draft environmental impact assessment report labs_eia_02_7_2019.pdfinspection on 4.10.2016 and...

DRAFT ENVIRONMENTAL IMPACT

ASSESSMENT REPORT

FOR

“MODIFICATION – MANUFACTURING UNIT

OF BULK DRUGS AND INTERMEDIATES”

AT

PLOT NO. 23-B,

KIADB INDUSTRIAL AREA, KOLHAR VILLAGE,

NIZAMPUR HOBLI, BIDAR TALUK &

BIDAR DISTRICT, KARNATAKA

PROMOTER:

M/s. CHORUS LABS LIMITED

BIDAR

Environmental Impact Assessment (EIA) Report

M/s. Chorus Labs Limited Page 1

CHAPTER - 1

1. INTRODUCTION

1.1 IDENTIFICATION OF THE PROJECT

M/s. Chorus Labs Limited is an existing small scale unit proposing modification

of Bulk drugs and Intermediate, unit located at Plot No. 23-B, KIADB Kolhar Industrial

Area, Kolhar Village, Nizampur Hobli, Bidar Taluk & District, Karnataka.

Any activity aimed at development will have repercussions on the environment,

both positive and negative. Environmental Impact Assessment (EIA) study is a

management tool, which enables the proponent to identify the negative impacts and to

mitigate the negative impacts through appropriate Environmental Management Plans.

Hence M/s. Chorus Labs Limited as a part of the compliance to the regulatory

requirement i.e. to obtain Environment Clearance (EC) from State Environmental

Appraisal Committee (SEAC), Karnataka and have appointed a consultant to carry out

the studies for the proposed development of pharma unit.

1.2 NEED OF THE REPORT

The industry has obtained CFE and CFO to manufacture Ibuprofen product with

a capacity of 50 MTPM in the year 2015. By considering the market demand the

industry intends to change the product and product mix of Bulk Drugs and

Intermediates without increasing the production load by substituting 5 new products in

the existing 17 products with a total capacity of 10.225 MTPM within the existing

premises by utilizing existing infrastructure facilities.

The project falls in the activities listed under the EIA notification, 2006 hence

does require prior Environmental Clearance under the EIA notification. The proposed

project is covered under activity 5 (f) “Synthetic organic chemicals industry” of

Category-“B” of MoEF as per the EIA notification vide gazette no. S.O. 1533 dated 14th

September, 2006. Hence the proposed project has to obtain environmental clearance

from SEIAA, Karnataka.



As per the requirements of the notification, an application was submitted to

SEIAA, Karnataka on 13th April, 2018 along with Form-1, Pre-feasibility and proposed

Terms of Reference (TOR). Based on the information furnished and presentation done

before the State Expert Appraisal Committee (SEAC) members, proposal was appraised

in the 198thState Expert Appraisal Committee (SEAC) meeting, held on 19thMay, 2018.

Subsequently Committee has issued the TOR (Terms of Reference) for preparing

Environmental Impact Assessment (EIA) report vide letter no. SEIAA 16 IND (VOIL)

2018 dated on 15thJune, 2018.

The purpose of the Environmental Impact Assessment study and report is to

comply with the ToR issued by the SEIAA as a part of the process to obtain

Environmental Clearance. Most importantly the purpose of EIA study is to identify and

mitigate environmental impacts in a timely manner. In order to address the nature and

extent of significant environmental impacts both negative and positive during the

construction and operation phase of the proposed project, M/s. Chorus Labs Limited

has appointed Environmental consultant -M/s. Enviro Resources, Mumbai to conduct

Environmental Impact Assessment (EIA) study as per the TOR accorded by SEIAA.

However, considering nature of the project, it requires an EIA study for prior

appraisal by Karnataka State Pollution Control Board (KSPCB) as part of the project

appraisal prior to grant of Consent to Operations; well as the report will be used for

decision making and implementation of mitigation measures and management plan

during construction and operation phases of the project.

An Environmental Impact Assessment (EIA) is prepared, based on studies

carried out during the month of October 2018 to December 2018. The environmental

attributes like ambient air, water, soil, noise selected for study are those, which are

likely to be affected by the project. The study is defined as an area within 10km radius

around site located at Kolhar Industrial area. The project requires public hearing

process as per the MoEF Notification No.S.O.1030 (E) dated 8th March 2018even though

the industry is located in the notified industrial area of Kolhar Industrial area.



1.2.1 Chronology of the industrial activity:

KIADB allotted land to M/s. Bidar Drugs Pvt Ltd in the year of 1987.

Karnataka State Financial Corporation (KSFC), Bangalore taken over the plant by

M/s. Bidar Drugs Pvt Ltd in the year of 1989.

M/s. BSN Pharma Limited purchased the plant from KSFC, Bangalore dated

12/9/2005.

M/s. BSN Pharma Limited obtained CFE for Ibuprofen product with capacity 50

TPM with order dated 22/11/2006.

M/s. BSN Pharma Limited changed the name in the year of 6/8/2009 to M/s.

Chorus Labs Limited.

CFO was issued for manufacturing of Ibuprofen product with capacity 50 TPM

and validity was till 30/06/2010.

M/s. Chorus Labs Limited has obtained CFEx for 17 products with the order

dated 20/08/2010. Subsequently CFO was obtained and its validity was till

30/09/2015.

In 11/4/2014, M/s. Chorus Labs Limited proposed to replace 5 projects in the

place of existing products and accordingly filed the application to KSPCB to

obtain CFE.

M/s. Chorus Labs Limited obtained CFEx for change of products with order

dated 8/8/2015.

Subsequently, industry was visited by Secretary, SEIAA, Karnataka and Member

Secretary, KSPCB on 28th& 29th April 2016 as compliant against industrial

activities subject to pollution of groundwater in and around the Kolhar industrial

area is made to legislation petition committee.

KSPCB has issued closure order to the industry to stop the industrial operation.

Presently plant is closed.

M/s. Chorus Labs Limited had applied for an Environmental Clearance and TOR

application is submitted to SEIAA, Karnataka dated on 21.5.2016. (FILE No.

SEIAA 20 IND 2016)



Terms of Reference (TOR) meeting held on 30.8.2016.

SEAC committee members along with KSPCB officers visited the industry for

inspection on 4.10.2016 and reported observation as well as recommendation.

M/s. Chorus Labs Limited submitted the EIA report dated 24.3.2017.

As per Notification No. S.O 804(E) dated 14.3.2017, SEIAA Karnataka decided to

close the file as it is a case of violation and received letter from SEIAA dated on

21.4.2017.

Accordingly we have filed the application to MoEF, Delhi with File No: [J-

11011/257/2017-IA-II(I)]

As per the MoEF new Notification dated 8th March 2018, all the violation cases

have been forwarded to individual state subject to Categorization in EIA

Notification 2006.

1.3 OBJECTIVE OF ENVIRONMENTAL IMPACT ASSESSMENT (EIA) STUDY

Environmental Impact Assessment (EIA) is a planning tool to give the

environment its due place in the decision making process by clearly evaluating the

environmental consequences of a proposed activity before action is taken. Thus, the

main objective of EIA is to determine as precisely as possible, within the present limits

of knowledge and expertise, the likely environmental impacts of a planned

development activity and incorporate efficient environmental protection measures right

at the planning stage of project in such a way that the residual adverse effects becomes

acceptable or almost none. The objectives of the present environmental impact

assessment study briefly described below:

The objective of Environmental Impact Assessment (EIA) study is to understand

the prevailing physical and biological environment.

The purpose of any EIA exercise is to identify and asses the adverse impacts of a

project in the planning stage itself, so that necessary mitigation measures to

prevent or minimize these adverse impacts can be planned early and cost-

effectively.



In view of this, the specific objectives of this EIA are,

To have an in-depth know how of the project and to identify the probable

sources of pollution that may arise from each stage of the process.

To review the current environmental status of the area within 10km radius of the

proposed project site –collection of baseline data on the environmental attributes

including air, noise, water, land, ecological, hydro-geological climate and socio-

economic environments.

To assess likely or potential environmental impacts of the proposed activity.

To estimate the impacts of the proposed project on the surrounding

environment.

To prepare a comprehensive Environmental Management Plan to ensure that the

environmental quality of the area would be preserved.

1.4 PROMOTERS AND THEIR BACKGROUND

Chorus Labs was incepted in 2009, with a clear vision to master API

manufacturing. The company is foraying aggressively in to the pharma market in

developing and commercializing products while catering to a variety of therapeutic

categories. True to its mission that epitomizes team work and strong expertise, the

company is making its presence felt, both nationally and internationally towards

creating a healthy society.

Coupled with an insight in to its core competencies and a strong foresight on the

current trends, Chorus Labs is raring to become a reliable and strong player by

investing in its Research and development, Manufacturing Capabilities, Human

Resources and well established quality management systems.

Mr. B. Narasa Reddy, the soul and heart behind Chorus Labs, is a person who

comes in with loads of expertise. Also the brain behind Chorus Labs, he started the

company basing it on his immense strength gained from the experience of running a

laboratory that was instrumental in developing and commercializing processes for

several APIs.



Started with a strong passion to drive the company to be recognized as an

aggressive company, he has built a culture that exemplifies this vision in the company's

strength of R&D and manufacturing. He started a company with definite advantages in

terms of cost and chemistry with a strong emphasis on quality of the products. His

undying attitude to excel has seen the company develop processes for several products

at relatively low cost, thus making several life saving drugs affordable.

For the company, he is a true inspiration and motivation. The company looks up

to this leader in working towards achieving the organizational goals.

Vision & Values

Chorus Labs values its position in the pharma industry as an aggressive player at

a global level and looks at solidifying its position in supplying generics, combining

intellectual property and strong human resource inputs. The company values social

responsibilities associated with companies in the pharma industry and its importance in

reaching higher altars.

Customer-focus, understanding the requirements of the eco-system and

delivering the products at the right pace is a core value of the company. Chorus Labs

values its people and considers it as the core of all its success. This company

continuously invests in their capabilities and believes in honing the skills of its

employees to reach the pinnacle of success.

The company believes in continuous evaluation and improvement that results in

transforming the organization into a global force to reckon with. Chorus envisions itself

a process driven company with a passion to develop products that are eco-friendly. The

company makes a conscious effort to ensure that none of its processes disturb the

ecological harmony.

Mission

Chorus‟s mission is to be a global player in the pharma world by deploying

processes that are in accordance with the requirements of healthcare. Imbibing the

philosophy of being conscious to both, its stakeholder and the social community, the

company is driven by its zeal to better its research and manufacturing capabilities.



Today, it‟s a name which epitomizes hard work, experience and success. A

young company that is making its presence felt and making its presence in nationally

and internationally. Involved in the manufacturing of active pharmaceutical

ingredients, Chorus Labs is one of its kinds of the very few companies which have been

able to carve a niche in the pharmaceutical industry given the present scenario where it

requires a right blend of intellectual strength, core competencies and a precise foresight

for the future.

Profile of Directors

Mr. P.Subba Reddy has a Post Graduation in Economies with 23 years

Experience in Purchase & Procurements.

Mr. B. Narasa Reddy has a Post-Graduation in Chemistry with 30 years overall in

Manufacturing Bulk Products and 15 years of experience as Operational Head of Hetero

Group of Companies and also Director of Hetero Drugs Limited & Hetero Labs Limited.

Mrs. B. Baby with a Graduation in Chemistry with 20 years overall Experience in

Bulk Products Quality.

All directors have experience in the field of drug manufacturing and different

lines of activities in Pharma Industry, and as well as worked for major leading

pharmaceuticals in the industry.



Figure 1.1 Organizational chart of M/s Chorus Labs Limited



1.5 PURPOSE OF EIA STUDY

The concept of EIA has corollaries in the long run for almost all development

activity because sustainable development depends on protecting the natural resources

which is the foundation for further development. The main purposes of doing

environmental impact assessment study are:

To assess the prevailing environmental status within the study area around the

project site.

To critically analyze the various activity of the proposed project and identify

potential source of environmental pollution.

To assess the impacts of the proposed project on the environment.

To identify and assess significant impacts of proposed project on environmental

components through matrix method.

To suggest preventive and mitigation measures to minimize or avoid the adverse

impacts on the environment and to maximize the beneficial impacts.

To prepare Environmental Management Plan (EMP) and delineate post-project

environmental monitoring program to be pursued by the industries.

To prepare an EIA Study report and utilize it for applicable statutory clearances

for proposed project and/or any other management purpose.

Thus, the present EIA study will help the proponent in their planning of effective

control measures to avoid or minimize the likely adverse impacts on environment due

to their proposed project.

1.6 EIA – BACKGROUND

Any new industrial project or modification/modernization of existing one are

likely to affect the quality of surrounding environment. The nature and magnitude of

impacts on different components of the environment depend on the nature and size of

project as well as topographical conditions at the proposed project site. The final net

impact due to the proposed project on environmental components can be quantified

through Environmental Impact Assessment (EIA) Studies within the study zone prior to



its implementation. The results of EIA studies form the basis for preparation of a viable

Environmental Management Plan (EMP).

The EIA studies can be broadly divided in to three phases.

The first phase involves identification of significant environmental components

in the area where the project is located and assessing their baseline (pre-project

or existing) status within the study zone. In case of existing projects,

environmental performance of existing manufacturing/ pollution control plants

is also required to be covered.

The second phase involves prediction of impacts using dispersion models on

various identified significant environmental parameters due to proposed project.

Data regarding the proposed manufacturing activities, design capacity of the

pollution control units; fuel consumption; solid or hazardous waste, effluent

generation, characteristics of each disposal medium and topography of the

impact zone is also assessed to evaluate project related impacts.

The third phase includes the evaluation of final impacts and delineation of an

Environmental Management Plan to mitigate adverse impacts on the quality of

surrounding environment.

In order to have scientific assessment of projects, Ministry of Environment &

Forest (MoEF), Govt. of India (GOI) passed a Notification (called the EIA Notification)

in January 1994 (now replaced by New Notification Dated 14.09.2006) making it

mandatory for new projects/modification of existing ones in identified sectors to

conduct a Environmental Impact Assessment (EIA) study & submit an Environment

Management Plan on the basis of the same. The MoEF then scrutinizes the studies

carried out & the EMP prepared & then grants Environmental Clearance for the project.

Environmental Clearance is required to be taken „prior‟ to all other clearances.

Manufacture of Bulk Drugs unit & any new project/ modification/ modernization of

existing one require Environmental Clearance to be obtained from MoEF.



1.7 SCOPE OF ENVIRONMENTAL IMPACT ASSESSMENT STUDY

EIA study includes determination of baseline conditions, assessment of the

impacts on the environment due to operation of the project and making

recommendations on the preventive measures to be taken, to minimize the impact on

the environment to acceptable levels. A suitable post-study monitoring program will be

outlined. Scope has been so evolved that the data meets all MoEF requirements for

conducting Environmental Impact Assessment (EIA). Various components covered in

the baseline environmental studies & methodologies adopted are given below.

EIA study shall cover the following aspects,

Evaluation of present environmental factors through analysis of generated and

collected baseline data for one complete non-monsoon season (3 months).

Assess the probable impact on the environmental factors due to implementation

of the project with respect to existing scenario.

A thorough study of the process including provisions of pollution control, and

Environmental Management Plan that includes prediction of impacts and

relevant mathematical modelling.

Assess the probable risk at the proposed plant.

Preparation of Environmental monitoring program.

Develop an Environmental Management Plan and on site Disaster Management

Plan for the proposed project to mitigate the negative significant impacts that

would arise from the proposed project and controlling the pollution levels

Environmental Monitoring Plan is suggested for monitoring the pollution loads

at various facilities in the premises and to ensure compliance with the statutory

requirements.

The baseline data has been collected for the following environmental

components, during October 2018 to December 2018

Air quality

Meteorology

Noise environment



Water use & quality

Soil quality

Land use, crop pattern, Agricultural practices

Demographic aspects

Ecology & Biodiversity

An Environmental Impact Assessment and Environment Management Plan

comprising an overall assessment of the impact due to project activity over baseline

condition of the existing environment and a mitigating action plan to counter the

adverse impact as defined. An environmental monitoring program is also prepared to

provide scientific support to future actions of environmental protection.

1.8 STRUCTURE OF EIA REPORT

The EIA report has been structured covering various aspects like project

description, baseline conditions, environmental impacts, mitigation measures,

environmental management plan as directed by SEIAA vide letter of awarded ToR.

Copy of ToR and its compliance is provided at the beginning of this report. Further, the

present EIA report has been prepared chapter-wise in accordance with generic structure

suggested by MoEF in EIA notification.

The present report of the EIA study for the proposed project of manufacturing of

synthetic organic chemicals (Bulk Drugs & Drug Intermediates) of M/s. Chorus Labs

Limited has been prepared in the following structure;

TABLE-1.1: STRUCTURE OF EIA REPORT

Sr. No. EIA structure Contents

Chapter – 1 Introduction Identification of project and project proponent

Need, objectives & purposes of EIA study

EIA structure & Regulatory frame work

Chapter – 2 Project Description Description & Justification of the project

Project location & salient features of the project

site

Maps showing project location, plant layout &

administrative map of study area



Proposed product and process description

Description of facilities, infrastructure need,

resource requirement, pollution potentials &

management

Chapter – 3 Description of the

Environment

Approach & methodology of baseline study

Establishment of baseline status for valued

environmental parameters as identified in scope

Maps of study area showing sampling &

monitoring locations and land use pattern

Chapter – 4 Anticipated Impacts

and Mitigation

Measures

Identification & prediction of environmental

impacts during construction as well as

operation phases of the proposed project

Evaluation of impacts on air environment using

mathematical model

Mitigation measures for minimizing and/or

avoiding adverse impacts during construction as

well as operation phase

Chapter – 5 Analysis of site

alternatives

Justification of site selection & technology for the

manufacturing of proposed product

Chapter – 6 Environmental

Monitoring

Program

Technical aspects of monitoring the effectiveness of

mitigation measures including measurement

methodologies, frequency, location, data analysis,

reporting schedules

Chapter – 7 Additional Studies --

Chapter – 8 Project Benefits Employment opportunity and corporate social

responsibility CSR

Socio-economic development and

improvements in the physical & social

infrastructure

Employment & other tangible benefits

Chapter – 9 Risk and safety

management

Details of hazardous chemicals and safety

measures for the transportation,

storage/handling etc



Risk Assessment

Safety measures for the manufacturing process

and preventive maintenance

Occupational health & safety management

Onsite emergency plan

Chapter – 10 Environmental

Management Plan

Environmental Management Plan for various

project activities

Illustration of greenbelt development plan, rain

water harvesting system

Budgetary allocation for environment protection

Chapter – 11 Summary and

Conclusion

Salient features of the project covering, project

description, location, mitigation measures,

costing, etc.,

Overall conclusion for the proposed project

Chapter – 12 Disclosure of

Consultant Engaged

Details of the EIA consultant, laboratory engaged

Chapter-13 Assessment of

Ecological Damage,

Remediation Plan

and Natural and

Community

Resource

Augmentation Plan

Damages during Construction Phase

Damages during Operational Phase

Analysis of retribution cost

Environmental Damage Remediation Plan and

Costing

Natural and Community Resource

Augmentation Plan

1.9 APPLICABLE ENVIRONMENTAL REGULATIONS

The Acts, Rules and Notifications applicable to environmental aspects of the

construction and operational phases of proposed project is summarized as below.

The Water (Prevention and Control of Pollution) Act, 1974 and its amendments

The Air (Prevention & Control of Pollution) Act, 1981 and its amendments

Environment (Protection) Act, 1986 and its amendments



Environmental Impact Assessment Notification dated 07.07.2004 as amended in

14.09.2006 and amendments;

The Manufacture, Storage and Import of Hazardous Chemicals Rules, 1989 and its

amendments;

Chemical Accident (Emergency Planning, Preparedness and Response) Rules, 1996;

Noise Pollution (Regulation and Control) Rules, 2000 and its amendments;

The Hazardous Waste (Management, Handling & Transboundary Movement)

Rules, 1989 and its amendments

Batteries ( Management and Handling) Rules, 2001

The Factories Act, 1948 and its amendments

The Explosive Act, 1884

The Indian Boiler Act, 1923

The Central motor vehicles Act, 1988

1.10 EIA CONSULTANT

M/s. Enviro Resources, Mumbai is a prominent provider of environmental

consulting to wide range of clients. Our comprehensive range of diversified services

includes obtaining environmental clearance from SEIAA/MoEF, CRZ clearance from

MoEF, preparation of EIA/EMP and approval/authorization from KSPCB.

TABLE-1.2: DETAILS OF ENVIRONMENTAL CONSULTANT

EIA consultant organization M/s. Enviro Resources, Mumbai

Contact information E-604, Crystal Plaza, Opp.Infinity Mall New Link Road,

Andheri(W)-400053

Status of accreditation with

NABET

Certificate No. NABET/EIA/1821/IA0038.

COPY ATTACHED AS ANNEXURE-2

1.11 IMPORTANCE AND BENEFITS OF PROJECT

M/s. Chorus Labs Limited proposed to change product mix by substituting new

products which are mentioned in second chapter by considering present market

scenario and expertise of same products in terms of technical with good market



exposure. There will not be any industrial effluent discharge from the proposed project

activities. As a result, it will become easier for the management to produce proposed

products. There is ample market for National & International market. In view of the

availability of scientific staff that able to develop sustainable process at relatively low

cost, and high demand of product in market company has decided to produce proposed

products.



CHAPTER - 2

2. PROJECT DESCRIPTION

This chapter encompasses the details of the proposed project, material and

resource requirement for proposed operation phases, utilities, sources of waste

generation, estimation of pollution loads and associated infrastructures etc.

2.1 TYPE OF PROJECT

The proposed development is modification and expansion of the existing

pharmaceutical unit which is located at Plot No. 23-B, KIADB Kolhar Industrial Area,

Nizampur Hobli, Bidar Taluk & District and Karnataka.

The Indian Pharmaceutical sector has more than 20,000 registered units. It has

expanded drastically in the last two decades. The leading 250 pharmaceutical

Companies control 70% of the market. The pharmaceutical industry in India meets

around 70% of the country‟s demand for bulk drugs, drugs intermediates,

pharmaceutical formulations, chemicals, tablets, capsules, orals and injectable. There

are about 250 large units and about 8000 small Scale Units, which form the core of the

pharmaceutical industry in India (including 5 Central Public Sector Units).These units

produce the complete range of pharmaceutical formulations, i.e. medicines ready for

consumption by patients and about 350 bulk drugs, i.e. chemicals having the

rapeutic value and used for production of pharmaceutical formulations.

M/s. Chorus Labs Limited is proposed for manufacture of Bulk Drugs and

Intermediates. The total site area of the proposed project is 14,038Sqmt.

The overall facilities proposed under the project broadly consist of the following

elements/operations;

Raw material storage area.

Production units



Safety and Pollution control facilities associated with the production of the

above.

Supporting services such as Boiler and DG sets utilities.

Administrate buildings, QC, laboratory, store yard and security services.

2.2 NEED FOR THE PROJECT

India with its large talented manpower, cost effective chemical synthesis, legal &

financial framework is poised to become sourcing destination of bulk drugs to the

global market. Chorus Labs Limited is positioned as one of the leading bulk drug

manufacturing and exporting company in India.

Global economic progress and social wellbeing depend a lot on health, both

human and animal. Therefore, Chorus Labs wants to help make a difference in these

two areas by our ability to compete, innovate and perform. Their strategies revolve

around the changing requirements of our customers and partners, and we comply with

evolving standards of regulators. They continue to build on their key capabilities, the

realignment has enabled us to enhance focus on key priorities, build their own brand

and increase the efficiency of operations. In other words, make tomorrow more

promising for customers, partners, investors and the wider community of stakeholders.

