF
Filtrate
Conc
entr
ate
RO /
Use
d to
Co
olin
g To
wer
Salts
to T
SDF
LTDS
/ L
COD
&
Dom
estic
Effl
uent
in
let
Reje
cts
Forced Evaporation
Cond
ensa
te to
U
tiliti
es
Salts
to T
SDF
Scru
bber
Ef
fluen
t inl
et
Slud
ge re
cycl
e
Eff
luen
t Tre
atm
ent F
low
Sch
eme
Annexure-XII
62
Schematic flow Sheet for EIA Procedure
Time schedule for obtaining the EC from MOEF
Submission of application by proponent (Form 1, Pre-feasilibility report and Draft Terms of Reference)
Scrutiny by EAC
Scoping an communication of Terms of Reference for EIA Studies to the Proponent for EIA preparation
Submission of proceedings of the public hearing by the SPCB / PCC to EAC
Conducting public hearing by SPCB / PCC or any other public Agency / authority engaged by regulatory authority
Submission of Draft EIA / Summary EIA / Application for Public consultation
Appraisal by EAC
Submission of final EIA by the proponent after improving EIA / EMP
Decision of MoEF
Decision of MoEF
Specific Concerns
Yes NO Rejection
Issuing clearance to project proponent
60 days
45 days
60 days
Scop
ing
Publ
ic C
onsu
ltanc
y De
cisio
n M
akin
g Ap
prai
sal
Reservation on the proposal conveyed to EAC
EAC views on reservations sent to MoEF
45 days
60 days
30 days
Category A Project
Preparation of FORM I Application & Prefeasibility report
30 days on obtaining information from industry
as per check list
Preparation of Draft EIA report 120 days minimum other than monsoon period of 120 days
30 days for preparation of Final REIA Maximum
Annexure-XIII
63
Environmental Baseline Monitoring (To Establish quality of the
Environment)
Application of Impact Prediction Tools (Quantitative Significance Analysis)
Identification of Likely Impacts (Quantitative Significance Analysis
(Ref: Impact Matrix)
EIA Team
Social Impact Assessment
Risk Assessment
Project Features (Pre-feasibility Report,
Form1)
Valued Environment Components
Mitigation Measures
Environmental Management Plan
Reporting
Approach of EIA Study – 4 months other than monsoon period after obtaining TOR copy from MOEF
Annexure-XIII
64
Annexure-XIV
65
Annexure-XV
66
Seismic Map of India
Annexure-XVI
67