2.3 LOCATION OF THE PROJECT

The proposed project is located at Plot No. 23-B, KIADB Kolhar industrial Area,

Nizampur Hobli, Bidar Taluk & District and Karnataka.

The environmental setting of the project site is given in the below table-2.1

TABLE-2.1: ENVIRONMENTAL SETTING

Sl No

Particulars Details

1. Plant site co-ordinates

(Latitude & Longitude)

Direction Latitude Longitude

North 17° 54‟ 57.56” N 77° 28‟ 11.62” E

South 17° 54‟ 54.66” N 77° 28‟ 11.95” E

East 17° 54‟ 56.03” N 77° 28‟ 15.36” E

West 17° 54‟ 56.13” N 77° 28‟ 11.01” E



2. Temperature Max. - 42ºC, Min. -28ºC

3. Present land-use KIADB land (Industrial area)

4. Average rainfall 885 mm per year

5. Nearest Highway SH- 105 (Bidar-Humnabad road) – 700m (W)

6. Nearest Railway station Bidar railway station – 4.8 Km (E)

7. Nearest Airport Rajiv Gandhi International Airport, Shamshabad –

128Km (SE)

8. Nearest Water body

Papnash river – 3.4 Km (NE)

Janwada kere – 8 Km (N)

Karanja Reservoir – 15 Km (W)

9. Nearest Village Kolhar –2.3km (W)

10. Nearest Town/City Bidar city – 5.3 Km (E)

11. Reserved/ protected

Forests

Honnikere Reserved forest – 2.0 Km (N)

Chitta Reserved forest – 3.2 Km (SE)

Kamthana Reserved forest – 3.9 Km (N)

Kaplapur protected forest – 5.6 Km (NW)

12. Seismic Zone Seismic zone-II as per IS-1893 (Part-1) - 2002

13. Hills / valleys None within 10 km radius

14. Archaeologically important

Places

None within 10 km radius

15.

Protected areas as per

Wildlife Protection Act,

1972

None within 10 km radius

16. Defence Installations Bidar Air Force – 800 m (S)

17. Interstate boundary Karnataka – Telangana– 11.3 Km (SE)

Karnataka – Maharashtra– 37 Km (N)

Note: All distances mentioned are aerial distance



FIGURE - 2.1: VICINITY OF THE PROJECT SITE



Source: Google earth

FIGURE- 2.2: LOCATION OF PROJECT SITE IN GOOGLE EARTH

2.4 JUSTIFICATION OF SITE SELECTION

The project site is located in the notified industrial estate of Kolhar having

various industrial units manufacturing chemical, pharmaceuticals, bulk drugs, agro

formulations etc. The selection of site is based and justified on the following reasons;

The project site is located in the notified industrial area Kolhar, which is aimed

to cater as a most suitable industrial location. Also having all basic facilities like

availability of water, electricity and hazardous waste disposal facility.

The raw materials required for the production of all the proposed products is

easily available in the vicinity of the project site, because of the proximity to the

Latitude: 17°54’57.89”N

Longitude: 77°28’10.46”E

Project site



industrial chemical markets at Kolhar and Humnabad. This will reduce both

the cost of raw material transportation and the associated risk.

Plant site is only 5.3 km away from Bidar City which is having transportation

facilities like linkage with Hyderabad and Maharashtra by Broad Gauge

railway and National Highway.

There is no protected area notified under the Wild Life (Protection) Act (1972)

& Eco-sensitive area notified under Section 3 of the Environment (Protection)

Act-1986 or no prime forestland exists within 10 Km radius areas from the

Plant Site.

As the project site is in the notified industrial estate of Kolhar, no displacement

of population will require.

Availability of trained and skilled manpower nearby because of the proximity

to various industrial areas and city/town.

2.5 INDUSTRIAL DEVELOPMENT OF THE AREA

The project site is located in Industrial Area –Kolhar, Bidar District, Karnataka,

where small, medium and large industries are operating in the area. The list of various

operating industries in 2-km radius around the project site is given in table-2.2.

TABLE-2.2: LIST OF MAJOR INDUSTRIES FOUND WITHIN 2KM RADIUS STUDY AREA

Sl. No. Name of the Industry Distance & direction

1 Vivimed Labs Ltd 1.3 km - SW

2 Sri Lakshmi Chemicals 1.4km - SW

3 Vani Organics Private Limited 1.2 km - NW

4 SynthoChirals Private Limited 740 m - SSW

5 Satvik Drugs 1.3 km – S

6 Suryakala laboratories 1.6 km - SSW

7 Corvine Chemicals &

Pharmaceuticals Limited 1.35 km - SSW

8 Shreegen Pharma Limited 1.3 km - SSW

9 Nirma Limited 2.2 km - SW

10 Chandra Life Science Private Limited 1.6 km -SW

11 Sathwik Drugs Ltd 1.4 km - NW

12 Stereo Drugs Private Limited 1.7 km - SSW



2.6INFRASTRUCTURAL FACILITIES

The total site area of the proposed project is 14,038 Sqmt. Their no additional

built up area is required for the proposed modification project.

TABLE-2.3: DETAILS OF PROPOSED LAND USE PATTERN IN PERMISES

Sl. No. Land Purpose Area in Sqmt In %

1 Build-up area 6,879 49

2 Road area 1,264 9

3 Green belt area 5,615 40

4 Vacant area for parking 280 2

Total area 14,038 100

2.7PROJECT COST

Overall cost of the proposed project is Rs. 6.5Crores. Details with expenditure on

land, land development, building plant and machinery, electrification, utilities, other

fixed assets, preliminary and pro-operations, contingencies etc., The details are listed in

the table below. The project activities will commence after obtaining Environmental

Clearance and will be completed within 3 months.

TABLE-2.4: BREAK-UP OF PROJECT COST

Particulars Amount

(Rs. Crores)

Land 1.20

Building, civil work 0.75

Plant & Machinery -Mechanical, Utilities, etc. 1.80

Furniture, Fixtures and other assets 1.25

Preliminary Preoperative 1.00

Miscellaneous 0.50

Total 6.50



FIGURE - 2.3: LOCATION OF PROJECT SITE IN TOPOSHEET



FIGURE - 2.4: SITE PHOTOS

MEE

PROCESS SHOP

PRODUCTION BLOCK

GREEN BELT GREEN BELT

GREEN BELT



2.8PROJECT DETAILS

EXISTING PLANT SCENARIO

M/s. Chorus Labs Limited was established in the year 2009 and has not obtained

EC from SEIAA, Karnataka. Industry obtained Consents and Authorization from the

competent Authority from time to time.

M/s. Chorus Labs Limited, is presently planning to modify its synthetic organic

chemicals (Bulk Drugs and intermediates), manufacturing unit located at Plot No23-B,

KIADB Kolhar Industrial Area, Nizampur Hobli, Bidar Taluk & District, Karnataka.

TABLE-2.5: COMPARATIVE STATEMENT OF THE SALIENT FEATURES OF THE EARLIER PROPOSAL &MODIFICATION PROPOSAL

Description As per CFO Consent After expansion

Project Name Manufacturing of Bulk Drug and

intermediates Modification of Bulk Drug and

intermediates

Proponent M/s. Chorus Labeled M/s. Chorus Labs Limited

Total Site Area 14,038 Sqmt 14,038 Sqmt

Production capacity/month

Total -50.0 TPM Total -10.225 TPD

Greenbelt area 40% 40%

Name of Products & its capacity

Products Capacity Products Capacity

Capecitabine 1000 Capecitabine 1000

Cefpodoxime 1000 Etodolac 1000

Diclofinac Sodium 600 Diclofinac Sodium 600

Efavirenz 1000 Efavirenz 1000

Leviteracitam 1000 Leviteracitam 1000

Moxifloxacin 750 Moxifloxacin 750

Cefixime 250 Oxalamine citrate 250

Nebivolal 750 Nebivolal 750

Neverapine 1000 Neverapine 1000

SaquinavirMesylate 200 SaquinavirMesylate 200

Stavudine 300 Stavudine 300

Telmisartan 150 Dothiepin 150

Torsimide 325 Oxalamine Phosphate 325

Zindovudine 300 Zindovudine 300



Valsatran 400 Diacerein 400

Terbinafine HCL 200 Terbinafine HCL 200

Ezitimibe 1000 Ezitimibe 1000

Land use KIADB land KIADB land

Man power 20 no‟s 20 no‟s

Water required 40 KLD 31.5 KLD

Source of water Bore well KIADB

Power Requirement 250 kVA 250 kVA

Power Source GESCOM GESCOM

Power Back up 1X200 kVA 1X200 kVA

Project cost 4.0 Crores Rs. 6.5 Crores

2.8.1 PRODUCTS AND CAPACITY:

As per the earlier consent for operation, company manufacturing the following

products; List of existing products produced with quantity is shown in the Table 2.6.

Due to change in market demand for the products, proposed to manufacture

Bulk drugs and intermediates and listed in the Table-2.6. However there is no change in

the land utilization and existing facility will be used for production of proposed

products. Only five new products will be substituted to the existing facility; quantity &

pollution load will not be changed after substitution of new products.

Table-2.6: DETAILS OF EXISTING & PROPOSED PRODUCTS WITH CAPACITIES

S. No. Existing consented

products

Proposed products Production capacity

after modification

Kg/day

1 Capecitabine 1000

2 Cefpodoxime Etodolac 1000

3 Diclofinac Sodium Diclofinac Sodium 600

4 Efavirenz Efavirenz 1000

5 Leviteracitam Leviteracitam 1000

6 Moxifloxacin Moxifloxacin 750

7 Cefixime Oxalamine citrate 250

8 Nebivolal Nebivolal 750

9 Neverapine Neverapine 1000

10 SaquinavirMesylate SaquinavirMesylate 200



11 Stavudine Stavudine 300

12 Telmisartan Dothiepin 150

13 Torsimide Oxalamine Phosphate 325

14 Zindovudine Zindovudine 300

15 Valsatran Diacerein 400

16 Terbinafine HCL Terbinafine HCL 200

17 Ezitimibe Ezitimibe 1000

Total 10,225

Note: At a time maximum 3 products are manufactured.

2.8.2 PROCESS DESCRIPTION:

The manufacturing process for the above mentioned products involve chemical

synthesis utilizing mainly organic chemicals as raw material in batch process. Use

organic and inorganic chemicals in batch operations to produce active pharma

ingredients with unique physical and pharmacological properties. Typically, a series of

chemical reactions are performed in multi-purpose reactors and the products are

isolated by extraction, crystallization and filtration. The finished products are usually

dried, and milled. The manufacturing process of each product, reaction scheme,

material balance and flow diagram is presented in the following pages.



Description of the products

1. CAPECITABINE

Description:

Stage-1:5'-Deoxy-2',3'-di-O-acetyl-5-fluirocytiine is condensed with Pentylchloroformate

in presence of Acetonitrile to give stage-I compound

Stage-2: Stage-I compound is treated with Sodium hydroxide (deprotected) in presence

of Methanol to give CAPECITABINE

Route of synthesis of product:

Stage-I:

Stage-II:

AcO

O

N

NF

NH2

O

Me

OAc

ClOCOMe

ONH

O

NO

F

Me

OAc

O

Me

AcO

5-deoxy-2 , 3-di-o-acetyl-5-fluoro -N-[(pentyloxy)carbonyl]cytidine

I I I

5'-deoxy-2',3'-di-O-acetyl -5-fluorocytidine

M.Wt:329 M.Wt:443

M.Wt:150.5

++ HCl

M.Wt:36.5

Acetonitrile

Pentyl chloroformate

AcO

ONH

O

N

NF

O

Me

OAc

O

Me

O

O

N

NHF

O

Me

Me

OH OH

O

5'-deoxy-2',3'-di-O-acetyl-5-fluoro- N-[(pentyloxy)carbonyl]cytidine

M.Wt:443

Capecitabine

M.Wt:359

+ +

M.Wt:164

M.Wt:80

2NaOH 2AcONaMethanol

Water Sodium acetate



Flow Chart:

Stage-I:

DAF*

HEAT TO REFLUX

CONDENSATION

COOL TO RT

STIR FOR 1 HOUR

CENTRIFUGATION

SOLID

WASHING

DRYING

STAGE-I COMPOUND

WATER

RECOVERY OF ACETONITRILE FROM MLS

DAF*: 5'-deoxy-2',3'-di-O-acetyl -5-fluorocytidine

WASTE WATER TO ETP

PENTYLCHLORO FORMATE

ACETONITRILE

HCl TO SCRUBBER

WASTE MLs TO ETP



Stage-II:

Material Balance:

Stage-I:

S.No: Input Kg/d Output Kg/d Remarks

1 5'-Deoxy-2',3'-di-O-

acetyl-5-

fluirocytiine

1552.6 Stage –I compound 1542.8 Stage –I

compound

2 Pentylchloroformate 710.21 Reuse

STAGE-I COMPOUND

SODIUMHYDROXIDE

STIR FOR 30-40 MINUTES

HEAT TO 45-500C

COOL TO RT

FILTERATION

METHANOL

STIR FOR 45 MINUTES

CENTRIFUGATION RECOVERY OF METHANOL

SOLID

DRYING

CAPECITABINE

SODIUM ACETATE RECOVERY

COOL TO 0-50C



3 Water 1200 Aq . mother liquor contains

HCl

127.2

4 Acetonitrile 1500 Acetonitrile Recovery 1470 Reuse

5 Water 1200 Acetonitrile Loss 30 Loss

Unreacted Organic 1. 5'-Deoxy-2',3'-di-O-acetyl-

5-fluirocytiine (400)

2. Pentylchloroformate(180

580 Recovery

Waste water with organics

1. 5'-Deoxy-2',3'-di-O-acetyl-

5-fluirocytiine (7.631)

2. Pentylchloroformate(6.46

)

1200

+7.631+6.46

MEE

Total input 4963.00 Total output 4963.00

Stage-II:

S.No:

Input Kg/d Output Kg/d Remarks

1 Stage –I

compound

1542.78 Capecitabine 1000 Final

compound

2 Sodium

hydroxide

278.2 Methanol Recovered 960 Reuse

3 Methanol 1000 Solvent loss 40 Loss

4 Water 800 Waste water-water with

Inorganic

1. Sodium hydroxide ( 56 ) Organic

1. Stage –I compound (8.1)

800 +56

+8.1

MEE

5 Unreacted Organic

1. Stage –I compound (300)

300.0 Recovery

Byproduct

Sodium acetate

455.52 By Product

Total Input 3620.6 Total Output 3620.62



2. ETODOLAC:

Description:

STAGE-I: 7-Ethyl Tryptophol is treated with Methyl 3-Oxopentanoate in the presence

of Sulphuric acid and Methanol to give the intermediate Stage-I (Etodolac Methyl

Ester).

STAGE-II: Stage-I(Etodolac Methyl Ester) is treated with Sodium hydroxide and

Hydrochloric acid in the presence of Water and Methanol to give the Product

ETODOLAC.

Flow chart:

STAGE-I:

Cool to 0-10°C

CONDENSATION

COOL TO RT

STIR FOR 1 HOUR

CENTRIFUGATION

SOLID

WASHING

DRYING

STAGE-I COMPOUND

Methanol Methanol Recovery

Methanol Recovery

7-Ethyl Tryptophol

Methanol

Methyl 3-Oxo-pentanoate

H2SO4

+

CYCLISATION



STAGE-II:

STAGE-I COMPOUND

SODIUMHYDROXIDE

STIR FOR 3-4 HRS

HEAT TO 45-500C

FILTERATION

CENTRIFUGATION WATER MLS TO ETP

SOLID

DRYING

ETODOLAC

ACTIVATED CARBON(SOLID WASTE)

COOL TO RT

WATER

ACTIVATED CARBON

REACTION MASS

HYDROCHLORIC ACID




Material Balance:

STAGE-I:

SL

No: Input Kg Output Kg Remarks

1 7-Ethyl

Tryptophol 189.3

Stage –I compound 270.1

Stage –I

compound

2 Methyl 3-

Oxopentanoate 145.3

3 Sulphuric Acid 46.6

O

O

O

NH

OH

NH

O

O

O

NH

O

O

O

NH

O

OH

O

CH3OH NaCl

Methyl-3-Oxo-pentanoate

Methanol

7-Ethyl Tryptophol

NaOH

+

STAGE-I

STAGE-II

Water

Sulphuric Acid

ETODOLAC

Etodolac Methyl Ester

Etodolac Methyl Ester

Hydrochloric Acid

Molecular Weight =189.26Molecular Formula =C12H15NO

Molecular Weight =130.14Molecular Formula =C6H10O3

Molecular Weight =301.39Molecular Formula =C18H23NO3



+

+

Molecular Weight =58.44Molecular Formula =NaCl

MethanolSodium Chloride

Molecular Weight =32.04Molecular Formula =CH4O

+ Water (H2O)

Molecular Weight =18.02Molecular Formula =H2O

+ + HCL

Molecular Weight =36.46Molecular Formula =HCl

Sodium Hydroxide

Molecular Weight =40.00Molecular Formula =NaOH

Yield - 89.5%

Yield- 91.2 %



4 Methanol 450 Methanol Recovery 440 Reuse

5

Unreacted Organic

1.7-Ethyl Tryptophol (20.5)

2. Methyl 3-Oxopentanoate

(17.1)

37.6

6 Solvent loss 10 loss

7 Sulphuric Acid (46.6) –water

(18) 64.6

8 Reside 9


STAGE-II:

SL

No: Input Kg Output Kg Remarks

1 Stage –I

compound

270.1 Etodolac 234.1

Final

compound

2 Sodium hydroxide 48.5

3 Hydrochloric Acid 146

4 Water 800 Waste water-water 780

5 Activated Carbon 3 Activated Carbon 3 Solid Waste

6 Unreacted Organic

1. Stage –I compound (1.1)

Unreacted inorganic

1. Hydrochloric Acid

1.1

55.0

To waste

water

To waste

water

7 Byproduct

Sodium Chloride

Methanol

52.1

28.8

To waste

water

8 Waste Water 113.5

Total Input 1264.6 Total Output 1264.6



3. DICLOFINAC SODIUM

Description:

Stage-1: Aniline andchloroa- cetyl chloride is treated with 2,6-dichlorophenol in the

presence of triethylamine and potassium carbonate to yield stage- I Compound.

Stage-2: Stage-I compound is reacted with sodium methoxide followed by treating with

chloroacetyl chloride in the presence of triethylamine to yield stage-II compound.

Stage-3: Stage-II compound is cycle zed with aluminum chloride followed by

hydrolyzed with sodium hydroxide to yield Diclofenac Sodium.


Cl Cl

OHNH2

NH

O

Cl

ClCl

O

NH

O

O

Cl

Cl

ClCl

ONH

O

O

Cl

Cl

N

Cl

O

ClCl

OHNaO

O

CH3OH

NH

Cl

Cl

2,6-Dichloro-phenolPhenylamine

K2CO3Toluene

Chloroacetyl Chloride

Stage-I:

M. Wt =163.00M. Wt =93.13

+ + TEA

TEA.HCl

M. Wt =112.94 M. Wt =101

M. Wt =137.51

+

+

Water

++ CO2 + KClH2O

Stage-II:

+

Chloroacetyl Chloride

M. Wt =112.94

+ TEA

M. Wt =101

+Water

NaOMe

M. Wt =296.16

M. Wt =296.16

M. Wt =314.60

TEA.HCl

M. Wt =137.51

+ + +

2-(2,6-Dichloro-phenoxy)-N-phenyl-acetamide

2-(2,6-Dichloro-phenoxy)-N-phenyl-acetamide

+

M. Wt =112.94

2-Chloro-N-(2,6-dichloro-phenyl)-N-phenyl-acetamide

M. Wt =44.00 M. Wt =18.00 M. Wt =74.5

M. Wt =54.00

M. Wt =98.03 M. Wt =32.00

Sodium methoxide

Triethylamine

TriethylamineHydrochloride

WaterCarbon dioxidePotassium chloride

Triethylamine

TriethylamineHydrochloride

MethanolSodium carboxymethanolate



NH

Cl

Cl

O

ONa

N

Cl

O

ClCl

N

Cl

OCl

Al(OH)3

[2-(2,6-Dichloro-phenylamino)-phenyl]-acetic acid

AlCl3 NaOH

M. Wt =296.16

M. Wt =314.60

+

HCl+

+

+H2O +

Water

M. Wt =133.34

Aluminum chloride

M. Wt =40.00

M. Wt =18.00 M. Wt =36.50M. Wt =78.00

Stage-III:

2-Chloro-N-(2,6-dichloro-phenyl)-N-phenyl-acetamide

Sodiumhydroxide

Water Aluminium hydroxides

Hydrochloric acid

Diclofenac Sodium



Flow Chart:

Stage-I:

K2CO

3

TOLUENE

ANILINE

STIR FOR 4 HOURS

FILTRATION

FILTRATE

STIR FOR 6 HOURS

LAYER SEPARATION Aq.LAYER

ORGANIC LAYER

DISTILLED OFF

WATER

TOLUENE RECOVERY

RESIDUE

STAGE-I COMPOUNED

TEA

FUME

REFLUX FOR 30 HOURS

CO2

CHLOROACETYL CHLORIDE

2,6-DICHLOROPHENOL



Stage-II:

Stage-III:

STAGE-I COMPOUND

SODIUM METHOXIDE

WATERSTIR FOR 45 MINUTES

LAYER SEPARATION

ORGANIC LAYER

STAGE-II COMPOUND

Aq.LAYER TO ETP

WATER

CHLOROACETYL CHLORIDE TEA

STIR FOR 5 HOURS

TOLUENE

DISTILLED OFF TOLUENE RECOVERY

RESIDUE

STAGE-II COMPOUND ALUMINUM CHLORIDE

STIR FOR 1 HOUR 30 MINUTES

SOLID

DRYING

DICLOFENAC SODIUM

RECOVERY OF TOLUENE

WATER

SODIUMHYDROXIDE

COOLED TO 5-100C


CENTRIFUGATION

TOLUENE



Material Balance:

Stage-I:

S. No. In put kg/d Out put Kg/d Remarks

1 Chloroacetyl Chloride

663.71 Stage-I product 1224.78 Stage-I product

2 2,6-Dichloro-phenol 981.03 Triethylamine HCl 1403.33 By product

3 Phenylamine 481.49 Carbon dioxide 228.48 emission

4 Triethylamine 607.87 Potassium chloride 1078.33 Solid waste

5 Water 1000.00 Water 1093.06 To waste water

6 Toluene 1034.78 Toluene 1034.78 To recovery & reuse

7 Potassium Carbonate

1293.99


Stage-II:


1 Stage-I product 1224.78 Stage-II product 910.61 Stage-II product

2 Sodium methoxide 421.30 Triethylamine Hydrochloride

568.68

3 Chloroacetyl Chloride

926.86 Sodium carboxymethanolate

405.41

4 Triethylamine 815.52 Methanol 1429.16 recovery

5 Water 1000.00 Water 1074.60 To MEE

6 Toluene 1600.00 Toluene recovery 1550.00 recovery

Toluene loss 50.00 Loss- residue-40, to waste water -10

Total input 5988 Total output 5988

Stage-III:


1 Stage-II product 910.61 Diclofenac Sodium 600.00 product

2 Aluminum chloride

771.83 Aluminium hydroxides

514.33

3 Sodiumhydroxide 455.30 Hydrochloric acid 682.76 Recovery and sold to vendors/for neutralization

4 Water 1000.00 Water +un reacted aluminium chloride and sodium hydroxide

1340.65 To MEE




4. EFAVERINZ

Description:

Stage-I: 4S-6 Chloro-4-(cyclopropylethynyl)-14-dihydro-4-trifiuoromethyl)-2H-3,1-

benzoxazin-2-one,tartaricacid salt is treated with NaoH (desaltification) in presence of

n-Hexane to yield Stage- I compound.

Stage-II: Stage-I compound is purified with ethyl acetate and water to yield Efaverenz.


Stage-I:

Stage-II:

O

NH

O

ClF

3C

.HO2CCH(OH)CH(OH)CO

2H

O

NH

O

ClF

3C

.HO2CCH(OH)CH(OH)CO

2Na

+ NaOHwater

M.Wt:40

M.Wt:465.5

(4S)-6-chloro-4-(cyclopropylethynyl)-1,4-dihydro-4- (trifluoromethyl)-2H-3,1-benzoxazin-2-one, tartaric acid salt

+ +

Efavirenz(crude) M.Wt:315.5

Sodium tartrate

H2O

M.Wt:172

M.Wt:18

n-Hexane

Yield : 90.7 %

O

NH

Cl

O

F3C

O

NH

O

ClF

3C

ethyl acetate

water

Efavirenz(crude) M.Wt:315.5

Efaviren(pure)

M.Wt:315.5

Yield : 92.5 %



Flow Chart:

Stage-I:

SODIUM HYDROXIDE

WATER

STIR FOR 60 MINUTES

HEXANE

STIR FOR 15 MINUTES

LAYER SEPARATION Aq.LAYER CONTAINS SODIUM TARTARATE(RECOVERY)

ORGANIC LAYER

DISTILLATION HEXANE RECOVERY

RESIDUE(STAGE-I COMPOUND)

CDBT*

CDBT*: (4S)-6-chloro-4-(cyclopropylethynyl)-1,4-dihydro-4- (trifluoromethyl)-2H-3,1-benzoxazin-2-one, tartaric acid salt



Stage-II:

Material Balance:

Stage-I:

S. No


1 4S-6Chloro-4-

(cyclopropyl

ethynyl)-14-dihydro-

4-trifiuoromethyl)-

2H-3,1-benzoxazin-

2-one,tartaricacid

salt

758.615 Efavirenz crude 1081.08 Stage-I

compound

2 n-Hexane 2000 By product-Sodium tartrate

589.358 Recovery and

sold to vendors

3 NaOH 151.116 n-Hexane recover 1890 Recovery

Reuse

4 Water 1000 Solvent loss 110 Residue -100

Loss- 10

STAGE-I COMPOUND

ETHYLACETATE

WATER

STIR FOR 30 MINUTES

COOL TO 5-100C

CENTRIFUGATION ETHYLACETATE RECOVERY FROM MLS

SOLID

DRYING

EFAVIRENZ



Unreacted Organics 1. 4S-6Chloro-4-

(cyclopropyl ethynyl)-14-

dihydro-4-

trifiuoromethyl)-2H-3,1-

benzoxazin-2-

one,tartaricacid salt(160 )

160 Recovery

Reuse

Waste water –Water

1. 4S-6Chloro-4-

(cyclopropyl ethynyl)-14-

dihydro-4-

trifiuoromethyl)-2H-3,1-

benzoxazin-2-

one,tartaricacid salt

(3.5767)

NaOH ( 14.056)

1000

+3.5767

+14.056

To MEE

Reaction water 61.677 To MEE


Stage-II:

S.No Input Kg/d Output Kg/d Remarks

1 Efavirenz crude 1081.08 Efavirenz 1000

2 Ethyl acetate 1000 Ethyl acetate recovery 950

3 Water 500 Solvent loss 50 Residue-40

Loss-10

Waste water- with ethyl

acetate solvent

500 +10 To MEE

Unreacted Efavirenz

crude

81.083 Recover &

reuse




5. Leviteracitam

Description:

Stage-I: (S)-2-aminobutanamide is condensed with 4-chlorobutanoicacid in presence of

Aceto nitrile to give stage-I compound

Stage-II: Stage-I compound is cyclised in presence of Sodium hydroxide and Ethyl

acetate to give LEVETIRACETAM

Flow Chart:

Stage-I:

(S)-2-AMINO BUTANAMIDE

HEAT TO REFLUX (Condensation)

COOL TO RT

STIR FOR 1 HOUR

CENTRIFUGATION

STAGE-I COMPOUND

ACETONITRILE

RECOVERY OF ACETONITRILE FROM MLS

4-CHLOROBUTANOIC ACID

WATER

WASTE WATER TO ETP



Stage-II:

STAGE-I COMPOUND

STIR FOR 20 MINUTES

COOL TO 0-5 C

STIR FOR 1 HOUR

RESIDUE

DRYING

WATER

Aq.LAYER TO ETP IT CONTAINS (NaCl)

SODIUM HYDROXIDE

DIMETHYL FORMAMIDE

CRYSTALLIZATION RECOVERY OF DIMETHYLFORMAMIDE FROM MLS

LEVETIRACETAM

ETHYL ACETATE

LAYER SEPARATION

ETHYLACETATE RECOVERYDISTILLATION

ORGANIC LAYER




Stage-I

LEVETIRACETAM

Stage-II

yield:75.1%

yield:83.4%

NO

O

NH2

CH3

Levetiracetam

NH2

O

NH2

CH3

+

Cl

COOH

acetonitrilewater

NHO

O

NH2

CH3

Cl

dimethyl formamidewater

(S)-2-[[(1-oxo-3-chloropropyl)-amino]butanamide

4-chlorobutanoic acid(S)-2-aminobutanamide

M.Wt:102 M.Wt:122.5

M.Wt:206.5

M.Wt:170

NHO

O

NH2

CH3

Cl

(S)-2-[[(1-oxo-3-chloropropyl)-amino]butanamide

M.Wt:206.5

+ OH2

M.Wt:18

+ NaOH

M.Wt:40

+ NaCl + OH2

M.Wt:58.5 M.Wt:18

Sodium hydroxide



Material Balance:

Stage-I:


1 (S)-2-aminobutanamide

957.954 Stage –I compound 1456.48 Stage –I compound

2 4-chlorobutanoicacid 1150.483 Acetonitrile recovery 1450 Recovery Reuse

3 Aceto nitrile 1500 Solvent loss 50 Loss Residue -40 Waste water-10

4 Water 1000 Waste water-water 1000 +8.54 +6.49

To MEE

Unreacted Organics (S)-2 aminobutanamide(230.0) 4-chlorobutanoicacid (280. 0)

Recovery Reuse

Reaction water 126.954 To MEE

Total 4608.43 Total 4608.47

Stage-II:

S.No: Input Kg/d Output Kg/d Remarks

1 Stage –I compound 1456.48 Levetiracetam 1000 Final compound

2 Di methylformamide 1500 Di methylformamide

Recovery

1450 Reuse

3 Sodium hydroxide 282.124 Di methylformamide

loss

50 Loss Residue-40

Waste Water-10

4 Water 2000 Waste water-

Unreacted Inorganic

Sodium hydroxide

(46.92 )

Stage –I compound

2.2245)

2000

+46.92

+2.2254

MEE

5 Ethyl acetate 1500 Unreacted Organic 1. Stage –I compound

242.2245)

Reuse

NaCl 343.98 To waste water

Reaction water 105.84 To waste water

Ethyl acetate 1460 Recovery & reuse



recovery

Ethyl acetate loss 40 30-residue

10- waste water

Total 6738.604 Total 6738.9

6. MOXIFLOXACIN

Description:

Stage-I:Methyl-1-cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline

carboxylate is hydrolised with water, hydrochloric acid in presence of diisopropyl ether

to yield stage-I compound.

Stage- II:Stage- I compound is condensed with ((S,S)-2,8-Diazobicyclo-[4,3,0]nonane to

get Moxyfloxacin.


NF

F

OMe

O

COOCH3

NF

F

OMe

O

COOH

NH

N N

F

OMe

O

COOH

NF

F

OMe

O

COOHNH

NH

Stage-I

MOXIFLOXACIN

Methyl 1-Cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolinecarboxylate

1-Cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolinecarboxylic acid

((S,S)-2,8-Diazobicyclo-[4,3,0]nonane)

Dimethylformamide

Triethylamine

Moxifloxacin

+

+

Stage-II

1-Cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolinecarboxylic acid

M.Wt:309

M.Wt:18

M.Wt:295

M.Wt:32

M.Wt:295

M.Wt:126

M.Wt:401

M.Wt:42

+ CH3OHMethanol

+NaFSodium fluoride

H2O

yield :81.5 %

yield :72.5%

+ NaOH

+ H2O

Sodium hydroxide

M.Wt:40

M.Wt:18



Flow Chart:

Stage-I:

WATER

DIISOPROPYL ETHER

REFLUX FOR 30 MINUTES

COOL TO RT

STIR FOR 30 MINUTES

COOL TO 5-100C

CENTRIFUGATION

RECOVERY OF DIISOPROPYL ETHERAND METHANOL FROM MLS

SOLID

DRYING

STAGE-I COMPOUND

MCQC*:METHYL-1-CYCLOPROPYL-6,7,DIFLUORO-1,4-DIHYDRO-8-METHOXY-4- OXOQUINOLINE CARBOXYLATE

STIR FOR 30 MINUTES

WATER

MCQC*

WASTE WATER TO ETP



Stage-II:

Material Balance:

Stage-I:

S.NO. In put Kg/d Out put Kg/d Remarks

1 Methyl-1-cyclopropyl-6, 7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolinecarboxylate

978.09 1-cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline carboxylic acid

761.028 Stage-I compound

2 Water 56.97 Water-waste water including HCL

1055.5 Waste water

3 Diisopropylether 1000 Un reacted Organics 1. Methyl-1-cyclopropyl-6, 7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinolinecarboxylate (181.074)

To waste water As residue

4 Water 1000

STAGE-I COMPOUND

STIRED AT 800CFOR 1 HOUR

((S,S)-2,8-DIAZOBICYCLO-[4,3,0]NONANE

DIMETHYLFORMAMIDE

COOL TO RT

WATER

CENTRIFUGATION

RECOVERY OF DIMETHYLFORMAMIDEAND NaF FROM MLS

SOLID

DRYING

MOXIFLOXACIN

NaOH

WASTE WATER



5 Hydro chloric acid 45 Methanol 82.53 To waste water

Diisopropylether recovery

980 Reuse

Diisopropylether Loss

20 Loss


Stage-II:

S. NO

In put Kg/d Out put Kg/d Remarks

1

1-cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline carboxylic acid

761.028 Moxofloxacin 750 Final Product

Water-waste

1000 +9.45+9.46

Waste water

2

((S,S)-2,8-Diazobicyclo-[4,3,0]nonane

324.954 Unreacted Organics 1-cyclopropyl-6,7-difluoro-1,4-dihydro-8-methoxy-4-oxo-3-quinoline carboxylic acid (200) ((S,S)-2,8-Diazobicyclo-[4,3,0]nonane(0) Unreacted Inorganics Sodium hydroxide(28.4)

3 Dimethylformamide 800 Sodium fluoride 78.54 Recovery and Reuse

4 Triethylamine 400 Dimethylformamide 770 Recovery and Reuse

5 Sodium hydroxide 103.16 Dimethylformamide 30 Loss Residue-20 Waste water-10

6 Water 1000 Triethylamine 370 Recovery and Reuse

Triethylamine loss 30 Residue-20 Waste water-10

Reaction water 33.66 To waste water




7. OXOLAMINE CITRATE

Description:

Stage-1: Benzamidoxime is treated with 3-chloropropinoyl chloride in the presence of

Acetone gives the intermediate O-(3-Chioropropionyl) benzamidoxime (Stage-I

Compound).

Stage-2: Stage-I Compound, which on treatment with Diethyl amine in the presence of

toluene gives the product Oxolamine.

Stage-3: Stage-II is salt formation with Citric acid in the presence of Methanol gives the

product OXOLAMINE CITRATE.

Flow chart:

ACETONE

3-CHLOROPROPINOYL CHLORIDE

COOL TO 5-100C

RESIDUE

RECOVERY OF ACETONE

STIR FOR 45 MINUTES

DISTILLATION

STAGE-I COMPOUND

BENZAMIDOXIME

STAGE-I:



STAGE-I COMPOUND

TOLUENE

STIR FOR 30 MINUTES

DIETHYL AMINE

HEAT TO 50-60°C

STIRR FOR 2-3 HRS

RECOVERY OF TOLUENE

SOLID

DRYING

OXOLAMINE

STAGE-II

WATER

STIR FOR 30 MINUTES

LAYER SEPARATION

Aq. LAYER COOL TO 5-10°C

WATER TO ETPLAYER SEPARATION




NH2

NOH

ClCOCH2CH

2Cl

NOCOCH2CH

2ClNH

2

N O

N NNH

NOCOCH2CH

2ClNH

2

+

STAGE-I:

BENZAMIDOXIME

3-CHLOROPROPIONYLCHLORIDE

DI-ETHYLAMINE OXOLAMINE

ACETONE

TOLUENE

WATER

Molecular Weight =136.15Molecular Formula =C7H8N2O

Molecular Weight =126.97Molecular Formula =C3H4Cl2O

+ HCL

Molecular Weight =226.67Molecular Formula =C10H11ClO2N2

O-(3-Chioropropionyl)benzamidoxime

Molecular Weight =73.14Molecular Formula =C4H11N


+ HCL



Hydrochloric acid

Hydrochloric acid

+

Water (H2O)


STAGE-II:

+



N

N

O

N

N

N

O

N

OHO

HO

OH

OH

OO

.

N,N-diethyl-2-(3-phenyl-1,2,4-oxadiazol-5-yl)

ethanamine

Citric Acid

Methanol

N,N-diethyl-2-(3-phenyl-1,2,4-oxadiazol-5-yl)ethanamine;

2-hydroxypropane-1,2,3-tricarboxylic acid

Molecular Weight=245.32Molecular Formula=C14H19N3O

Molecular Weight=437.50Molecular Formula=C14H19N3O.C6H8O7

STAGE-III



Material Balance:

Stage-I:

Sl No:

Input Kg Output Kg Remarks

1 Benzamidoxime 100.0 Stage-I compound. 150.0 Stage-I compound

2 3-chloropropinoyl chloride

100.0 Hydrochloric acid 26.7 To scrubber

3 Acetone 180 Acetone 165 15

For Recovery Loss

4

Unreacted organics: 1. Benzamidoxime (8.6) 2. 3-chloropropinoyl chloride (14.7)

23.3 Recovery and reuse


Stage-II:

Sl No:


1 Stage-I compound. 150.0 Stage-II compound. 140.0 Oxolamine

2 Diethyl amine 120.0 Hydrochloric acid 22.5

3 Toluene 565 Toluene 510 55

For Recovery Loss

4 Water 300 Water-waste water 311.5

5

Unreacted organics: 1. Stage-I compound (5.3) 2. Diethyl amine (75.5)


6 Residue 15


Stage-III:

S No.


1 Stage-II Compound 140 Stage-III Compound 183 OxolamineCitrate

2 Citric Acid 110

3 Methanol 500 Methanol 480 20

For Recovery Loss

4 Unreacted Organics: 1. Stage-II Compound

37 Recovery and Reuse

5 Residue 30

Total Input 750 Total Output 750



8. NEBIVOLAL

Description:

Stage-I: 6-Fluoro-3,4-dihydro-2-oxiranyl-2H-1-benzopyran is condensed with 2-

(benzylamino)-1-(6-fluoro-3,4-dihydro-2H-chromen-2-yl)ethanol in presence of

methanol to yield Stage- I Compound.

Stage-II: In presence of palladium carbon, Stage- I compound is hydrogenated and then

reacted with HCl to yield Nebivolol Hydrochloride.

Flow Chart:

Stage-I:

FDOB*

2-(BENZYLAMINO)-1-(6-FLUORO-3,4-DIHYDRO-2H-CHROMEN-2-YL)ETHANOL

METHANOL

REFLUX FOR 3HOUR 30 MINUTES

COOL TO RT

CRYSTALIZATION

CENTRIFUGATION METHANOL RECOVERY

STAGE-I COMPOUND

6-FLUORO-3,4-DIHYDRO-2-OXIRANYL-2H-1-BENZOPYRANFDOB*:

WATER



Stage-II:

STAGE-I COMPOUND

WATER

10%Pd/C

ACETONITRILE

FOR 1HOUR 30 MINUTES

HYDROGENATION

FILTERATION

FILTERATE

Pd/C RECOVERY

LAYER SEPARATION Aq.LAYER TO ETP

ORGANIC LAYER HYDROCHLORIC ACID

STIR FOR 30 MINUTES

CENTRIFUGATION RECOVERY OF ACETONITRILE AND TOLUENEFROM MLS

DRYING

SOLID

NEBIVOLOL HYDROCHLORIDE

H2 AT 1.5Kg/Cm2




STAGE-I

STAGE-II

O

O

F

+ CH3OH, O

F

OH

NH

O

OH

F

N

OH

O

F

CH2Ph

'-[[(Phenylmethyl)imino]bismethylene]bis-[6-fluoro-3,4-dihydro

-2H-1-benzopyran-2-methanol]

O

OH

F

N

OH

O

F

CH 2Ph

Pd/C(10%)

Aceto nitrile

O

OH

F

NH

OH

O

F

NEBIVOLOL HYDRO CHLORIC ACID

6-Fluoro-3,4-dihydro-2-oxiranyl-2H-1-benzopyran

'-[[(Phenylmethyl)imino]bismethylene]bis-[6-fluoro-3,4-dihydro

-2H-1-benzopyran-2-methanol]

M.Wt: 495.55

M.Wt: 194.20

M.Wt: 441.93

M.Wt: 496.56

M.Wt: 301.35

M.Wt: 92.13

+

CH3

Toluene

2-(benzylamino)-1-(6-fluoro-3,4-dihydro-2H-chromen-2-yl)ethanol

H2+

M.Wt: 2

Yield : 35 %

yield :62.5 %

+ ClH

M.Wt :36.5

ClH

NEBIVOLOL HYDROCHLORIC ACID



Material Balance:

Stage-I:

S.

No


1 6-Fluoro-3,4-dihydro-

2-oxiranyl-2H-1-

benzopyran

1509.708 Stage-I compound 1348.34 Stage-I

compound

2 2-(benzylamino)-1-(6-

fluoro-3,4-dihydro-2H-

chromen-2-yl)ethanol

2342.39 Methanol 1950 Recovery

and Reuse

3 Methanol 2000 Methanol 50 Loss

4 Water 2000 Waste water-water 2000+

1.29+2.72

Waste-

water

Unreacted Organics

1. 6-Fluoro-3,4-dihydro-2-

oxiranyl-2H-1-

benzopyran (980)

2. 2-(benzylamino)-1-(6-

fluoro-3,4-dihydro-2H-

chromen-2-

yl)ethanol(1520)

Total 7852.098 Total 7852.3

Stage-II:

S.No


1 Stage-I compound

1348.34 Nebivolol Hydrochloric acid

750 Final compound

2 Water 2000 Pd.Carbon 50 Solid waste

3 Pd.Carbon 50 Acetonitrile 1450 Recovery and reuse

4 Acetonitrile 1500 Acetonitrile 50 Loss Residue-40 Waste water-10

Waste water + Hydrochloric acid ( 43.03)

2000 +43.03

MEE

5 Hydrogen gas 5.43 Unreacted Organic 1.Stage-I compound 501.448

500

Recovery and reuse



2.Hydrogen gas (2.0358) 2.0358 Emission

6 Hydrochloric acid 99.0975

By product 1.Toluene

156.35 Waste water

Waste water-water

Total 5002.86 Total 5002.86

9. NEVERAPINE

Description:

Stage-I: 3-Amino-2-chloro-4-methylpyridine is reacted with 2-ChloronicotinoylChloride

(condensed) to give stage-I compound

Stage-II: Stage-I compound is reacted with Cyclopropyl amine (condensed) in presence

of Methanol to give stage-II compound

Stage-III: Stage-II compound is cyclised with Sodium hydroxide in the presence of O-

Xylene to give the Stage-III compound

Stage-IV: Stage-III compound is purified with n-Heptane to give NEVIRAPINE


N

CH3

NH2

Cl N Cl

COCl NNH

O ClN

CH3

Cl

NNH

O ClN

CH3

Cl

NH2

NH

NNH

ON

CH3

Cl

Stage - I

3-Amino-2-chloro-4-methylpyridine

+

2-Chloronicotinoylchloride

Toluene

Water

2-Chloro-N-(2-chloro-4-methyl-3-pyridyl)-3-pyridinecarboxamide

+ HCl

Stage - II

2-Chloro-N-(2-chloro-4-methyl-3-pyridyl)-3-pyridinecarboxamide

+

Cyclopropylamine

Methanol

Water

+ HCl

N-(2-Chloro-4-methyl-3-pyridinyl)-2-(cyclopropylamino)-3-pyridinecarboxamide

M.Wt: 142.5 M.Wt: 176 M.Wt: 282 36.5

M.Wt: 282 M.Wt: 57 M.Wt: 302.5 36.5

Yield :76%

Yield:80 %



NN Cl

NH

CH3

O

NH

N

CH3

N

NH

N

O

N

CH3

N

NH

N

O

N

CH3

N

NH

N

O

NaCl

Stage-III:

Nevirapine

N-(2-Chloro-4-methyl-3-pyridinyl)-2-cyclopropylamino)-3-pyridinecarboxamide

Nevirapine (crude)

Purification

o-Xylene

NaOH

Nevirapine (crude)

Stage-IV:

M.Wt:302.5

M.Wt:266

M.Wt:266 M.Wt:266

+ +

M.Wt:40

M.Wt:58.5

+ H2O

M.Wt:18

n-Heptane

yield : 71%

yield : 95.1%

Sodium hydroxide



Flow Chart:

Stage-I:

3-AMINO-2-CHLORO-4-METHYLPYRIDINE

2-CHLORONICOTINOYLCHLORIDE

STIR FOR 30 MINUTES

WATER

LAYER SEPARATION Aq.LAYER CONTAINS HCl TO ETP

ORGANIC LAYER

COOL TO 0-50C

CENTRIFUGATIONRECOVERY OF TOLUENE ANDUNREACTED RAW MATERIAL

SOLID

DRYING

STAGE-I COMPOUND

TOLUENE

STIR FOR 1 HOUR



Stage-II:

STAGE-I COMPOUND METHANOL

CYCLOPROPYLAMINE

REFLUX FOR 3 HOURS

COOL TO 0-50C

CHILLED WATER

STIR FOR 1 HOUR

CENTRIFUGATIONRECOVERY OF METHANOL AND WATER

SOLID

DRYING

STAGE-II COMPOUND(cmpc*)



Stage-III:

o-XYLENENaH

(under nitrogen atmosphere)

HEAT TO 120-1300C

CMCPC*

COOL TO RT

WATER

FILTERATION

DRYING

STAGE-III COMPOUND

STAGE-III

CMCPC*: N-(2-Chloro-4-methyl-3-pyridinyl)-2-cyclopropylamino)-3-pyridine carboxamide

STIR FOR 1 HOUR

CENTRIFUGATION RECOVERY OF o-XYLENE ANDTHEN MLS TO ETP

SOLID


ORGANIC LAYER

COOL TO 0-50C



Stage-IV:

Material Balance:

Stage-I:

S.No Input Kg/day Output Kg/day

1 3-Amino-2-chloro-4- methylpyridine

1304.8 2-Chloro-N-(2-chloro-4-methyl-3-pyridyl)-3-pyridinecarboxamide

1962.602

2 2-Chloronicotinoyl chloride

1611.544 HCL 254.0

3 Toluene 1500 Unreacted organics: 3-Amino-2-chloro-4- methylpyridine( 310.0)

2-Chloronicotinoyl Chloride ( 380.0 )

HEAT TO REFLUX

COOL TO 25-350C

NEVIRAPINE

STAGE-III PRODUCT

n-HEPTANE

DRYING

RECOVERY OF n-HEPTANE

DM WATER

LAYER SEPARATION

ORGANIC LAYER

Aq.LAYER TO ETP

COOL TO 0-50C

CRYSTALLIZATION



4 Water 1500 Wastewater 1500+3.143 +6.776

5 Toluene- Rec Toluene-Loss

1450 50

Total 5916.344 5916.5

Stage-II:

S. No

Input Kg/day Output Kg/day Remarks

1 2-Chloro-N-(2-chloro-4-methyl-3-pyridyl)-3pyridinecarboxamide

1962.6 N-(2-Chloro-4-methyl-3-pyridinyl)-2-(cyclopropylamino)-3-pyridinecarboxamide

1684.21

2 Cyclopropyl amine 396.663 HCL 202.94 recover

3 Unreacted: 2-Chloro-N-(2-chloro-4-methyl-3-pyridyl)-3pyridinecarboxamide(390.0) Cyclopropyl amine ( 75.0)

465

4 Methanol 2000 Methanol -Rec Methanol- Loss

1950 50

Recover Loss

5 Water 1000 Wastewater 1000+ 2.518 +4.743

To MEE

Total 5359.26 5359.42

Stage-III:

S. No. In put Qty Kgs Out put Qty Kgs Remarks

1 N-(2-chloro-4-methyl-3-pyridinyl)-2-cyclopropylamino)-3-pyridinecarboxamide

1684.219 Nevirapine crude (Stage-III) compound

1051.51 Stage-III compound

2 O-Xylene 2000 O-Xylene recovery 1980 Reuse

3 Sodium hydroxide 222.68 Solvent loss 20 Loss

5 Water 1000 Waste water-Water 1000 +8.235

Unreacted Organics 1. N-(2-chloro-4-methyl-3-pyridinyl)-2-cyclopropylamino)-3 pyridinecarboxamide (488.235 )

480 Reused



2. Sodium hydroxide (64.56)

NaCl (231.25 ) Into Waste

Reaction water 71.154 Into Waste

Total input 4906.899 Total output 4906.8 Stage-IV:

S. No. In put Qty Kgs Out put Qty Kgs Remarks

1 Nevirapine crude

1051.51 Nevirapine 1000 Final product

2 n-Heptane 500 n-Heptane recovery 480 Reuse

3 Water 500 Solvent loss 20 Loss Residue 10 Waste water-10

Waste water -Water 500+1.58 MEE

Unreacted Organics 1. Nevirapine crude

50 Recovered & reuse


10. SAQUINAVIR MESYLATE

Description:

Stage-I: (S,S,S)-N-Tert-butyl-decahydro-3-isoquinolinecarboxamide is reacted with

(S,S)-2-[1-[1-[(Benzyloxy)carbonyl]amino]-2-phenylethyl]oxirane (condensed) to give

stage-I compound

Stage-II: Stage-I compound is reduced in presence of ethanol to give stage-II compound

Stage-III: Stage-II compound is reacted with N-(2-quinolinylcarbonyl)-L-asparagine

(condensed) in presence of Carbonyl diimidazole and THF to give the Stage-III

compound

Stage-IV: Stage-III compound is salt formation with Methanesulfonic acid in presence

of Methanol to give SAQUINAVIR MESYLATE



Flow Chart:

Stage-I:

(S,S,S)-N-TERT-BUTYL-DECAHYDRO-3-ISOQUINOLINECARBOXAMIDE

(S,S)-2-[1-[1-[(BENZYLOXY)CARBONYL]AMINO]-2-PHENYLETHYL]OXIRANE

TOLUENE

SODIUM HYDROXIDE

REFLUX FOR 4 HOURS

COOL TO RT

WATER

LAYER SEPARATION Aq.LAYER CONTAINS NaOH TO ETP

ORGANIC LAYER



Stage-II:

ORGANIC LAYER

5%Pd/C

H2 AT 2 ATM

HYDROGENATIONFOR 3H 30 MINUTES

FILTRATION 5%Pd/C RECOVERY

FILTRATE

WATER

STIR FOR 30 MINUTES


ORGANIC LAYER

COOL TO 0-50C

SOLID

WASH WITH ETHANOL

DRYING

STAGE-II COMPOUND(AHDI*)



Stage-III:

[3S-[2[1R*(R*),2S*],3,4a,8a]]-2-[3-amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

STAGE-III

WATER

STIR FOR 30 MINUTES (Condensation)

LAYERS SEPERATION

DISTILLATION

RESIDUE

STAGE-III COMPOUND

AHDI*

N-(2-quinolinylcarbonyl)-L-asparagine

CARBONYL DIIMIDAZOLE

ORGANIC LAYER

RECOVERY OF THFANDTRIETHYLAMINE

RECOVERY OF n-HEXANE

DM WATER

AHDI*:

THF

TRIETHYLAMINE

COOL TO 0-50C

STIR FOR 30 MINUTES

Aq.LAYER TO ETP

DISTILLATION

n-HEXANE

RESIDUE

STIR FOR 60 MINUTES

CENTRIFUGATION WASTE WATER TO ETP

SOLID



Stage-IV:

STAGE-IV

STAGE-III COMPOUND

METHANESULFONIC ACID

METHANOL

METHANOL RECOVERYFROM MLS

SOLID

DRYING

SAQUINAVIR MESYLATE

STIR FOR 1 HOUR AT 45-500C

DISTILLATION

RESIDUEMETHANOL

STIR FOR 1 HOUR AT RT

CENTRIFUGATION METHANOL RECOVERY




NH

H

H

NH

O

CH3

CH3CH

3

NH O

OPh

OPh

NH

OPh

OPh

OH

N

NH

O CH3

CH3

CH3

H

H

NH

OPh

OPh

OH

N

NH

O CH3

CH3

CH3

H

H

NH2

Ph

OH

N

NH

O CH3

CH3

CH3

H

H

Stage - I

(S,S,S)-N-Tert-butyl-decahydro-3-isoquinolinecarboxamide

+

(S,S)-2-[1-[1-[(Benzyloxy)carbonyl]amino]-2-phenylethyl]oxirane

Toluene

[3S-[2[1R*(R*),2S*],3alpha,4abeta,8abeta]]-2-[3-[(Phenylmethoxy)carbonyl]amino]-2-hydroxy-4-phenylbutyl]-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

Stage - II

[3S-[2[1R*(R*),2S*],3alpha,4abeta,8abeta]]-2-[3-[(Phenylmethoxy)carbonyl]amino]-2-hydroxy-4-phenylbutyl]-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

Water

[3S-[2(2S*,3S*)3alpha,4abeta,8abeta]]-2-(3-Amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)decahydro-3-isoquinolinecarboxamide

+ PhCH2COOH

M.Wt: 238 M.Wt: 297

M.Wt: 535

M.Wt:535 M.Wt: 401 M.Wt:136

+ H2

Water

Ethanol

Yield :72 %

Yield :78 %

M.Wt :2

benzene acetic acid



Stage-III

SAQUINAVIR MESYLATE

Stage-IV

N

O

NH

O

NH2

NH

O

Ph

OH

N

NH

O

C(CH3)3

H

H

N

O

NH

COOH

O

NH2

+ NH2

Ph

OH

N

NH

O

C(CH3)3

H

H

THFCDI

N-(2-quinolinylcarbonyl)-L-asparagine [3S-[2[1R*(R*),2S*],3,4a,8a]]-2-[3-amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

Saquinavir

M.Wt:670

M.Wt:287

M.Wt:401

N

O

NH

O

NH2

NH

O

Ph

OH

N

NH

O

C(CH3)3

H

H

Saquinavir

N

O

NH

O

NH2

NH

O

Ph

OH

N

NH

O

C(CH3)3

H

H

Saquinavir mesylate

M.Wt:766

CH3SO

3H+

.CH3SO3H

methanol

M.Wt:96

+ OH2

M.Wt:18

M.Wt:670

Yield :75.7%

Yield :86.4%

Methanesulfonic acid

Triethylamine



Material Balance:

Stage-I:

S. No

Input Kg/day Output Kg/ day

Remarks

1 (S,S,S)-N-Tert-butyl-decahydro-3-isoquinolinecarboxamide

121.045 [3S-[2[1R*(R*),2S*],3alpha,4abeta,8abeta]]-2-[3-[(Phenylmethoxy)carbonyl]amino]-2-hydroxy-4-phenylbutyl]-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

195.91

2 (S,S)-2-[1-[1-[(Benzyloxy)carbonyl]amino]-2-phenylethyl]oxirane

151.0245

1.(S,S,S)-N-Tert-butyl-decahydro -3-isoquinolinecarboxamide) (33.8674 ) 2. (S,S)-2-[1-[1 [(Benzyloxy)carbonyl]amino]-2-phenylethyl]oxirane(42.2637 )

76.130 Recovery & reuse

3 Water 500 Wastewater 500 MEE

4 Toluene 500 Toluene-Recovery Toluene -Loss

450 50

Recovery Loss+ residue

Total 1272.0 1272.0 Stage-II:

S. No

Input Kg/day Output Kg/day

Remarks

1 [3S-[2[1R*(R*),2S*],3alpha,4abeta,8abeta]]-2-[3-[(Phenylmethoxy)carbonyl]amino]-2-hydroxy-4-phenylbutyl]-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

195.91 [3S-[2(2S*,3S*)3alpha,4abeta,8abeta]]-2-(3-Amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)decahydro-3-isoquinolinecarboxamide

114.54 Stage-ii product

2 Hydrogen 0.7324 Benzene acetic acid recovery 38.84 Byproduct

3 Unreacted organics: [3S-[2[1R*(R*),2S*],3alpha,4abeta,8abeta]]-2-[3-[(Phenylmethoxy)carbonyl]amino]-2-hydroxy-4-phenylbutyl]-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

(43.121)

Hydrogen Emission (0.1612)

43.121 0.1612

Recover emission

4 Water 500 Wastewater 500 Waste water

5 Ethanol 500 Ethanol-Rec Ethanol-loss

480 20

Recovery Loss+ residue

Total 1196.64 Total 1196.66



Stage-III:

S. No


1 [3S-[2[1R*(R*),2S*],3,4a,8a]]-2-[3-amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide

114.5417

Saquinavir 202.47

Stage-III compound

2 N-(2-quinolinylcarbonyl)-L-asparagine

160.039 THF Recover, Triethylamine recovery

360 450

Reuse

3 THF 400 Solvent loss 90 Loss

4 Carbonyl diimidazole 100 Waste water- water 600 MEE

5 Water 600 Unreacted Organic 1. [3S-[2[1R*(R*),2S*],3,4a,8a]]-2-[3-amino-2-hydroxy-4-phenylbutyl)-N-(1,1-dimethylethyl)-decahydro-3-isoquinolinecarboxamide (27.839) 2. N-(2quinolinylcarbonyl)-L-asparagine (38.897)

Recover & reuse

6 Triethylamine 500 Reaction water 5.437

After the reaction is completed the reagent Carbonyl diimidazole is reacted with water and is converted in to Imidazole (recovery) and carbon dioxide

100 Reuse


Stage-IV:

S. No


1 Saquinavir 202.470 Saquinavirmesylate

200 Final product

2 Methanesulfonic acid

29.00 Methanol recovery 450 Reuse

3 Methanol 500 Methanol loss 50 Loss



4 Water 500 Waste water-water 500 MEE

Unreacted Organic 1. Saquinavir(27.53)

2. Methanesulfonic acid (3.945)



11. STAVUDINE

Description:

Stage-I: 5-Methyluridine is reacted with Acetyl bromide and Benzoylchloride

(Benzoylation) in presence of Acetic acid to give stage-I compound

Stage-II: Stage-I compound is hydrogenation with Zn, Acetic acid in the presence of

isopropyl alcohol to give the Stage-II compound

Stage-III: Stage-II compound is reacted with water (De Benzoylation) and followed by

salt formation with NMPO to give stage-III compound

Stage-IV: Stage-III compound is Desalt formation with n-Hexane in presence of acetone

to give STAVUDINE




O

NH

N

O

CH3

OH OH

OOH O

NH

N

O

CH3

OAc Br

OPhCOO

O

NH

N

O

CH3

OAc Br

OPhCOO

O

NH

N

O

CH3

OPhCOO

+ CH3COBr + C6H5COClacetic acid

STAGE-II

STAGE-I

Zn,aceticacid

Isopropyl alcohol

5-methyl uridine

Acetylbromide Benzoylchloride

+

H2O

HCl

5'-Benzoyl-3'-O-Acetyl2'-Bromo-5-methyluridine

Hydrochloride

M.Wt:258

M.Wt:123 M.Wt:140.5

M.Wt:467

M.Wt:36.5

M.Wt:18

M.Wt:467

5'-Benzoyl-3'-O-Acetyl2'-Bromo-5-methyluridine

+ H2

M.Wt:2

5'-Benzoyl-2',3'-didehydro3'-deoxythymidine

+

CH3COOH

HBr

Aceticacid

Hydrobromide

M.Wt:328

M.Wt:81

M.Wt:60



Material Balance:

Stage-I:

S. No

Input Kg/day Output Kg/ day

Remarks

1 5-Methyluridine 1090.44 5'-Benzoyl-3'-O-Acetyl 2'-bromo-5-methyluridine.

1381.65 1ststage product

2 Acetyl bromide 519.85 Reaction eater 53.253 To waste water

3 Benzoylchloride 593.823 Unreacted organics: 1) 5-Methyluridine(327.144) 2) Unreacted Acetyl bromide 155.964 3) Unreacted Benzoylchloride 178.154

Recovery & reuse

4 Water 1000 Wastewater 1000 MEE

O

NH

N

O

CH3

PhCO2

O

O

NH

N

O

CH3

OHO

O

NH

N

O

CH3

OHO

O

NH

N

O

CH3

OHO

COOH

.H2O

StavudineNMPO solvate

5'-Benzoyl-2',3'-didehydro-3'-deoxythymidine

N-Methylpyrrolidinone(NMPO)

Monomethylamine

Isopropyl acetate

Purification:

Acetone

Stavudine

NMPO

Stage-III:

StavudineNMPO solvate

.NMPO

Stage-IV:

M.Wt:328

M.Wt:323

M.Wt:99

M.Wt:224

+.NMPO

M.Wt:323

M.Wt:99

+ +

M.Wt:122

+

M.Wt:18

Yield :91.3%

Benzoic acid

N-Methylpyrrolidinonen-Hexane



5 Acetic acid 500 Acetic acid recovery Acetic acid loss

400 100

Recovery & reuse Loss

HCl 107.985 By product


Stage-II:

S. No

Input Kg/day Output Kg/day Remarks

1 5'-Benzoyl-3'-O-Acetyl 2'-bromo-5-methyluridine.

1381.65 5'-Benzoyl-2'.3'-didehydro- 3'-deoxythymidine

679.138 Stage II compound

2 Zinc 16.9 Unreacted organics: I i)51-Benzoyl-3'-O-Acetyl

2'-bromo-5-methyluridine (419.5092).

Recovery and reuse

3 Acetic acid 1500 Acetic acid- Recovery Acetic Acid Loss

1450 50

Recovery Loss

4 Water 500 Wastewater 500 Waste water

5 IPA 1000 IPA- Recovery IPA -Loss

960 40

Recovery Loss

5 Sodium Hydroxide 24 Byproducts: recovery I) Acetic acid (124.26) II) Hydrogen bromide(167.75) Sodium Hydroxide 24.0

By product

6 Hydrogen 5.7 Zinc 12.4 recovery

Total 4428.25 Total 4428.5 Stage-III:

S. No.

In put Qty kgs

Out put Qty Kgs Remarks

1 5'-Benzoyl-2',3'-didehydro-3'-deoxythymidine

679.138 Stage-III compound 473.5 Stage-III compound

2 Monomethylamine 600 Isopropyl acetate-rec Isopropyl acetate-loss

760 40

Reuse

3 N-Methylpyrrolidinone 207.306 Monomethylamine recovery Loss

500

100

Reuse

4 Isopropyl acetate 800 Loss

5 Reactant water 37.278 Unreacted Organics 1.5'-Benzoyl-2',3'-

Recovery &reuse



didehydro-3'-deoxythymidine(200.4728) 2. N-Methylpyrrolidinone(59.9049) 3. Reactant water ( 10.89)

By product Benzoic acid recovery

178.8398 Reuse


Stage-IV:

S. No. In put Qty kgs Out put Qty kgs Remarks

1 Stage-III compound

473.5 Stavudine 300 Reuse

2 Acetone 600 Acetone recovery, n-Hexane recovery

550 370

Reuse

3 Activated Carbon

50 Activated Carbon recovery

50 Solid waste

4 n-Hexane 400 Solvent loss Acetone , n-Hexane

50

30

Loss-20-waste water Residue-60

5 water 500 Unreacted Organic 1. Stage-III compound

41.2477 Recovery & reuse

By product N-Methylpyrrolidinone

132.5 By product

Waste water 500

Total Input 2023.5 Total output 1523.7



Flow Chart:

Stage-I:

5-METHYL URIDINE DIISOPROPYLETHER

STIR FOR 1 HOUR

ACETIC ACID

ACETYL BROMIDE


WATER

STIR FOR 30 MINUTES

COOL TO 0-50C

CENTRIFUGATION RECOVERY OF ACETIC ACID FROM MLS

SOLID

DRYING

STAGE-I COMPOUND

BENZOYL CHLORIDE

COOL TO 0-50C

WATER

SOLID

CENTRIFUGATIONRECOVERY OF BENZOICACIDAND DIISOPROPYL ETHER FROM MLS



Stage-II:

STAGE-I COMPOUND

Zn,ACETIC ACID (EXCESS)

STIR FOR 3 HOURS

ISOPROPYL ALCOHOL

STIR FOR 45 MINUTES

COOL TO 5-100C

CENTRIFUGATIONRECOVERY OF ACETICACID ANDISOPROPYL ALCOHOL

SOLID

DRYING

STAGE-II COMPOUND(BDD)*

SODIUM HYDROXIDE

STAGE-I COMPOUND

Zn,ACETIC ACID (EXCESS)

STIR FOR 3 HOURS

ISOPROPYL ALCOHOL

STIR FOR 45 MINUTES

COOL TO 5-100C

CENTRIFUGATIONRECOVERY OF ACETICACID ANDISOPROPYL ALCOHOL

SOLID

DRYING

STAGE-II COMPOUND(BDD)*

SODIUM HYDROXIDE



12.

STAGE-IV

ACETONE

STAGE-III COMPOUND

HEAT TO REFLUX

ACTIVATED CARBON

COOL TO 0-100C

FILTERATION

RECOVERY OF n-HEXANE AND ACETONE

HEAT TO REFLUX

CENTRIFUGATION

SOLID

DRYING

STAVUDINE

SOLID

n-HEXANE

WATER

CENTRIFUGATION WASTE WATER TO ETP

CARBON RECOVERY

FILTERATE

STAGE-III

BDD*

MONOMETHYLAMINE

HEAT TO 45-500C

COOL TO RT

N-METHYLPYRROLIDINONE

STIR FOR 15 MINUTES

RECOVERY OF BENZOIC ACID AND ISOPROPYLACETATE

SPIN DRY

STAGE-III COMPOUND

ISO PROPYL ACETATE

BDD*: 5'-Benzoyl-2',3'-didehydro- 3'-deoxythymidine

WATER

LAYER SEPARATION

ORGANIC LAYER

RECOVERY OF MONOMETHYL AMINE FROM Aq.LAYER

COOL TO 5-100C

CENTRIFUGATION

SOLID

WASTE TO ETP



12 DOTHIEPIN (DOSULEPIN) HCL

Description:

Stage-1: 11H-10-Thia-dibenzo[a, d]cyclohepten-5-one is treated with 3-chloropropyl

dimethyl amine in the presence of Mg Toluene and Tetrahydrofuran to give 5-(3-

Dimethylamino-propyl)-5,11-dihydro-10-thia-dibenzo[a,d]cyclohepten-5-ol (Stage-I)

compound.

Stage-2: 5-(3-Dimethylamino-propyl)-5,11-dihydro-10-thia-dibenzo[a,d]cyclohepten-5-

ol (Stage-I) is treated with Hydrochloric acid to give Dothiepin

(Dosulepin)Hydrochloride.




S

O

Cl N

S

OH

N

S

OH

N

S

N

MgCl2

11H-10-Thia-dibenzo[a,d]cyclohepten-5-one

Stage-I:

+

(3-Chloro-propyl)-dimethyl-amine

Mg

TOLUENE + THF

5-(3-Dimethylamino-propyl)-5,11-dihydro-10-thia-dibenzo[a,d]cyclohepten-5-ol

5-(3-Dimethylamino-propyl)-5,11-dihydro-10-thia-dibenzo[a,d]cyclohepten-5-ol

DOSULEPIN (DOTHIEPIN)

HYDROCHLORIDE

Stage-II:

WATER

DichloromethaneACETONE

. HCl

Molecular Weight =226.30Molecular Formula =C14H10OS

Molecular Weight =121.61Molecular Formula =C5H12ClN

Molecular Weight =313.47Molecular Formula =C19H23NOS

Molecular Weight =313.47Molecular Formula =C19H23NOS

Molecular Formula: C19H21NS. HClMolecular Weight: 331.90.

Hydrochloric Acid

HCL


+ +

Magnesium

Molecular Weight =24.87

+

Magnesium chloride


Hydrochloric Acid

HCL


+

+

Water (H2O)


METHANOL



Flow Chart:

STAGE-I

TETRAHYDROFURAN

RECOVERY OF TOLUENE AND TETRAHYDROFURAN

ORGANIC LAYER

DISTILLATION

STIR FOR 45 MINUTES

COOL TO 0-10°C

LAYER SEPARATION

MAGNESIUM3-chloropropyl-Dimethyl amineTOLUENE

11H-10-Thia-dibenzo [a,d]cyclohepten-5-oneTOLUENE

STIR FOR 2 TO 3 HRS

HYDROCHLORIC ACIDWATER

STIR FOR 30 MINUTES

Aq. LAYER TO ETP

METHANOL

SOLID

STIR FOR 2 TO 3 HRS

CENTRIFUGATION

SOLID

DRYING

STAGE-I COMPOUND

METHANOL RECOVERY



Stage-II:

STAGE-I COMPOUND

WATER

STIR FOR 3-4 HRS

HEAT TO 50-600C

COOL TO RT

STIR FOR 30 MIN

Aq. LAYER TO ETP

HYDROCHLORIC ACID

DICHLOROMETHANE

LAYER SEPARATION

RECOVERY OF DICHLOROMETHANE

ORGANIC LAYER

DISTILLATION

ACETONE

SOLID

STIR FOR 2 TO 3 HRS

CENTRIFUGATION

SOLID

DRYING

STAGE-II COMPOUND

ACETONE RECOVERY



Material Balance:

Stage-I:

S.No: Input Kg Output Kg Remarks

1 11H-10-Thia-dibenzo [a,d]cyclohepten-5-one

100.0 Stage-I compound. 110.0 Stage-I compound

2 3-chloropropyl-Dimethyl amine

95.0 Waste water + Unreacted Hydrochloric acid

270 To waste water

3 Magnesium 18.3 Toluene+ Tetrahydrofuran 490 For Recovery

4 Toluene 370 Toluene+ Tetrahydrofuran 60 Loss

5 Tetrahydrofuran 180

4 Hydrochloric Acid 80

5 Water 200 Residue 20

6

Unreacted organics: 1. 211H-10-Thia-

dibenzo[a,d]cyclohepten-5-one (7.3)

2. 3-chloropropyl-Dimethylamine (42.7)

Unreacted Inorganic: Magnesium (1.2 )

51.2

To waste water To waste water

MgCl2 42.1 Solid Waste


Stage-II:

SL No:


1 Stage-I compound 110.0 Stage-I compound. 100.0 Stage-I compound

2 Hydrochloric Acid 30 kg Waste water + Unreacted Hydrochloric acid

220 To waste water

3 Dichloromethane 665 Dichloromethane 530 135

For Recovery Loss


For Recovery Loss

5 Water 200 Residue 18

6 Methanol 200 Methanol 180 20

For Recovery Loss

7

Unreacted organics: Stage-I compound (2.0)

2.0 To waste water




13 OXOLAMINE PHOSPHATE

Description:

Stage-1: Benzamidoxime is treated with 3-chloropropinoyl chloride in the presence of

Acetone gives the intermediate O-(3-Chioropropionyl) benzamidoxime (Stage-I

Compound).

Stage-2: Stage-I Compound, which on treatment with Diethyl amine in the presence of

toluene gives the product Oxolamine.

Stage-3: Stage-II is salt formation with Phosphoric Acid in the presence of Acetone gives

the product OXOLAMINE PHOSPHATE.


NH2

NOH

ClCOCH2CH

2Cl

NOCOCH2CH

2ClNH

2

N O

N NNH

NOCOCH2CH

2ClNH

2

+

STAGE-I:

BENZAMIDOXIME

3-CHLOROPROPIONYLCHLORIDE

DI-ETHYLAMINE OXOLAMINE

ACETONE

TOLUENE

WATER


Molecular Weight =126.97Molecular Formula =C3H4Cl2O

+ HCL



Molecular Weight =73.14Molecular Formula =C4H11N


+ HCL



Hydrochloric acid

Hydrochloric acid

+

Water (H2O)


STAGE-II:

+





Material Balance:

SL No

Input (Stage-1)

Kg Output Kg Remarks

1 Benzamidoxime 100.0 Stage-I compound. 150.0 Stage-I compound

2 3-chloropropinoyl chloride

100.0 Hydrochloric acid 26.7 To scrubber


For Recovery Loss

4

Unreacted organics: 1. Benzamidoxime (8.6) 2. 3-chloropropinoyl

chloride (14.7)



Stage-II:

Sl. No:


1 Stage-I compound

150.0 Stage-II compound. 140.0 Oxolamine

2 Diethyl amine 120.0 Hydrochloric acid 22.5

3 Toluene 565 Toluene 510 55

For Recovery Loss

4 Water 300 Water-waste water 311.5

5

Unreacted organics: 1. Stage-I compound (5.3) 2. Diethyl amine (75.5)


6 Residue 15


N

N

O

N

N

N

O

N

P

O

HO OH

OH

N,N-diethyl-2-(3-phenyl-1,2,4-oxadiazol-5-yl)

ethanamine

Phosphoric Acid

Acetone

N,N-diethyl-2-(3-phenyl-1,2,4-oxadiazol-5-yl)ethanamine;phosphoric acid

Molecular Weight=245.32Molecular Formula=C14H19N3O

Molecular Weight=343.31Molecular Formula=C14H22N3O5P

STAGE-III



Stage-III:

SNo. Input Kg Output Kg Remarks

1 Stage-II

Compound

140 Stage-III Compound. 165 Oxolamine

Phosphate

2 Phosphoric Acid 56

3 Acetone 500 Acetone 475

25

For Recovery

Loss

4 Unreacted Organics:

1. Stage-II Compound

16 Recovery and

Reuse

5 Residue 15

Total Input 696 Total Output 696

14 ZINDOVUDINE

Description:

Stage- I: Thymidine is reacted with Methane sulfonyl chloride (protection) in presence

of n-Hexane to give Stage-I compound

Stage-II: Stage-I compound is cyclised with Acetic anhydride to give Stage-II

compound

Stage-III: Stage-II compound is reacted with Sodium azide in presence of HCl to give

the final compound of ZIDOVUDINE.



Flow Chart:Stage- I:

THYMIDINE

METHANE SULFONYL CHLORIDEn-HEXANE

WATER

STIR FOR 90 MINUTES

LAYER SEPARATION

ORGANIC LAYER

DISTILLATION

RESIDUE

STAGE-I COMPOUND

RECOVERY OF n-HEXANE

Aqueous layer contains methane sulfonic acid (recovery)

HCl TO SCRUBBER



Stage- II:

Stage- III:

STAGE-I

ACETIC ANHYDRIDE

REFLUX FOR 1 HOUR

STIR FOR 40 MINUTES

COOL TO 0-50

C

CENTRIFUGATION

SOLID

STAGE-II COMPOUND

WATER

WASTE WATER TO ETP

STAGE-II COMPOUND

SODIUM AZIDE

ETHYL ACETATE

MAINTAIN FOR 1 HOUR AT 45 C0

COOL TO 0-5 C0

CENTRIFUGATION

SOLID

DRYING

ZIDOVUDINE

HYDROCHLORIC ACIDMETHANOL




O

NH

N

O

CH3

MsO O

OMs

O

NH

N

O

CH3

OH O

OH

O

NH

N

O

CH3

OMsO

O

NH

N

O

CH3

MeoTrO OO

NH

N

O

CH3

OH O

N3

O

NH

N

O

CH3

MsO O

OMs

CH3SO

2Cl

MsOH

MsOH NaOH

Methanesulfonyl chloride

Thymidine

2,3'-anhydro-5'-O-(methoxytrityl) thymidine

3',5'-bis-O-(Monomethylsulphonyl)thymidine

Scheme:

STAGE-I

STAGE-II

STAGE-III

NaN3

Zidovudine

M.Wt:242 M.Wt:398

M.Wt:302M.Wt:398

M.Wt:302 M.Wt:267

+

M.Wt:229

+ 2HCl

M.Wt:73

M.Wt:96

+

M.Wt:96M.Wt:65

+ + ++ 2H2O

M.Wt:36

M.Wt:40

n-Hexane

Yield : 69.3 %

Yield : 79.3 %

Yield : 85.2 %

Sodium azideSodiumhyroxide


2

3',5'-bis-O-(Monomethylsulphonyl)thymidine

2,3'-anhydro-5'-O-(methoxytrityl) thymidine

HCl


Water

Acetic anhydride



Material Balance: Stage-I:


1 Thymidine 580.3 Stage-I compound 661.6 Stage-I compound

2 Methane sulfonyl chloride

549.2 n-Hexane recovery 980 Reuse

3 n-Hexane 1000 Waste water-Water 1000+5 MEE

4 Water 1000 Solvent loss 20 Loss-10 Residue-10

Unreacted Organics 1. Thymidine (173.1) 2. Unreacted Methane sulfonyl chloride 168.7

341.8

Aqueous mls contain HCl 121.4 Waste water Total 3129.5 Total 3129.8

Stage-II:


1 Stage-I compound

661.86 Stage-II compound 398.26 Stage-II compound

2 Acetic anhydride 100 Acetic anhydride recovery 90 Reuse

3 Water 1000 Solvent loss 10 Loss

Waste water-Water 1000 MEE

Unreacted Organics 1. Stage-I compound

137 Reuse

By productMethanesulfonic acid recovery

126.5 Reuse

Total 1761.86 Total 1761.8

Stage-III:


1 Stage-II compound

398.26 Zidovudine 300 Final compound

2 Sodium azide 85.7155 HCl 100 Reuse

3 HCl 100 Solvent loss Loss



4 Water 147.81 Waste water- 107 +5 MEE

Unreacted Organic 1. Stage-II compound (54.1014) 2. Unreacted Sodium azide 12.72

66.8214 (recovery and reuse)

Byproducts 1. Methanesulfonicacid(107.8) 2.Sodium hydroxide (44.92)

152.72

Total 731.7855 Total 731.67

15 DIACEREIN

Description:

Stage-1: Aloe-emodin is treated with acetic anhydride in the presence of Sodium acetate

gives the intermediate product

Stage-2: Tri acetyl aloe emodine which upon treatment with CrO3 in the presence of

acetic acid gives product Stage-I (Diacerein Crude).

Stage-3: (Diacerein Crude) is treated purified in DMA to give the product Diacerein.




O

O

OH

OH OH O

O

O

O OO O

O

O

O

OH

O OO O

O

O

O O

OH

O

O

O

OH

O OO O

O

O

O

OH

O OO O

O

O

O

O

O OO O

O.H

2O

OH

O

CrO3H

2

Acetic Anhydride

Sodium Acetate

Aloe-emodin Triacetyl Aloe-emodin

2 CrO3

Acetic Acid

Diacerein Crude

+

Stage-I




+



Acetic acid

Stage-III

Diacerein Crude


Diacerein


N,N-Dimethylacetamide

3 x 102.09 = 306.27

3.

3 x 60.05 = 180.15

3.

Triacetyl Aloe-emodin

+


Chromium trioxide


+2

Water Moleculer Weight= 18.02


Acetic acid+

2 x 99.9 = 199.8

2 x 18.02 = 36.04 +

2


2 x 102.01 = 204.02

Stage-II



Material Balance:

Stage-I:

SL No Input Kg Output Kg Remarks

1 Aloe-emodin 100 Tri acetyl aloe emodine 142.0 Stage-I compound

2 Acetic Anhydride

1000 Acetic Acid as byproduct 66.7 Recovery and Reuse

3 Sodium Acetate

100 Sodium Acetate 95 Recovery and Reuse

4 Unreacted organics: 1. Aloe-emodin (1.3) 2. Acetic anhydride (870)

871.3 Recovery and Reuse

5 Mixture of Acetic acid, acetic anhydride and sodium acetate

25

Total input 1200 Total output 1200 Stage-II:

SL No:


1 Tri acetyl aloe emodine

142.0 Diacerein Crude 122.0 Stage-II compound

2 Acetic Acid 600 Acetic Acid 620 Recovery and Reuse

3 Water 60 Waste water Water 33

4 Chromic anhydride (CrO3)

200 Unreacted organics: Tri acetyl aloe emodine(2.5)

2.5 Recovery and Reuse

5 CrO3 H2 36.5

Unreacted Chromic anhydride (CrO3) as Chromic acid

170

Residue 18


Stage-III:

Sl No In put Kg/d Out put Kg/d Remarks

1. Diacerein Crude 122.0 Diacerein 90 Final Product

2 N, N-Dimethylacetamide

600 N, N-Dimethylacetamide 580 20

Recovery Loss

3 Activated carbon 2 Activated carbon 2 Solid waste

Unreacted Diacerein Crude

32 Recovery and reuse




Flow Chart:

ACETICANHYDRIDE

HEAT TO100-1100C

SOLID

RECOVERY OF ACETIC ANHYDRIDE, ACETIC ACID

STIR FOR I HR

COOL TO 5-10°C

ALOE EMODIN

STAGE-I:

SODIUM ACETATE

CENTRIFUGATION

DRYING

STAGE-I COMPOUND

ACETICACID

HEAT TO 50-600C

SOLID

RECOVERY OF ACETIC ACID

STIR FOR 4-5 HRS

COOL TO 25-30°C

TRI ACETYL ALOE EMODIN

STAGE-II:

CHROMIC ANHYDRIDE+WATER

CENTRIFUGATION

DRYING

STAGE-II COMPOUND



16 TERBINAFINE HCL

Description:

Stage-I: N-methyl-naphthalene methanamine is condensed with 1-bromo-6,6-dimethyl-

2-hepten-4-yne in presence of Dimethyl sulfoxide to get Terbinafine (Stage- I product).

Stage-II: Terbinafine is reacted with HCl (Salt formation) in presence of NaoH and

ethanol to yield Terbinafine HCl.

DIACEREIN CRUDESTAGE-II COMPOUND

N,N-DIMETHYL ACETAMIDE

STIR FOR 30 MINUTES

ACTIVATED CARBON

STIR FOR 30 MINUTES

FILTRATION ACTIVATED CARBON RECOVERY

COOL TO 10-150C

CENTRIFUGATION RECOVERY OF N,N-DIMETHYL ACETAMIDE

SOLID

DRYING

DIACEREIN

HEAT TO 75-80°C

STAGE-III:




Stage-I

TERBINAFINE HCl

N

CH3 C(CH3)3

.HCl

N

CH3 C(CH3)3

N

CH3 C(CH3)3

NH

CH3

+ Br

C(CH3)3

TERBINAFINE HCl

Terbinafine baseN-methyl-naphthalene methanamine

dimethyl sulfoxide

water

M.Wt:201.1

M.Wt:171.2M.Wt:291.4

1-bromo-6,6-dimethyl-hept-2-ene-4-yne

M.Wt:327.9

+

Stage-II

NaBr

Terbinafine base

M.Wt:291.4

+ NaCl

M.Wt:102.9

M.Wt:58.5

+NaOH

M.Wt:40

sodium hydroxide

H2O+M.Wt:18

NaOH

M.Wt:40

sodium hydroxide

+ 2HCl+M.Wt:73

H2O

M.Wt:18

+Ethanol

Yield : 58.2 %

Yield :96.0 %



Flow Chart:

Stage- I:

Stage- II:

DIMETHYL SULFOXIDE

1-BROMO-6,6-DIMETHYL-HEPT-2-ENE-4-YNESODIUM HYDROXIDE

REFLUX FOR 45 MINUTES

COOL TO 5-100C

CENTRIFUGATION

SOLID

RECOVERY OF DIMETHYL SULFOXIDE

RECOVERY OF SODIUM BROMIDE

STAGE-I COMPOUND

N-MNMAH*

WASTE TO ETP

N-MNMAH*: N-methyl-naphthalene methanamine

STAGE-I COMPOUND

HEAT TO 400C FOR 1 HOUR

COOL TO RT

CENTRIFUGATION

SOLID

DRYING

TERBINAFINE HYDROCHLORIDE

HYDROCHLORIC ACID

ACETONITRILE

Neutralise with sodium hydroxide

RECOVERY OF SODIUM CHLORIDE

RECOVERY OF ACETONITRILE

WASH WITH ACETONITRILE



Material Balance:

Stage-I:


1 N-methyl-naphthalene methanamine

186.872 Stage-I product 185.12 Stage-I product

2 1-bromo-6,6-dimethyl-2-hepten-4-yne

219.5 Dimethyl sulfoxide (Rec) 370 Reuse

3 Sodium hydroxide 43.66 Waste water-Water 500 MEE

4 Dimethyl sulfoxide 400 Unreacted Organics- 1. N-methyl-naphthalene methanamine(78.118) 2. 1-bromo-6,6-dimethyl-2-hepten-4-yne (91.76) Unreacted Inorganics

1. Sodium hydroxide (18.252)

188.13 ML‟s for reuse

5 DM Water 500 Aqueous mother liquors contain Sodium bromide recovery

65.37 By Product

Reaction water 11.4336

Waste water

Solvent loss 30 Residue-20 Waste water-10

Total 1350.03 Total 1350.05

Stage-II:

S.No Input Kg/d Output Kg/d Remark

1 Stage-I product 185.12 Terbinafine hydrochloride 200 Final product

2 Conc.Hydrochloric acid

46.3769 Waste water- 600

3 Sodium hydroxide 25.412 Unreacted Organics-

1. Stage-I product (10.256) Unreacted Inorganics 1.Conc.Hydrochloric acid (1.8542) 2.Sodium hydroxide (1.016)

12.27 Reuse

4 Acetonitrile 500 Acetonitrile recovery 480 Reuse

Acetonitrile loss 20 loss

5 Water 600 Aqueous mother liquors contain Sodium chloride

35.679 Waste water



Reaction water 10.9782 Waste water

Total 1359. 0 Total 1359. 0

17 EZITIMIBE

Description:

Stage- I: 3R-(3R*, 4S*)]-1-(4-fluorophenyl)-3-[3-(-4-fluorophenyl)-3-oxopropyl]-4-

(phenylmethoxyl-2-azetidinone is reduced with Bistrimethylsilylurea in presence of

Diisopropyl ether to give Stage-I compound

Stage-II: Stage-I compound is deprotected with Pd/C in presence of acetone to give

EZETIMIBE


Stage- I:

NO

O

F

F

OBn

NOF

F

OH

OBn

[3R-(3R*,4S*)]-1-(4-fluorophenyl)-3-[3-(-4-fluorophenyl)-3-oxopropyl] -4-[4-(phenylmethoxy)phenyl-2-azetidinone

[3R-[3R*(S*),4S*]]-1-(4-fluorophenyl)-3-[3-(4-fluorophenyl)-3-hydroxypropyl] -4-[4-(phenylmethoxy)-2-azetidinone

M.Wt:497

M.Wt:499

M.Wt:499

+ H2

M.Wt:2

Bistrimethylsilylurea

Water

Yield : 58.4 %



Stage- II:

Flow Chart:

Stage- I:

NO

OH

F

F

OBn

Pd/C

NOF

F

OH

OH CH3

10%

[3R-[3R*(S*),4S*]]-1-(4-florophenyl)-3- [3-(4-fluorophenyl)-3-hydroxypropyl]-4- [4-(phenylmethoxy)phenyl]-2-azetidinone

Ezetimibe

M.Wt:499

M.Wt:409

+

M.Wt:92

+ H2

M.Wt:2

Acetone

Yield : 81.5 %

Toluene

FOPA*: [3R-[3R*(S*),4S*]]-1-(4-fluorophenyl)-3-[3-(4-fluorophenyl)-3-oxypropyl]-4-[4- (phenylmethoxy)phenyl]-2-azetidinone

FOPA*

BISTRYLSILYLUREA

DIISOPROPYL ETHER

DISTILLATION

RESIDUE

RECOVERY OF DIISOPROPYL ETHER

(H2)

REDUCTION

STAGE-I COMPOUND



Stage- II:

Material Balance:

Stage-I:


1 3R-(3R*, 4S*)]-1-(4-fluorophenyl)-3-[3-(-4-fluorophenyl)-3-oxopropyl]-4-(phenylmethoxyl-2-azetidinone

2553.06

Stage-I compound 1496.99

Stage-I compound

2 Bistrimethylsilylurea 50 Bistrimethylsilylurea 50 To waste

STAGE-ICOMPOUND

HYDROGENATION

FILTERATION

DISTILLATION

RESIDUE

STIR TO 45 MINUTES

CENTRIFUGATION

SOLID

DRYING

EZETIMIBE

WATER

WASTE WATER TO ETP

10% Pd/C

RECOVERY OF Pd/C

RECOVERY OF ACETONE&TOLUENE

ACETONE

H2 AT 3-4 Kg/cm2



water

3 Water 2000 Solvent loss 100 Residue-90,to waste water-10

4 Hydrogen gas 10.273

Unreacted Organic 1. 3R-(3R*, 4S*)]-1-(4-fluorophenyl)-3-[3-(-4-fluorophenyl)-3-oxopropyl]-4-(phenylmethoxyl-2-azetidinone (1052 ) 2. Hydrogen gas (4.2758)

1052 4.2758

Recovery & reuse Emission

5 Diisopropyl ether 3000 Diisopropyl ether recovery

2900 Reuse

6 Waste Water with 3R-(3R*, 4S*)]-1-(4-fluorophenyl)-3-[3-(-4-fluorophenyl)-3-oxopropyl]-4-(phenylmethoxyl-2-azetidinone (10. 53)

2000 +10. 53+10

To waste water for MEE

Total input 7613.4 Total output 7613.4 Stage-II:


1 Stage-I compound

1496.99 Final compound 1000 Final compound

2 Pd.Carbon 25 Pd.Carbon 25 Solid waste

3 Hydrogen gas 5.988 Acetone recovery 1450 Reuse

4 Acetone 1500 Solvent loss 50 Loss(residue-40, Waste Water-10)

5 Water 1500 Unreacted Organics 1.Stage-I compound (270) 2. Hydrogen gas (1.1082 )

270 Reuse Emission

By product toluene recovery

224.93 Reuse

Waste Water Stage-I compound (7.4959)

1500 +7.4959 +10

To MEE




2.9 RESOURCEREQUIREMENT

2.9.1 MAJOR RAW MATERIALS

Synthetic Organic Chemicals involves the use of various chemicals and organic

solvents either directly as reactant or for extraction of a product of interest from the

reaction mixture. The chemicals required for the process are mostly bought from the

local markets. Mode of transportation of all raw materials and finished products for /

from the project site is by road from/to local markets. The list of solvents & hazardous

chemicals and other chemicals with their storage capacity for the manufacture of

aboveproducts are presented in Table-2.7.

TABLE-2.7: LIST OF SOLVENTS & HAZARDOUS CHEMICALS AND THEIR

CONSUMPTION & STORAGE

S. No.

Raw material Maximum storage KL

Physical status

Storage container

Packets/ drums/ bags

etc (Nos.)

Storage area

Solvents

1 Methanol 28 Liquid MS Tank Tank Solvent storage yard

2 Acetone 14 Liquid MS Tank Tank Solvent storage yard

3 Toluene 7 Liquid MS Tank Tank Solvent storage yard

4 Tetrahydrofuran 1 Liquid HDPE Drum Drum Drum yard 5 Dichloromethane 1 Liquid HDPE Drum Drum Drum yard 6 N,N-

Dimethylacetamide 1 Liquid HDPE Drum Drum Drum yard

7 Acetic Acid 2 Liquid HDPE Drum Drum Drum yard 8 Acetonitrile 1 Liquid HDPE Drum Drum Drum yard 9 n-Hexane 7 Liquid MS Tank Tank Solvent

storage yard 10 Ethyl Acetate 9 Liquid MS Tank Tank Solvent

storage yard 11 Dimethyl

Formamide 1 Liquid HDPE Drum Drum Drum yard

12 Diisopropyl Ether 1 Liquid HDPE Drum Drum Drum yard 13 O-Xylene 1 Liquid MS Drum Drum Drum yard 14 n-Heptane 1 Liquid HDPE Drum Drum Drum yard 15 Ethanol 1 Liquid MS Drum Drum Drum yard 16 Isopropyl alcohol 1 Liquid HDPE Drum Drum Drum yard



17 Isopropyl acetate 1 Liquid HDPE Drum Drum Drum yard 18 Dimethyl sulfoxide 1 Liquid HDPE Drum Drum Drum yard

Hazardous chemicals 1 Sulphuric Acid 10 Liquid MS Tank Tank Solvent

storage yard 2 Hydrochloric Acid 10 Liquid PP/FRP Tank Tank Solvent

storage yard 3 3-Chloropropinoyl

chloride 1 Liquid HDPE Drum Drum Drum yard

4 Diethylamine 1 Liquid MS Drum Drum Drum yard 5 Acetic Anhydride 1 Liquid HDPEDrum Drum Drum yard 6 Chromic

Anhydride 0.5 Tonn Solid MS Drum Drum Ware house

7 Pentyl chloroformate 0.5 Liquid HDPE Drum Drum Drum yard 8 Chloroacetyl

chloride 0.5 Liquid HDPE Drum Drum Drum yard

9 Phenylamine 0.5 Liquid HDPE Drum Drum Drum yard 10 Triethylamine 1.0 Liquid MS Drum Drum Drum yard 11 Aluminium chloride 0.5 Tonn Solid LDPE bags LDPE bags Ware house 12 Cyclopropyl amine 0.5 Liquid MS Drum Drum Drum yard 13 Acetyl bromide 0.5 Liquid Glass Liner

Drum Liner Drum Drum yard

14 Benzyl Chloride 0.5 Liquid HDPE Drum Drum Drum yard 15 Monomethylamine 0.5 Liquid MS Drum Drum Drum yard 16 Methyl sulfonyl

chloride 0.5 Liquid HDPE Drum Drum Drum yard

Other chemicals 1 Palladium Carbon 25 Kg Solid HDPE Drum LDPE bag Ware house 2 H2 Gas -- Gas Cylinder Cylinder Cylinder

storage area 3 Zinc Dust 100 Kg Solid HDPE Drum LDPE bag Ware house

During transportation of the raw material the procedures given in the MSDS will

be followed and MSDS copy of for all the chemicals used are attached as ANNEXURE-

3. The raw materials and their quantities to be used in proposed production facility are

mentioned above.

Chorus labs Limited is not proposing any use of banned chemicals and

Hazardous chemicals in the proposed modification project. The list of ban chemicals

declared by International Labour Organization is presented in ANNEXURE-4.



2.9.2 STORAGE & TRANSPORTATION OF RAW MATERIALS & PRODUCTS

All the raw materials will be first received by the stores department and samples

of raw materials will be sent to quality control (QC) laboratory wherein the quality of

raw material will be tested. Only after confirmation of quality by the QC lab, the raw

material will be transferred / unloaded at the respective ware house storage area in the

factory with proper labeling. The raw material in general will be received in bags /

cartons / carboys /drums / cylinders as well as through tankers. Material received

from tanker will be stored in above ground tanks. All the storage tanks of hazardous

flammable substances will be located within premises in separate approved storage

area i.e. Tank farm area.

Source of raw material will be local. Warehouse will be containing store office,

raw material store, dispensing area, finished product store, etc. Personnel protective

equipment‟s like hand gloves, safety shoes, goggles, helmet, clothing are being

provided to the persons in required area. All motors and electrical connections are

flame proof. Raw materials transported from the storage area to the production plant by

hydraulic trolley/fork lift/trolley / closed pipe as applicable. Modes of transportation

of all raw materials to the plant site and finished products from the plant site are by

road. Final Products are transported through vehicles according to the requirement and

capacity of the customer requirement.

All the bulk liquid raw materials are stored in storage tanks at separate storage

area. The storage area for hazardous chemicals is located within the boundary wall with

a constant watch by security round the clock. All necessary firefighting system and

safety arrangements are provided near the storage area to combat any emergency

accident. The liquid chemicals are transported through pipes via rack to day tank of

production area from storage tanks.

STORAGE:

Industry provided adequate and proper storage facilities for all the raw materials

and finished products. Corrosive substances are being stored away from the moisture.

Solid raw material is stored in covered area and liquid raw material stored in closed



horizontal tank. Hazardous chemicals and solid wastes are stored away from other

plant activities. The storage yards of chemical are isolated and it will be equipped with

all necessary safety measures.

Raw material storage is in two forms:

1. Liquid type storage: Storage Tankers of seven numbers with total capacity of 85

Kilo liter capacity each are utilized for the storage of the solvents. All other liquid

and seamy liquid raw material is stored in drums with different sizes as per the

products requirement.

2. Solid storage types: Raw materials which are solid in nature are stored in bags

within the closed building and exclusively 1800 sq meter area is reserved for

solid raw material storage area.

HANDLING:

All the raw materials, finished products are being handled as per the standard

practice. For proper handling, company adapted good housekeeping technology to

entire building.

TRANSPORTATION:

All the necessary precautions are taken while carrying out transport of the above

materials as per the Hazardous Rules of transportation. The vehicles for transportation

of raw materials, products are being parked at specified loading facilities where there is

a provision of fire extinguishers. The finished product is also transported by road.

ROAD CONNECTIVITY:

The site is bounded by 12m wide KIADB road on Northwest side of the project

site. This road is connected to SH 105 –Bidar Humnabad Road within 700m radius of

the site.

2.9.3 MACHINERIES & UTILITIES

As the proposed project is carried out in the existing premises, existing

infrastructure facilities will also be utilized with the addition of some new machineries

and utilities for the proposed project.



The plant and machinery for modification of synthetic organic chemicals

manufacturing consists of glass lined and stainless steel reactors, centrifuges, filters,

dryers, flame proof motors, pumps and storage tanks. The utility systems consist of

boiler, cooling tower, DG generators, chilling plants, vapor absorption system, water

purification systems etc. In addition to this some of the pollution control equipment

such as scrubbers, solvent distillation column, steam strippers, Multiple Effect

Evaporation (MEE) with condensers, ATFD, multi cyclone separators, bag filters, RO

systems, etc. will be provided. List of plant and machinery is presented in ANNEXURE-

5.

TABLE-2.8: LIST OF NO. OF REACTORS AND VOLUME FOR EACH PROPOSED

PRODUCT

Sl.

No. Name of the Product

Number of

Reactor

Total Volume

(KL)

1. ETODOLAC 3 9.5

2. OXOLAMINE CITRATE 4 9.0

3. DOSULEPIN(DOTHIEPIN) HCL 5 9.0

4. OXOLAMINE PHOSPHATE 4 10.7

5. DIACEREIN 8 14.86

6. CAPECITABINE 4 13.0

7. DICLOFENAC SODIUM 8 24.0

8. EFAVIRENZ 4 12.0

9. LEVITERACITAM 4 18.7

10. MOXIFLOXACIN 4 10.0

11. NEBIVOLAL 7 22.0

12. NEVIRAPINE 10 27.7

13. SAQUINAVIR MESYLATE 5 10.5

14. STAVUDINE 11 25.68

15. ZIDOVUDINE 4 11.0

16. TERBINAFIEN HCL 3 7.0

17. EZITAMIBE 4 13.5

Note: Total Reactors are at present in the industry are 16.

The water consumption is 31.5 KLD. Wastewater generation is 13.91 KLD

including domestic wastewater of 1.3 KLD. The effluents are being segregated into

High TDS and Low TDS streams. HTDS effluents are collected, neutralized, and

evaporated in MEE. The condensate from MEE is taken in to the biological treatment

system along with the LTDS wastewater.



The purpose of solvent recovery system is to recover solvents from spent solvent

streams and reuse the pure solvent in manufacturing process. Industry is having

solvent recovery system (single distillation column) in the process to recover the spent

solvents after reaction. The solvent bulk storage tanks are provided with vent

condensers. Reactors are connected to chilled brine condenser system. Mechanical seals

provided to reactor and solvent handling pump to prevent leakages. Earthing has been

provided to all the electrical installations. Flame proof mechanism has been provided

and breather valves installed to solvent storage tanks to prevent losses. A dedicated

closed pipeline is installed to the reactors for transfer of solvents from storage tanks.

Reflux condenser provided over the reducer. Leak proof mechanism installed as a

precautionary measure for safety. All bulk liquids are transferred / filled / handled by

pumping through pipelines. Wherever closed feed is not possible, it is being handled

manually as per standard operating procedures (SOPs). SOPs adopted for all individual

activities are attached as ANNEXURE – 6

Permitted hazardous /solid waste are segregated, detoxified and collected in the

HDPE drums/bags and is stored in the covered and raised platform with Leachate

collection system prior to disposal to authorized parties. The existing solid waste with

other waste generated, handling and disposal method from the various stages of

Synthetic Organic Chemicals plant is presented in the Table 2.13.Spillages such as

wastewater/solid wastes/raw materials 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.

Coal consumption of about 5 TPD is used in the existing coal fired boilers of

capacity 1×2TPH. Fly ash generated from the boiler is disposed to brick manufacturing

units. Adequate stack height has been provided with pollution control devices like dust

collector and multi-cyclone separator.



Noise levels are being monitored both day and night by in-house. Further, noise

levels are monitored by the MoEF&CC approved laboratory once in a month.

Occupational health surveillance of the workers is carried out once in a year.

Industry is monitoring the ambient air quality (AAQ), Stack emissions, effluent,

Noise, VOC within plant premises from time to time with the help of third party

laboratory services and found within prescribed standards.

WAREHOUSES AND ITS SAFETY FEATURES:

Storage of bulk chemicals mainly solvents is stored in respective storage tanks in

licensed tank form area. Apart from tank form area, the liquid chemicals are stored in

specified drums i.e. PVC & MS and also in carboys in dedicated ware house. Solid /

Power chemicals are stored in dedicated Ware house. The ware house floors are made

of impervious and the room is well ventilated. Gas cylinders are stored at dedicated

areas; storage of chemicals is depicted in plant layout.

Warehouse is containing store office, raw material store, dispensing area,

finished product store, etc. Personnel protective equipment‟s like hand gloves, safety

shoes, goggles, helmet, clothing, etc., wherever required, will be provided to the

persons. All motors and electrical connections is flame proof. Raw materials transported

from the storage area to the production plant by hydraulic trolley/fork lift/trolley /

closed pipe as applicable.

MSDS for all hazardous chemicals are placed in each chemical storage area in

addition to the store office & EHS cell. Respective fire extinguishers are placed as per

safety norms. Employees will use PPEs during handling of chemicals. Dedicated closed

with scrubber facility attached dispensing area provided in Ware house for dispensing

the required chemicals.

CORPORATE ENVIRONMENT POLICY:

The company has a well laid down Environment Policy approved by its Board of

Directors. The environment, health & safety (EHS) policy approved and signed by Vice



Chairman. To comply with approved EHS policy, proponent developed standard

operating procedures/ work instructions for EHS activities. The EHS management

systems are certified with ISO 9001:2008, ISO-14001:2004 & OHSAS-18001:2007.

Proponent is having a dedicated EHS department headed by Manager rank employee

with 8 years of experience in the field of EHS management. The EHS head (Sr.

Manager) is directly reporting to the Director-Operations who is directly overseen the

EHS department. Proponent has established the reporting mechanism of violations

/deviations /non- compliances with respect to Environment. Regular management

review meetings is conducted at site level with all functional heads and chaired by

Director. The minutes of meeting/decision will be presented to the Board by the

Director.

2.9.4 WATER CONSUMPTION

Water during operation phases for the proposed modification project is procured

through KIADB. Daily water requirement during operation phase is estimated to be 31.5

KLD, out of which approximately 1.5 KLD of water required for domestic consumption,

4 KLD is for gardening and remaining 26 KLD for industrial use.

2.9.5 POWER REQUIREMENT

Power demand during operation phase is 250 kVA. The supply of power is met

through GESCOM supply. Diesel generators set of 1×200 kVA is provided as source for

power backup in case of emergency.

2.9.6 MAN POWER REQURIEMENT

The manpower is one of the main resource requirements to operate and maintain

the plant in a better and efficient way. Total 20 personnel are working in the existing

plant and after modification project there is no additional manpower required.

2.9.7 GREENBELT DEVELOPMENT

Vegetation is the natural extension of the soil ecosystem on a site. It can provide

summer shade, wind protection, and a low-maintenance landscape that is adapted to



the local environment. It is proposed to develop a 40% of the total site area as greenbelt

area which amounts to about 5,615 Sqmt of total site area.

40% of total plot area has been earmarked for developing green belt all along the

boundary.

Avenue trees will also be raised along the road side.

Native trees will be planted where ever required.

2.10SOLVENT REQUIREMENTS & RECOVERY SYSTEM

The industry proposes to manufacture synthetic organic chemicals (Bulk Drugs

& Drugs Intermediates), which require solvents during various unit processes. The unit

intends to use various solvents viz. Methanol, Toluene, Acetone etc are tabulated below.

The spent solvent generated during the manufacturing process will be recovered by

way of distillation and reused in the process.

The process of the solvent recovery system is described hereunder;

After the completion of the reaction, the spent solvent/mother liquor will be

separated by centrifuge and pumped to distillation reactor. It will be subjected to

distillation to separate and recover solvent.

Firstly, the mass will be distilled at required temperature where pure solvents will

be distilled out depending on their boiler points and it will be collected in the

recovered solvent storage tank and reused in the process

Measures for achieving maximum solvent recovery:

The entire manufacturing activities & distillation process will be carried out in the

totally closed system.

Maintenance of the pipeline and valves & fittings will be carried out regularly to

avoid any leakages.

Reactor will be connected with two numbers of condensers where cooling water

and chilled water will be used as media and also equipped with vacuum system as

per requirement.

The condenser will be provided with the sufficient HTA and residence time to

achieve more than 90% recovery.



The fresh solvent requirement will be depended on generation of distillation loss.

The details of solvent consumption and mass balance are given below.

TABLE-2.9: PROPOSED PRODUCT WISE SOLVENT USAGE, LOSSES AND RECOVERY

No. Product details Stage wise

Solvents details Used Recovery Loss

1. Etodolac Stage-1 Methanol 450 440 10 Stage-2 Activated Carbon 3 3 --

2. Oxolamine Citrate

Stage-1 Acetone 180 165 15 Stage-2 Toluene 565 510 55 Stage-3 Methanol 500 480 20

3 Dosulepin (Dothiepin) Hcl

Stage-1 Toluene+ Tetrahydrofuran 550 490 60 Stage-2 Dichloromethane

Acetone Methanol

665 475 200

530 430 180

135 45 20

4 Oxolamine Phosphate

Stage-1 Acetone 180 165 15 Stage-2 Toluene 565 510 55 Stage-3 Acetone 500 475 25

5 Diacerein Stage-3 N, N-Dimethylacetamide

Activated Carbon 600 2

580 2

20 --

6 Capecitabine Stage-1 Acetonitrile 1500 1470 30 Stage-2 Methanol 1000 960 40

7 Diclofenac Sodium Stage-2 Toluene 1600 1550 50

8 Efavirenz Stage-1 n-Hexane 2000 1890 110 Stage-2 Ethyl acetate 1000 950 50

9 Leviteracitam Stage-1 Acetonitrile 1500 1450 50 Stage-2 Di methylformamide 1500 1450 50

10 Moxifloxacin Stage-2 Di methylformamide

Triethylamine 800 400

770 370

30 30

11 Nebivolal Stage-1 Methanol 2000 1950 50 Stage-2 Acetonitrile 1500 1450 50

12 Nevirapine

Stage-1 Toluene 1500 1450 50 Stage-2 Methanol 2000 1950 50 Stage-3 O-Xylene 2000 1980 20 Stage-4 n-Heptane 500 480 20

13 SaquinavirMesylate

Stage-1 Toluene 500 450 50 Stage-2 Ethanol 500 480 20 Stage-3 THF

Triethylamine 400 500

360 450

40 50

Stage-4 Methanol 500 450 50

14 Stavudine Stage-1 Acetic acid 500 400 100



Stage-2 Acetic acid IPA

1500 1000

1450 960

50 40

Stage-3 Isopropyl acetate Monomethylamine

800 600

760 500

40 100

Stage-4 Acetone Activated Carbon n-Hexane

600 50 400

550 50 370

50 -- 30

15 Zidovudine

Stage-1 n-Hexane 1000 980 20 Stage-2 Acetic anhydride 100 90 10 Stage-3 HCl 100 100 --

16 TerbinafienHcl Stage-1 Dimethyl sulfoxide 400 370 30 Stage-2 Acetonitrile 500 480 20

17 Ezitamibe

Stage-1 Di Isopropyl ether 3000 2900 100 Stage-2 Pd.Carbon

Acetone 25

1500 25

1450 -- 50

2.11POLLUTION POTENTIAL AND MANAGEMENT

The proposed project will have potential of pollution mainly due to the

wastewater generation& disposal, gaseous emission from process, flue gas emission

from utilities and hazardous waste generation & disposal. These potentials of pollution

are described below under respective heading with necessary details.

2.11.1 WATER POLLUTION


through KIADB. Daily water requirement during operation phase is estimated as

31.5KLD, out of which approximately 1.5 KLD of water required for domestic

consumption, 4 KLD is for gardening and remaining 26KLD for industrial use. The

breakup of daily water requirement for operation phase is given in Table-2.10.

The total water required after modification would be about 31.5 KLD. The total

water requirement will be met from KIADB. Treated effluent will be recycled/reused

from ETP-ZLD in utility make-up thereby fresh water consumption will be reduced.

The proposal is to minimize the effect on the level of water table by working out reuse

of the treated water wherever it is possible thereby reducing the fresh water

requirement. The proposed wastewater generation will be 12.61 KLD from process.



TABLE 2.10: WATER CONSUMPTION, WASTEWATER GENERATON

AND TREATMENT METHOD

S.

No.

Purpose Water Requirement

in KLD

Effluent generation in

KLD

Treatment method

1 Domestic usage 1.5 1.3 Biological treatment system

2 Process water 11.5 12.61 Treated in ETP followed by MEE and ATFD 3 Cooling tower 4.0 0.8

4 Boiler feed 8.0 0.8

5 Washing 2.5 2.5

6 Gardening 4.0 -- --

Total 31.5

FIGURE - 2.5: WATER BALANCE CHART

The sources of wastewater generation are from the process, floor & reactor

washings, utilities, scrubber and plant domestic waste. Total generation of wastewater

after modification will be 18.31 KLD, which will be segregated into considering TDS/

COD concentrations and collected by gravity into a collection tank separately. This



individual effluent will be pumped to the RCC lined tanks for storage and

neutralization then sent to ETP-ZLD.

Proposed MEE treatment plant will be constructed / installed above the ground

with water proof lining. This individual effluent will be pumped to the RCC lined tanks

for storage and neutralization then sent to ETP-ZLD of 20 KLD capacity within the

premises.

ETP–ZLD facility with primary (equalization and neutralization), secondary

(stripper with MEE, ATFD & biological) and tertiary treatment (PSF, ACF & RO) will be

provided. Domestic wastewater will be sent to biological treatment. Concentrate from

MEE system will be sent to ATFD.

2.11.2 AIR POLLUTION

The main source of air pollution will be flue gas emission and process gas

emission from the proposed project. There will be also chances of fugitive emission due

to manufacturing activities and storage, handing & transportation of raw materials

&products. Various potential of air pollution are described hereunder;

Gaseous emission from fuel burning, which consists of common pollutants like

SO2, NO2 and PM, would be discharged into atmosphere through 30 m height

stack with Multi-cyclone separator followed by Bag filter. All reactor vessels are

protected by primary and secondary condenser with circulation of cooling and

chilled water in order to prevent emission of volatile solvent. Reactors also

connected to multi-stage scrubbers to control the process emissions during the

reaction.

The hazardous chemicals and volatile organic solvents are carefully handled in a

closed system, thereby preventing any discharge of these chemicals into the air.

All internal roads are Cement concrete to reduce the fugitive emissions

Green belt will be further developed at the plant boundary as dust preventive

barrier.



Flue Gas Emission:

Boilers and DG sets are the main sources which contribute to emissions from the

plant. The existing boiler will be utilized after the proposed project. Coal is being used

for steam generation, Particulate Matter (PM), Sulphur dioxide (SO2) and Oxides of

Nitrogen (NOx) will be the major pollutants. The various measures proposed to

minimize the pollution from the boiler are: Multi-cyclone separator followed by Bag

filter is be installed to control the particulate (PM) emissions within statutory limit of

100 mg/Nm3. To facilitate wider dispersion of pollutants, suitable stacks height for each

boiler 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 staging in

boiler. The NOx emissions will be restricted to below 500 mg/Nm3.

TABLE-2.11: DETAILS OF FLUE GAS EMISSION

Sl. No.

Source of air Pollution Type of

Fuel Sulphur content

Chimney height

(in m) AGL

Constituents to be

controlled

Air pollution control system

provided

Existing

1 Coal fired Boiler

- 2 TPH Coal 0.8% 30 m AGL PM, SO2, NOx Dust collector

2 250 kVA DG Set HSD -- 5 m AGL SO2 Acoustic Measures

3 Process emission -- -- 20 m AGL Acid mist Scrubber

Process Emissions:

Synthetic Organic Chemicals process generates gaseous emissions. Proposed

gaseous emissions will be scrubbed in multi stages with water/caustic solution/HCl

based on the characteristics of gases. A stack of suitable height (above roof level) will be

provided to each of the scrubber.

TABLE-2.12: PROPOSED PRODUCT WISE PROCESS EMISSION

Sl. No.

Source of air Pollution

Type of Fuel Sulphur content

Chimney height (in m)

AGL

Constituents to be

controlled


provided

1 Process

emission -- -- 20 m AGL Acid mist Scrubber



Fugitive Emissions from Solvents Handling and their Recovery:

Various types of solvents are used in the Synthetic Organic Chemicals

manufacturing process. The product wise solvents input, solvent loss and recovery is

presented in below table. Solvent is a leading source of Hazardous Waste. By reducing

the solvent use it also reduce cost of purchasing solvent as well as solvent losses.



1. Etodolac Stage-1 Methanol 450 440 10

Stage-2 Activated Carbon 3 3 --

2. Oxolamine Citrate Stage-1 Acetone 180 165 15

Stage-2 Toluene 565 510 55


3 Dosulepin(Dothiepin) Hcl

Stage-1 Toluene+ Tetrahydrofuran 550 490 60

Stage-2 Dichloromethane Acetone Methanol

665 475 200

530 430 180

135 45 20

4 Oxolamine Phosphate Stage-1 Acetone 180 165 15


Stage-3 Acetone 500 475 25

5 Diacerein

Stage-3 N, N-Dimethylacetamide


580 2

20 --

6 Capecitabine Stage-1 Acetonitrile 1500 1470 30



8 Efavirenz Stage-1 n-Hexane 2000 1890 110

Stage-2 Ethyl acetate 1000 950 50

9 Leviteracitam Stage-1 Acetonitrile 1500 1450 50

Stage-2 Di methylformamide 1500 1450 50

10 Moxifloxacin

Stage-2 Di methylformamide Triethylamine

800 400

770 370

30 30

11 Nebivolal Stage-1 Methanol 2000 1950 50

Stage-2 Acetonitrile 1500 1450 50

12 Nevirapine Stage-1 Toluene 1500 1450 50


Stage-3 O-Xylene 2000 1980 20

Stage-4 n-Heptane 500 480 20

13 SaquinavirMesylate Stage-1 Toluene 500 450 50

Stage-2 Ethanol 500 480 20



Stage-3 THF Triethylamine

400 500

360 450

40 50




1500 1000

1450 960

50 40


800 600

760 500

40 100


600 50 400

550 50 370

50 -- 30

15 Zidovudine Stage-1 n-Hexane 1000 980 20

Stage-2 Acetic anhydride 100 90 10

Stage-3 HCl 100 100 --

16 TerbinafienHcl Stage-1 Dimethyl sulfoxide 400 370 30


17 Ezitamibe Stage-1 Di Isopropyl ether 3000 2900 100

Stage-2 Pd.Carbon Acetone

25 1500

25 1450

-- 50

The solvents are stored in drums and bulk quantities are stored in above storage

tanks of suitable capacities. Solvents are handled in closed conditions thereby reducing

the losses in the form of evaporation. The industry taking measures for reduction of

fugitive emissions and further reduction will be achieved by providing vent condensers

to the tanks. Chilled brine circulation will be carried out to condensate the solvent

vapor and to the receivers of the solvent vapors which ensures the maximum recovery

and also controlled by closed operations and handling methods. Good ventilation will

be provided to reduce the workroom concentrations. The reactor generating solvent

vapors being connected to double condensers with receivers. Solvent vapours from the

Centrifuge and Catch pots will be connected to vent condensers. Vent condensers will

be provided to the solvent receiver tank and height of the vent is above production

block roof level and the diameter is 20 mm. The solvent loss is depending on the boiling

point of the solvent.



Solvent management for effective recovery:

Solvents used in the manufacturing process will be stored in drums and bulk

quantities will be stored in above storage tanks with all safety measures.

Solvents are handled in closed conditions thereby reducing the losses in the form

of evaporation.

Proper earthling 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.

Reactor will be connected to chilled brine condenser system. Condensers will be

provided with sufficient Heat Transfer Area (HTA) and residence time so as to

achieve maximum recovery

Chilled brine circulation will be carried out to condensate the solvent vapor and to

the receivers of the solvent vapors which ensures the maximum recovery.

The industry will take measures for reduction of fugitive emissions and further

reduction industry will be provided vent condensers to the tanks.

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/ equipment‟s/ pumps/ lighting will continue to be used

wherever solvents are used. The solvent storage tanks will be provided with

breather valve to prevent losses.

2.11.3 HAZARDOUS WASTE

The product wise solid/hazardous waste and other waste generated are

estimated, handling and disposal method from the various stages of Synthetic Organic

Chemicals plant is presented in the Table 2.13.

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. Spillages such as wastewater/solid wastes/raw materials 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.

Solid/Hazardous waste mainly segregated into process organic residues,

Inorganic salts, spent mixed unrecoverable solvents and spent carbon. These wastes are

hazardous in nature as they emanate from the chemical reactions or un-reacted

chemical wastes. The organic residues & spent carbon can be stored in HDPE drums

and sent to KSPCB Authorized Cement industries as recommended by CPCB for use as

alternate fuels either in the solid or liquid form and copy of MOU and manifesto is

attached as ANNEXURE - 7. Solid waste will be segregated, stored and disposed. Boiler

Ash will be stored in covered area and sold to Brick Manufacturers and copy of MOU

and manifesto is attached as ANNEXURE -8.

The main sources of hazardous waste generation from proposed manufacturing

activity will be process wastes viz. inorganic residue, distillation residue, spent carbon.

Dried sludge will be generated from effluent treatment plant. The ancillary source of

hazardous waste generation will be discarded bags/liners/drums/Carboys/Containers

from storage and handling of raw materials and spent oil generation from plant

machinery. The details of hazardous waste generation and handling/ Management are

given in Table 2.13.

TABLE-2.13: DETAILS OF SOLID & HAZARDOUS WASTE GENERATION AND MANAGEMENT

Source Description Quantity in Kg/day Disposal method

Process

Inorganic solid waste 1,080 Sent to TSDF

Spent carbon 100 Sent to cement industries

MEE salts 1122 Sent to TSDF

Raw Material Storage & Handling

Detoxified containers 200 nos./Month KSPCB authorized agencies for reprocessing/

recycling LDPE bags 500 nos./month HDPE drums 200 nos./month

Plant and Machineries

Waste oil 2 KL/Annum

Coal ash from boiler 300 Kg/day Sent to Brick manufactures



Solvent distillation

bottom residue.

25 kg/day Sent to TSDF

The unit will provide an adequate designated storage area for the hazardous

waste storage within premises having impervious floor and roof cover system. The unit

has obtained membership of KSPCB approved Hazardous waste management unit for

disposal of hazardous waste and copy of certificate is enclosed as ANNEXURE-9.

2.11.4 NOISE & VIBRATION

Compressors, Boilers and DG sets are the major noise generating units in the

plant. Out of these, the generator will be functioning at the time of power failure. The

noise levels of the DG sets will be well within the limits as these will be installed with

built-in acoustic enclosures. However the workers in this area will always be provided

with ear muffs. 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.

Proposed modification project site boundary with greenbelt is located in Kolhar

Industrial area, Kolhar (V), Bidar Taluk in Bidar District, Karnataka, which is about

700m from Kolhar village; no impact of noise will be felt at these habitations. As per

factory act, under the general health checkup scheme, the workers will be examined for

any Noise Induced Hearing Loss (NIHL) by a trained ENT Doctor. The noise levels in

the work place environment will be monitored periodically and action will be taken in

the form of regular maintenance schedule to reduce noise and vibration in generating

sources. Noise Attenuation targeted & achieved with 3-4 m greenbelt of Pure Species

Monoculture.

However, adequate precautionary measure for noise and vibration control

measures as described below will be taken by the unit;

Periodical monitoring is being carried out on regular basis.

DG sets are enclosed with built-in acoustic enclosures.

Noise generating unit like boiler etc. A Regular maintenance is practiced for plant

machinery and equipment‟s which helps to avert potential noise problems.



Future enhancement and installation of the plant machinery will be done after due

consideration to design noise levels and noise mitigation measures.

The green belt developed helps in reducing noise levels in the premises as a result

of attenuation of noise generated due to plant operations and transportation.

There are no major sources of industrial noise; minor noise is being generated from

the industrial operations which are being controlled by proper maintenance and

technology.

Proper mitigation measures are taken for the reduction of noise levels i.e. acoustic

enclosures and the workers are provided with personal protective equipment‟s.

Proper maintenance, padding, oiling and greasing of machines at regular intervals

is done to reduce generation of noise.

To reduce the noise generation during the transportation activities; the transport

contractor will be instructed kept vehicle periodically serviced and maintain as per

the requirement of latest trend in automobile industry. Only those vehicles

withPUC‟s will be allowed for the transportation.

2.11.5GREENBELT DEVELOPMENT

The main objective of the green belt is to provide a barrier between the source of

pollution and the surrounding areas. The green belt helps to capture the fugitive

emissions and to attenuate the noise generated apart from improving the aesthetics.

Development of green belt and other forms of greenery will also prevent soil erosion

and washing away of topsoil besides helping in stabilizing the functional ecosystem

and further to make the climate more conducive and to restore water balance.

• Green belt helps in achieving biodiversity by providing possible habitats for

birds and animal, thus recreating hospitable nature in an otherwise drab urban

industrial scene.

• Green belts increase the aesthetic value of the site.

Industry is proposed to develop Greenbelt in an area of 40% i.e., 5615 Sqmt of

total area of the project. Local species are planted as per the guidelines in consultation

with the local horticulturist.



2.12RESOURCES OPTIMIZATION / RECYCLING AND REUSE

All efforts will be made by the industry to carryout R&D on the wastes to recycle

/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 recycling options proposed by the industry.

Industry uses Zero liquid discharge plant to reuse all treated effluents as makeup

water for utilities like Cooling Tower/ Boiler. Thereby reduce the fresh water

consumption.

Industry proposing dedicated reactors for all products thereby 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 KSPCB Authorized Cement

industries to burn in Cement Kiln.

Boiler ash will be sold to Cement Brick manufacturing units.

Waste/Used oil will be sent to KSPCB Authorized Waste / Used oil Reprocessing/

recycling units.

Waste Lead acid batteries will be sent back to suppliers on buy- back basis.

Conservation of energy by implementing energy conservation methods/systems.



CHAPTER - 3

3. BASELINE ENVIRONMENTAL STATUS

Baseline data describes the existing environmental status of the identified study

area with reference to the prominent environmental attributes. An area covering 10 km

radius, with project site as centre, is considered as the study area. The study area of 10

km radius around project is covered in survey of India topo sheet no. 56G/5, 56G/9

(1:50,000).

The existing environmental setting is considered to establish the baseline

conditions which are described with respect to geology, hydrogeology, climatic,

atmospheric conditions, water quality, noise quality, soil quality, vegetation pattern,

ecology, land use and socioeconomic profile of people.

The site-specific primary data were monitored for the identified parameters and

supplemented by the available secondary data. Secondary data was collected from

various Government and Semi – Government organizations. Baseline environmental

status is the most important study based on which probable impacts from the project

are predicted.

The EIA report incorporates the baseline data monitored for three months

covering Pre Monsoon Season (during October 2018 to December 2018). The study has

been conducted in accordance with the Ministry of Environment and Forest (MoEF)

guidelines.

The main objectives of characterization are as follows:

To assess the existing baseline status of air, water, noise, land, biological and socio-

economic environments within the project site and around 10 km radius of the

study area.

To identify and quantify significant impacts due to the proposed activity on various

environmental components through prediction of impacts.

To evaluate the beneficial and adverse impacts of the proposed activity.



To prepare an Environmental Management Plan (EMP) detailing control

technologies and measures to be adopted for mitigation of adverse impacts if any,

as a consequence of the proposed activity.

To prepare a Post Project Monitoring Programme for checking and regulating the

environmental quality of the project and help in sustainable development of the

area.

FIGURE – 3.1: LOCATION OF PROJECT SITE IN TOPOSHEET

The environmental quality status of the study area prior to initiation of the

project will serve as the baseline for anticipating and superimposing the possible



impacts due to the proposed project and to derive the post project status of the

environment in the project region.

The various environmental attributes monitored for compiling the

environmental baseline data and frequency of monitoring methodology employed for

the various environmental attributes is given in below table.

TABLE-3.1: ENVIRONMENTAL ATTRIBUTES & FREQUENCY OF MONITORING

Attribute Parameters Frequency of Monitoring

Climatology &

Meteorology

Surface: Wind Speed, direction,

temperature, relative humidity

and rainfall

Surface continuous monitoring

station for entire study period and

also data collection from

secondary sources.

Water Quality Physical, Chemical and

Bacteriological Parameters

Once during the study season

Ambient Air

Quality

PM10, PM 2.5, SO2, NOx, O3, Pb,

CO, NH3, C6H6, BaP, As, Ni and

VOC

24 hourly twice a week for three

months during study period

Noise Levels Noise Levels in db (A) Hourly observations for 24 hours

per location.

Ecology Existing terrestrial Flora and

Fauna within the study area

Through field visit during the

study period and substantiated

through secondary sources.

Soil

Characteristics

Physical & Chemical Once during the season.

Land Use land use change for different

categories

Data from various Government

agencies

Socio-economic

aspects

Socio-economic characteristics Census Handbooks, 2011.

3.1LAND ENVIRONMENT

The main objective of this section is to provide environmental baseline status of

the study area covering 10 km radius around the proposed project site so that temporal

changes due to the proposed development on the surroundings can be assessed.



The first feature which influence the development of a project is the existing land

use pattern of the neighborhood of the project, whether the proposed development

conforms to the development for that area or not.

The detail study of the land environment will include the following sectors;

Study of land use pattern, habitation, cropping pattern, forest cover,

environmental sensitive places etc, by employing remote sensing techniques (if

available) and ground truth and also secondary data sources.

Objectives: The objectives of land environment/land use studies are:

To determine the present land use pattern

To ascertain the temporal changes in land use pattern due to construction and

operation phase; and

To scrutinize the impacts on land use due to proposed project in the study area.

Topography of the study area:

The project site is located at the western side of Bidar town at a distance of 5.3

km. The elevation of the project site is 662 meter above mean sea level. An area

covering 10 km radius, with project site as centre, is considered as the Study area. The

important features within the study area are listed in table 3.2.

TABLE 3.2: IMPORTANT FEATURES WITHIN STUDY AREA

Sl no. Features Location Distance Direction

1. National park/Wildlife sanctuary

-- -- --

2. Reserved Forest Land Honnikere Reserved Forest Chitta Reserved Forest

Kamthana Reserved Forest Kaplapur protected

2.0 Km 3.2 Km 2.9 Km 5.6 Km

N SE N

NW

3. Lakes/Reservoir/Dames --

4. Streams/Rivers Papnash river Janwada kere

Karanja Reservoir

3.4 Km 8 Km 15 Km

NE N W

5. Notified Archaeological sites

-- -- --

6. Defense Installation Bidar Air Force 800m S



7. State Boundary Karnataka – Telangana Karnataka – Maharashtra

11.3 Km 37Km

SE N

8. National/state Highways SH- 105 (Bidar-Humnabad road)

700 m S

9. Airports Rajiv Gandhi International Airport, Hyderabad

128Km SE

10. Railway Bidar railway station 4.8Km E

3.1.1 LAND USE PATTERN

Geology: The entire district forms a part of the Deccan Plateau and is made up

mostly of solidified lava. The northern part of the district is characterized by expanses

of level and treeless surface punctuated here and there by flat and undulating hillocks,

black soils and basaltic rocks. The southern half of the district is a high plateau about

715 m above mean sea level and is well drained. The average elevation of the district is

between 580 to 610 m above mean sea level. Alluvial deposit is normally found along

the banks of the Manjra River and its main tributaries.

The soils covering this region are black to deep brown in color which are rich in

humus and form some of the most valuable fertile lands in the country well suited for

cultivating pulses.

Physiographically, the district can be divided into two regions. They are northern

low lands and southern high lands. The southern high lands are popularly known as

Bidar plateau, which is made up of laterite.

The district is entirely covered by the Deccan trap flows of the tertiary period.

The Deccan trap is composed of horizontal flows of basaltic lava. They generally form

flat-topped hillocks and terrace-like features. The physical characteristics of individual

flows show considerable variations. Some flows are hard and massive while others are

weathered, soft and friable. This character has resulted in terraced landscape, suddenly

ending in escarpments. The traps are seen generally 618 m above mean sea level. These

are jointed and show the characteristics of spherical weathering leaving massive hard

cores. Columnar jointing is predominantly developed in these rocks, besides horizontal

joints, which impart to the rocks bedded appearance. The top layers of the Deccan trap



in parts of Bidar and Humnabad Taluk are altered to reddish vesicular laterite, forming

and extensive undulating plateau.

The minerals found in the area are Bauxite, Kaolin and Red ochre. A deposit of

highly siliceous bauxite clay has been located about three kilometers south of

Basavakalyan. Similar deposits are noticed near Alwal and Kamthana Villages of Bidar

taluk. A large deposit of Kaolin is located near Kamthana village. Red ochre deposits

are found near Sirsi and Aurad Village.

Soils: Two types of soils founds in the district are Lateritic red soil and black

cotton soil. Aurad and BhalkiTaluks have mainly black cotton soil. Bidar and

Humnabad Taluks have mainly lateritic red soil. Basavakalyan Taluk has both types of

soils.

Ground studies were conducted to identify the land use in and around 10 km

radius of the site. Representative soil samples were collected from- eight sampling

locations within an area of 10 km radius in and around the proposed project site for

analysis of the Physico chemical characteristics to assess the cropping pattern, microbial

growth etc. standard procedures were followed for sampling and analysis.

Soil samples were collected at different locations (Boreholes) within the Study

area; the sampling locations are given in table 3.3 and there locations on Topo sheet are

shown in figure 3.2

LABORATORY TESTING:

Following laboratory tests were conducted on soil samples for 9 sampling

locations as per the IS: standards and the results are tabulated in the Table-3.4.

The soil sampling locations are given in table 3.3.

Grain size by sieve analysis

Prominent chemical parameters



FIGURE-3.2: SOIL SAMPLING LOCATIONS

TABLE 3.3: SOIL SAMPLING LOCATIONS AROUND THE STUDY AREA

Sample No.

Name of Sampling station

Distance & direction from

project site Co-ordinates

S1 Chorus Labs Limited -- 17° 54‟ 55.1” N 77° 27‟ 12.3” E

S2 Chauli 4.8 km (N) 17° 57‟ 20.88” N 77° 27‟ 54.83” E

S3 Atiwal 4.6 km (NW) 17° 55‟ 59.16” N 77° 25‟ 59.44” E

S4 Andur 4.8 km (W) 17° 54‟ 43.77” N 77° 24‟ 33.58” E



S5 Bellura 2.9 km (SW) 17° 53‟ 18.2” N 77° 27‟ 32.3” E

S6 Sikandrapur 2.7 km (SE) 17° 53‟ 25.70” N 77° 27‟ 43.36” E

S7 Amlapur 6.9 km (SE) 17° 52‟ 31.60” N 77° 30‟ 11.96” E

S8 Chidri 4.3 km (E) 17° 54‟ 27.50” N 77° 29‟ 36.47” E

S9 Chikpet 6.7 km (NE) 17° 56‟ 12.62” N 77° 30‟ 45.76” E

Chorus Labs Limited Chauli

Atiwal Andur

Bellura Sikandrapur



Amlapur Chidri

Chickpet

Fig-3.3: SOIL PHOTOGRAPHS OF THE STUDY AREA



TABLE 3.4: PHYSICO-CHEMICAL CHARACTERISTICS OF THE SOIL

Sl. No

Parameters Units S1 S2 S3 S4 S5 S6 S7 S8 S9

1 pH Value -- 6.9 6.4 6.7 7.1 7.2 7.0 7.6 7.7 7.4

2 Color -- Brown Brown Brown Brown Brown Brown Brown Brown Brown

3 Sand % 42.4 45.6 52.5 31.3 46.3 52.1 43.6 40.9 33.5

4 Silt % 25.6 27.1 23.6 25.5 27.1 22.9 29.3 33.0 19.7

5 Clay % 32.0 27.3 23.9 43.2 26.6 25 27.1 26.1

46.8

6 Conductivity µS/cm 0.07 0.05 0.17 0.08 0.10 0.05 1.17 0.05 0.05

7 Moisture Content % 43.5 31.8 33.0 37.4 28.3 20.6 30.9 44.0 32.7

8 Organic Matter % 3.34 3.26 3.78 2.82 2.83 3.24 2.75 2.88 3.60

9 Calcium as Ca mg/kg 1.02 0.77 1.54 1.34 1.92 0.96 4.61 1.15 1.15

10 Chlorides as CI mg/kg 1.86 1.27 1.48 1.13 2.04 1.76 9.72 1.55 1.48

11 Magnesium as Mg mg/kg 1.78 1.92 1.92 0.96 0.96 0.64 1.6 1.92 1.28

12 Nitrogen as N Kg/Ha 518 596 721 533 690 721 1568 596 502

13 Phosphorus Kg/Ha 4.8 6.7 5.5 4.9 2.9 3.3 3.8 7.1 6.6

14 Potassium as K Kg/Ha 4.5 6.2 3.8 4.6 5.5 4.8 7.0 6.6 3.6

15 Sulphur as S04 mg/kg 0.67 0.23 0.53 0.30 0.83 0.32 2.81 0.40 0.40

16 Iron as Fe mg/kg 2.6 3.4 2.5 3.9 3.2 3.9 3.1 3.4 3.8

17 Copper as Cu mg/kg 48 68 81 58 77 119 90 57 45

18 Mercury as Hg mg/kg BDL BDL BDL BDL BDL BDL BDL 0.25 BDL

19 Cadmium as Cd mg/kg 2.3 3.4 2.8 2.1 3.9 4.4 3.7 2.5 2.3

20 Selenium as Se mg/kg BDL BDL BDL BDL BDL BDL BDL 0.25 BDL

21 Arsenic as As mg/kg BDL BDL BDL BDL BDL BDL BDL 0.25 BDL

22 Lead as Pb mg/kg 25 26 23 20 22 26 34 28 14

23 Zinc as Zn mg/kg 41 BDL 87 41 77 112 192 57 42

24 Manganese as Mn mg/kg 1112 1013 841 1284 1398 1504 1191 1566 897

25 Cyanide as Cn mg/kg BDL BDL BDL BDL BDL BDL BDL 0.25 BDL



3.2 WATER ENVIRONMENT

Water environment includes two environmental settings, i.e. ground andsurface.

Baseline data with regard to these environmental settings should be generated.

Industrialization at any region is contingent on the availability of sufficient water

resources as there would be a continuous requirement of water for various industrial

activities. The potential for exploitation and contamination of either or both surface and

ground water resources in the project area would increase through discharge of

effluents. In order to identify the possible impacts on water environment in the study

area due to the major industrial development project, the available water resources

have been collected and analyzed to assess the existing quality to represent the baseline

status of water environment.

The significant representative sampling locations for ground water and surface

water are chosen through reconnaissance of project area to determine the pre-project

status of the water quality in the study area. Physico-chemical and biological

parameters having relevance to public health and aesthetic significance are selected to

assess the water quality status with special attention to raw water resources for

proposed project. The standard methods prescribed for surface, groundwater sampling

as well as the analytical procedures for individual parameters is followed in this study.

DRAINAGE PATTERN

The drainage pattern in the district varies from sub-dendritic to dendritic and

some streams have a sub parallel drainage to the main river.

Major parts of the district are covered by Godavari basin, drained by its two

major tributaries the Manjara and the Karanja Rivers. The Manjara River is Perennial

River flows over a distance of 155 km in the central parts of the district and flow eastern

direction with a meandering course. The Karanja River flows in northern-western

direction for 74km with Karanja reservoir being major water source. The river

Mullamari takes its origin near Matala village of Basavakalyan Taluk flows from west to

east length of 38 Sqkm and then flows into Gulbarga district and joins the river Kagna.



The KagnaRiver is one of the main tributary of Bhimariver. Besides, there are several

streams, which are of ephemeral in nature. The drainage pattern in the district varies

from sub-dendritic to dendritic and some streams have a sub parallel drainage to the

main river. Drainage map of the study area showing 5 Km is shown in Figure - 3.4

FIGURE-3.4: DRAINAGE SYSTEM OF THE STUDY AREA

HYDROGEOLOGY:

The entire district is underlain by lava flows of the Deccan trap except small area

covered with the laterites capping. Deccan trap consists of successive lava flows, almost

horizontal in disposition. Individual flows show considerable variation in physical

character, thickness, nature and extent of weathering etc. The basaltic lava flows are

generally dark, grey, hard and compact. Each lava flows normally consists two units

lower massive basalt and upper vesicular basalt. Secondary minerals like zeolites,

quartz, calcite or some earthy or ferruginous material fill the vesicles. Well-developed



columnar joints and spherical weathering are characteristic features of the massive

basalt. The massive basalt and vesicular basalt are similar in term of compositionally

and texturally.

3.2.1 GROUND WATER

Ground water is the accumulation of water below the ground surface, caused by

rainfall and its subsequent percolation through pores and crevices. Percolated water

accumulates till it reaches the impervious strata consisting of confined clay/rocks.

Occurrence of ground water is controlled by landform, structure and lithology. These

resources are predominantly exploited in most of the nearby villages only for domestic

and agricultural purposes. Ground water abstraction is by means of bore wells.

3.2.2 SURFACE WATER

The district has two river basins, the Godavari and the Krishna. Major parts of

the district are covered by Godavari basin, drained by its two major tributaries the

Manjra and the Karanja Rivers. The Godavari basin extends to over 4,411 Km2 of which

Manjra covers up to 1,989 Km2 and Karanja up to 2,422 Km2. The Manjra River is

Perennial River flows over a distance of 155 Km in the central part of the district and

flows in eastern direction with a meandering course. The Karanja River flows in

northwestern direction for 74 Km with Karanja reservoir being major water source.

Mainly the source of water in the region in from the groundwater and there are

no surface water body with in the study area, therefore groundwater samples are

collected from 9 different locations along with project site area and analyzed. The

description of the water sampling locations is as given in the table 3.5.

3.2.3 RECONNAISSANCE

To establish the baseline status of water environment, existing representative

sampling locations for surface water and ground water within a radial distance of 10

Km radial from the site, have been selected as per CPCB guidelines of Water Quality

Monitoring through an adequate survey of the project area. The prevailing status of



water quality at 9 sampling locations each for ground water and surface water has been

assessed during October 2018 to December 2018.

Grab samples were collected once during the study period. Physico-chemical and

microbiological parameters have been analyzed to establish the baseline status of

ground water resources in the study area. Methods as per IS (IS 10500:2012) were

adopted for analysis of these parameters. The sampling protocol specified in the

Guidelines for Water Quality Management, of CPCB was followed for sampling,

preservation and transport of samples to the lab.

Following are the water quality monitoring stations where the water samples

were collected for analysis during the study period.

FIGURE-3.5: WATER SAMPLING LOCATIONS



TABLE 3.5: WATER SAMPLING LOCATIONS

Sample No.




W1 Chorus Labs Limited -- 17° 54‟ 55.1” N 77° 27‟ 12.3” E

W2 Chauli 4.8 km (N) 17° 57‟ 20.88” N 77° 27‟ 54.83” E

W3 Atiwal 4.6 km (NW) 17° 55‟ 59.16” N 77° 25‟ 59.44” E

W4 Andur 4.8 km (W) 17° 54‟ 43.77” N 77° 24‟ 33.58” E

W5 Bellura 2.9 km (SW) 17° 53‟ 18.2” N 77° 27‟ 32.3” E

W6 Sikandrapur 2.7 km (SE) 17° 53‟ 25.70” N 77° 27‟ 43.36” E

W7 Amlapur 6.9 km (SE) 17° 52‟ 31.60” N 77° 30‟ 11.96” E

W8 Chidri 4.3 km (E) 17° 54‟ 27.50” N 77° 29‟ 36.47” E

W9 Chikpet 6.7 km (NE) 17° 56‟ 12.62” N 77° 30‟ 45.76” E

Chorus Labs Limited Chouli

Atiwal Andur



Bellura Sikandrapur

Amalapur Chidri

Chickpet

FIGURE-3.6: WATER SAMPLING STATIONS OF PROJECT AREA

TABLE - 3.6: GROUND WATER QUALITIES STANDARDS

Sl.

No Parameter

Maximum

Desirable Limit

IS 10500: 2012

Maximum

Permissible Limit

IS 10500: 2012

Protocol

1 Colour (Hazen units) 5 15 IS 3025 (Part– 4): 1983

2 Odour Unobjectionable Unobjectionable IS 3025 (Part– 5): 1983

3 Taste Agreeable Agreeable IS 3025 (Part– 8): 1984

4 pH Value 6.5 to 8.5 No Relaxation IS 3025 (Part– 11): 1983

5 Turbidity, NTU 1 5 IS 3025 (Part– 10): 1984



6 Chlorides as Cl, mg/l 250 1000 IS 3025 (Part– 32): 1988

7 Total Hardness as CaCo3,

mg/l 200 600

IS 3025 (Part– 21): 2009

8 Calcium as Ca, mg/l 75 200 IS 3025 (Part– 40): 1991

9 Magnesium as Mg, mg/l 30 100 IS 3025 (Part– 46): 1994

10 Dissolved solids mg/l 500 2000 IS 3025 (Part– 16): 1984

11 Sulphate as SO4, mg/l 200 400 IS 3025 (Part– 24): 1986

12 Fluoride as F, mg/l 1.0 1.5 APHA 22nd Edition

13 Chromium as Cr+,mg/l 0.05 No relaxation IS 3025 (Part– 52): 2003

14 Residual free chlorine, mg/l 0.2 1 IS 3025 (Part– 26): 1986

15 Alkalinity as CaCo3, mg/l 200 600 IS 3025 (Part– 23): 1986

16 Nitrate as NO3, mg/l 45 No Relaxation IS 3025 (Part– 34): 1988

17 Copper as Cu,mg/l 0.05 1.5 IS 3025 (Part– 42): 1992

18 Iron as Fe, mg/l 0.3 No Relaxation IS 3025 (Part– 53): 2003

19 Manganese as Mn, mg/l 0.1 0.3 IS 3025 (Part– 59): 2006

20 Phenolic Compounds as C 6

H5OH, mg/l 0.001 0.002

IS 3025 (Part– 43): 1992

21 Mercury as Hg,mg/l 0.001 No relaxation IS 3025 (Part– 48): 1994

22 Cadmium as Cd, mg/l 0.003 No relaxation IS 3025 (Part– 41): 1992

23 Selenium as Se, mg/l 0.01 No relaxation IS 3025 (Part– 56): 2003

24 Arsenic as As,mg/l 0.01 No relaxation IS 3025 (Part– 37): 1988

25 Cyanide as CN,mg/l 0.05 No relaxation APHA 22nd Edition

26 Lead as Pb,mg/l 0.01 No relaxation IS 3025 (Part– 47): 1994

27 Zinc as Zn,mg/l 5 15 IS 3025 (Part– 49): 1994

28 Anionic detergents as

MBAS,mg/l 0.2 1.0

Annex K of IS: 13428:

2005

29 Aluminium as Al,mg/l 0.03 0.2 IS 3025 (Part– 55): 2003

30 Boron as B,mg/l 0.5 1.0 APHA 22nd Edition

31 Coliform organism/ 100ml -- Less than 1 IS 1622 - 1981

32 Escherichia coli/ 100ml -- Absent IS 1622 - 1981



TABLE 3.7 GROUND WATER QUALITIES RESULTS

Sl.

No Parameter W1 W2 W3 W4 W5 W6 W7 W8 W9

1 Colour (Hazen units) BDL (<1) BDL (<1) BDL (<1) BDL (<1) BDL (<1) BDL (<1) BDL (<1) BDL (<1) BDL (<1)

2 Odour Odourless Odourless Odourless Odourless Odourless Odourless Odourless Odourless Odourless

3 Taste Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable Agreeable

4 pH Value 7.2 6.9 6.6 7.6 6.6 6.4 7.6 7.1 7.1

5 Turbidity, NTU 2.7 2.2 3.2 4.1 2.5 1.6 3.3 2.2 3.0

6 Chlorides as Cl, mg/l 124 140 100 180 110 160 170 50 90

7 Total Hardness as

CaCo3, mg/l 103 81 127 340 132 207 216 110 147

8 Calcium as Ca, mg/l 140 126 152 178 178 120 165 156 158

9 Magnesium as Mg,

mg/l 79 91 68 55 77 84 68 46 75

10 Dissolved

solids mg/l 146 136 275 265 134 156 165 220 210

11 Sulphate as SO4,

mg/l

86 105 72 80 68 93 102 69 70

12 Fluoride as F, mg/l 0.47 0.5 0.32 0.65 0.51 0.55 0.8 0.51 0.47

13 Chromium as Cr+,

mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

14 Residual free

chlorine, mg/l <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2 <0.2

15 Alkalinity as CaCo3,

mg/l

121 135 146 144 119 150 156 145 134

16 Nitrate as NO3, mg/l 3 2 9 6 4 2 6 2 1

17 Copper as Cu, mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

18 Iron as Fe, mg/l 0.10 0.19 0.14 0.15 0.10 0.30 0.15 0.017 0.323



19 Manganese as Mn,

mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

20 Phenolic Compounds

as C 6 H5OH, mg/l Absent Absent Absent Absent Absent Absent Absent Absent Absent

21 Mercury as Hg,mg/l <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005

22 Cadmium as Cd,

mg/l <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

23 Selenium as Se, mg/l <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005

24 Arsenic as As, mg/l <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005 <0.005

25 Cyanide as CN, mg/l Absent Absent Absent Absent Absent Absent Absent Absent Absent

26 Lead as Pb, mg/l <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

27 Zinc as Zn, mg/l 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05 0.05

28 Anionic detergents as

MBAS, mg/l Absent Absent Absent Absent Absent Absent Absent Absent Absent

29 Aluminium as Al,

mg/l 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02 0.02

30 Boron as B, mg/l 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3 0.3

31 Coliform organism/

100ml <1 <1 <1 <1 35 24 <1 <1 <1

32 Escherichia coli/

100ml Absent Absent Absent Absent Present Present Absent Absent Absent



3.3 AIR ENVIRONMENT

3.3.1 METEOROLOGICAL DATA

The meteorological data recorded during the study period is very useful for

proper interpretation of the baseline information and selection of air quality monitoring

locations. Historical data on meteorological parameters will also play an important role

in identifying the general meteorological regime of the region.

The representative months for climate are divided into four seasons winter lasts

from January to February, summer lasts from March to May, South-West monsoon

rains from June to September and North-East monsoon rains from October to

December. (Ref: Assessment of Impact to Air Environment: Guidelines for Conducting

Air Quality Modeling, Central Pollution Control Board)

METHODOLOGY

The methodology adopted for monitoring surface weather parameters is as per

the norms laid down by Bureau of Indian Standards (IS:8829) and India Meteorological

Department (IMD). The study of micro-meteorological conditions of a particular region

is of utmost importance to understand the variations in ambient air quality status in

that region. The prevailing micrometeorology at project site plays a crucial role in

transport and dispersion of air pollutants released from the pollution sources. The

persistence of the predominant wind direction and wind speed at the project site will

decide the direction and extent of the air pollution impact zone.

Secondary information on meteorological conditions for the Bidar region was

collected from the IMD station at Bangalore. Data of previous years have been collected

and analyzed. Meteorological parameters such as wind speed, wind direction,

maximum, and minimum temperatures, Relative humidity, atmospheric pressure,

recorded on monthly basis continuously covering the entire months. Wind speed &

Wind direction data recorded during the study period were used for computation of

relative percentage frequencies of different wind directions. The meteorological data

thus collected has been used for interpretation of the existing Ambient Air Quality



status, and the same data has been used for prediction of impacts of future scenario due

to the activities of the proposed scheme.

FIGURE - 3.7: WIND ROSE DIAGRAM

3.3.2 AMBIENT AIR QUALITY MONITORING

The major objective of baseline air monitoring is to evaluate the existing air

quality of the area. Formulation of baseline Ambient Air Quality (AAQ) data of the

study area occupies a significant role in the Environmental Impact Assessment studies

in assessing the conformity to standards of the ambient air quality during the

construction and operation of the proposed project.

RECONNAISSANCE:

The predominant monsoon winds persisting in India dictates the transport and

dispersion of air pollutants during different seasons. As per the



Climatologicalconditions prevailing in India, the seasons accounted for carrying out air

pollution studies are winter, summer and post-monsoon seasons. After reconnaissance

of the area and observing the topographical features and review of the available

meteorological data and local conditions the sampling sites were chosen which will be

the representative of the local areas under study.

A preliminary survey was conducted at 9 AAQM locations along with the

project site (within the radius of 10 km) that were chosen based on the well-designed

ambient air quality stations network. The baseline status of air environment has been

assessed through ambient air quality monitoring (AAQM) network covering 9 sampling

locations considered based on the following criteria:

Micrometeorological conditions-Persistence of wind direction and speed,

atmospheric stability

Predominant upwind and downwind directions

Identification of regional background

Location of industries, their emission magnitude and topography of the study

area.

Determination of sensitive receptors such as hospitals, schools, thickly populated

residential localities.

Consideration of all the major conventional air pollution parameters as per latest

NAAQS (National Ambient Air Quality Standards)

An intensive monitoring was carried out as per CPCB guidelines (twice a week

sampling and 24 hour continuous sampling) to generate the baseline monitoring status

of air environment within the study area during the period of October 2018 to

December 2018.

The ambient air quality has been monitored for all the parameters as per NAAQS

notified on 16th September, 2009. The major air pollutants monitored on 24 hourly bases

are, Particulate matter (PM10 and PM2.5 µg/m3), Sulfur dioxide and oxides of Nitrogen.

Sampling and analysis of the above variables is according to the guidelines of Central



Pollution Control Board. Following are the air quality monitoring stations which were

identified during the study period.

FIGURE-3.8: AIR SAMPLING LOCATIONS



TABLE 3.8: AMBIENT AIR QUALITY MONITORING LOCATIONS

Sample No.




A1 Chorus Labs Limited -- 17° 54‟ 55.1” N 77° 27‟ 12.3” E

A2 Chauli 4.8 km (N) 17° 57‟ 20.88” N 77° 27‟ 54.83” E

A3 Atiwal 4.6 km (NW) 17° 55‟ 59.16” N 77° 25‟ 59.44” E

A4 Andur 4.8 km (W) 17° 54‟ 43.77” N 77° 24‟ 33.58” E

A5 Bellura 2.9 km (SW) 17° 53‟ 18.2” N 77° 27‟ 32.3” E

A6 Sikandrapur 2.7 km (SE) 17° 53‟ 25.70” N 77° 27‟ 43.36” E

A7 Amlapur 6.9 km (SE) 17° 52‟ 31.60” N 77° 30‟ 11.96” E

A8 Chidri 4.3 km (E) 17° 54‟ 27.50” N 77° 29‟ 36.47” E

A9 Chikpet 6.7 km (NE) 17° 56‟ 12.62” N 77° 30‟ 45.76” E

Figure 3.9 below shows the air quality monitoring locations within the study area and

the ambient air quality values are given in table 3.10.

Chorus Labs Limited Chauli



Atiwal Andur

Bellura Sikindrapur

Amalapur Chidri

Chickpet

FIGURE-3.9: AIR SAMPLING STATIONS OF PROJECT AREA



TABLE 3.9: NATIONAL AMBIENT AIR QUALITY STANDARDS (NAAQS)

Pollutant Units Time

Weighted Average

Concentration in Ambient Air (g/m3)

Industrial, Residentia

l, Rural And Other

Area

Ecologically Sensitive

Area (Notified by

Central Government)

Methods of Measurement

Sulphur dioxide (SO2)

µg/m3

Annual* 50 20 - Improved West and Gaeke

- Ultraviolet fluorescence 24

Hours** 80 80

Nitrogen dioxide (NO2)

µg/m3

Annual* 40 30 - Modified Jacob &Hochheiser (Na-

Arsenite) - Chemiluminescence

24 Hours**

80 80

Particulate Matter (Size <

10 µm) or PM10

µg/m3

Annual* 60 60 - Gravimetric - TOEM

-Beta attenuation 24

Hours** 100 100

Particulate Matter (Size <

2.5µm) or PM2.5

µg/m3

Annual* 40 40 - Gravimetric - TOEM

-Beta attenuation 24

Hours** 60 60

Ozone (O3) µg/m3 8 Hours** 100 100 - UV photometric

- Chemilminescence - Chemical Method

1 Hour** 180 180

Lead (Pb)

µg/m3

Annual* 0.5 0.50 - AAS/ICP method after sampling on EPM 2000 or

equivalent filter paper - ED-XRF using Teflon

filter

24 Hours**

1.0 1.0

Carbon monoxide

(CO)

mg/m3

8 Hours** 02 02 - Non Dispersive Infra Red

(NDIR) spectroscopy 1 Hour** 04 04

Ammonia (NH3)

µg/m3 Annual* 100 100

- Chemiluminescence - Indophenol blue method

24 Hours**

400 400

Benzene (C6H6)

µg/m3 Annual* 05 05

- Gas chromatography based continuous analyzer

- Adsorption and Desorption followed by

GC analysis



Benzo (a) Pyrene (BaP) –

particulate phase only

ng/m3 Annual* 01 01 - Solvent extraction

followed by HPLC/GC analysis

Arsenic (As) ng/m3 Annual* 06 06 - AAS/ICP method after sampling on EPM 2000 or

equivalent filter paper

Nickel (Ni) ng/m3 Annual* 20 20 - AAS/ICP method after sampling on EPM 2000 or

equivalent filter paper



TABLE 3.10: AMBIENT AIR QUALITY PARAMETERS RESULTS

Details A1 A2 A3 A4 A5 A6 A7 A8 A9

PM10,µg/m3 48 52 47 53 45 50 49 56 48

PM2.5, µg/m3 25 21 23 24 21 25 26 25 22

NOx, µg/m3 20 22 21 24 19 20 15 14 18

SO2, µg/m3 17 18 18 16 16 17 17 16 15

Ozone as O3, μg/ m3 5 4 5 6 5 8 2 5 4

Lead as Pb, μg/m3 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05 <0.05

Carbon Monoxide,

as CO, mg/m3 0.40 0.42 0.49 0.47 0.45 0.42 0.47 0.42 0.42

Ammonium as NH3,

in µg/m3 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Benzene as C6H6,

μg/m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Benzo (a) Pyrene as

BaP, ng/ m3 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01 <0.01

Arsenic as As, ng/

m3 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

Nickel as Ni, ng/ m3 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1 <0.1

VOC, ppm ND - - - - - - - -

ND- Not detected



3.4 NOISE ENVIRONMENT

The source of most outdoor noise worldwide is mainly evolved from industries,

constructions and transportation systems, including motor vehicle noise, aircraft noise

and rail noise, poor urban planning may give rise to noise pollution.

The noise generated due to operation of individual process units at an industrial

project site cause significant impacts on the surrounding environment including nearby

human habitats. Such operations fall in the category of continuous point sources of

noise generation. There is also some secondary noise sources associated with almost all

types of large scale industrial projects, which are mainly vehicles used for

transportation of materials as well as employees and material handling equipment at

the project site. However, such sources could be categorized as intermittent/continuous

noise sources depending on frequency/intensity.

The objective of noise pollution survey in the study area was to assess the impact

of noise generated by the existing noise sources in the region especially on the human

settlements. The noise levels of a region can be estimated from the cumulative noise

pressure levels considering all the noise pollution sources in the region and the

prevailing environmental conditions.

A reconnaissance survey was conducted with a view to establish the baseline

status of the environment with respect to the noise levels in the region particularly with

respect to industrial activity in the region, sound pressure levels (SPL) were measured

using precision sound level meter.

Survey was carried out in the following steps:

Reconnaissance

Measurement of background noise levels in the study area

Identification and characterization of noise sources

Measurement of prevailing noise levels due to vehicular movements

The impact of noise on the health of an individual depends on physical dose of

noise viz. Noise level, frequency spectrum, annoyance etc and human factors viz sex,

age health status, type of activity, occupational exposure etc. The impacts also depends



on psychological and physiological status of individuals, the impact due to noise do not

undergo seasonal variations except some directional changes depending upon the

environmental wind direction.

The baseline studies for noise environment have been carried out through

reconnaissance followed by field observations to identify the major activities

contributing to noise within the study area. A reconnaissance was conducted with a

view to establish the baseline status of the environment with respect to noise levels of

the plant area, surrounding villages and other centres of human activities.

Ambient noise monitoring was carried out in residential, commercial, silence

zones and roadside in the study area. The terrain of project site as well as in the

surrounding impact zone is highly undulated with hilly terrain and the area is under

the influence of noise generated by heavy traffic on highways as well as from

commercial activities in the individual villages.

The prevailing ambient noise levels were monitored using precision noise level

meter in and around 10Km distance in 9 locations during October 2018 to December

2018. The details of sampling locations are depicted in figure 3.10 and described in table

3.11.

TABLE 3.11: NOISE QUALITY MONITORING LOCATIONS

Sample No.




N1 Chorus Labs Limited -- 17° 54‟ 55.1” N 77° 27‟ 12.3” E

N2 Chauli 4.8 km (N) 17° 57‟ 20.88” N 77° 27‟ 54.83” E

N3 Atiwal 4.6 km (NW) 17° 55‟ 59.16” N 77° 25‟ 59.44” E

N4 Andur 4.8 km (W) 17° 54‟ 43.77” N 77° 24‟ 33.58” E

N5 Bellura 2.9 km (SW) 17° 53‟ 18.2” N 77° 27‟ 32.3” E

N6 Sikandrapur 2.7 km (SE) 17° 53‟ 25.70” N 77° 27‟ 43.36” E



N7 Amlapur 6.9 km (SE) 17° 52‟ 31.60” N 77° 30‟ 11.96” E

N8 Chidri 4.3 km (E) 17° 54‟ 27.50” N 77° 29‟ 36.47” E

N9 Chikpet 6.7 km (NE) 17° 56‟ 12.62” N 77° 30‟ 45.76” E

FIGURE-3.10: NOISE SAMPLING LOCATIONS



Chickpet Chauli

Atiwal Andur

Bellura Sikindrapur

Amalapur Chidri

FIGURE 3.11-NOISE SAMPLING STATIONS



TABLE 3.12: AMBIENT NOISE STANDARDS

Area Code Category of Area Noise Levels dB(A) Leq

Day Time* Night Time

A Industrial Area 75 70

B Commercial Area 65 55

C Residential Area 55 45

D Silence Zone** 50 40

Source: CPCB

Note:

* Day time is from 6 am to 10 pm.

** Silence zone is defined as area up to 100 meters around the premises of hospitals,

educational institutions and courts. Use of vehicle horns, loud speakers and

bursting of crackers are banned in these zones.

TABLE 3.13: MEASURED AMBIENT NOISE LEVELS db (A)

Sampling station Leq (day) in dB (A)

Leq (night) in dB (A) Result dB (A)

Min Max

Chorus Labs

Limited 51.5 52.7 52.1

Chauli 42.1 64.0 52.8

Atiwal 53.4 57.9 53.6

Andur 48.5 53.4 52.4

Bellura 47.8 48.8 46.8

Sikandrapur 46.1 46.8 45.7

Amlapur 49.5 51.3 53.4

Chidri 48.6 54.8 49.5

Chikpet 50.1 58.5 54.2

3.5 BIOLOGICAL ENVIRONMENT

Study of biological environment is one of the most important aspects for

Environmental Impact Assessment, in view of the need for conservation of

environmental quality and biodiversity. Ecological systems show complex inter-

relationships between biotic and abiotic components including dependence,



competition and mutualism. Biotic components comprises of both plant and animal

communities which interact not only within and between themselves but also with the

abiotic components viz. Physical and Chemical components of the environment.

Generally, biological communities are the good indicator of climatic and edaphic

factors. Studies on biological aspects of ecosystems are important in environmental

impact assessment for safety of natural flora and fauna information on the impact of

environmental stress on community structure serves as an inexpensive and efficient

early warning system to check the damage to a particular ecosystem. The biological

environment includes mainly terrestrial ecosystem and aquatic ecosystem.

An ecological survey of the study area was conducted particularly with reference

to recording the existing biological resources. Secondary data was collected from forest

department.

Methodology of Data Collection:

Following methods are being adopted for the ecological study:

Generation of primary data through systematic ecological studies in the study area;

Secondary data collected from publications of various Government agencies like

Forest Department, Agriculture Department etc.; and

Consulting local people for gathering information on ethnobotany, local plants and

animals.

FLORA:

This section describes terrestrial ecology of the area based on reconnaissance

survey and information gathered from secondary data available for the area. List of

flora observed in the study area of 10 km radius is given below in table.

TABLE-3.14: FLORISTIC COMPOSITION IN THE STUDY AREA

Sl. No Botanical Name Sl. No Botanical Name

1. Juglansregia 2. Odinawodier

3. Aquilariaagallocha 4. Mallotusphilippinensis

5. Sesbaniagranditfora 6. Calotropis gigantea

7. TaraktogenosKurzil 8. Adina cordifolia



9. Saraca indica 10. Helicteresisora

11. Antiaristoxicaria 12. Hardwkia pinnata

13. Erythroxylonmonogynum 14. Mina cordifolia

15. Scolopiacrenata 16. Diospyrosebenum

17. Aconitum heterophylia 18. Tetramelesnuldiflora

19. Ficusgiornerata 20. Tetramelesnudiflora

21. Oroxytumindicum 22. Erianthusravennae

23. Spondiasmangitera 24. Zizyphusjujuba

25. Anonasquamosa 26. Euphorbia nerifolia

27. Araucaria bidwiQii 28. Alstoniascholaris

29. A cookii 30. oxytenanthera

31. A cunninghamii 32. thewaitessii

33. Garciniacambogia 34. Cassia auriculata

35. Ficusreiigiosa 36. Azadirachta indica

37. Garcinamorella 38. Quercusincana

39. Adina cordifolia 40. Ochlandra

41. Cochiospermumgossipium 42. travancorica

43. Antiaristoxicaria 44. Cassia fistula

45. Arundinareaaristida 46. Rhussuccedanis

47. A. hookeriana 48. Acacia catechu

49. Shorearobusta 50. Myricanagi

51. Ficusretigiosa 52. Ficusgibbosa

53. Saraca indica 54. Trewianudiflora

55. Terrninaliachebula 56. Stephegyneparviflora

57. Ailangiumlamarkii 58. Garciniacambogia

59. Hardweckiabinata 60. Anthocephaluscadamba

61. Ficuscarcia 62. Stephegyneparviflora

63. Sapindustrifoliatus 64. Anthocephalusparviflora

65. Andagomesii 66. Stephegyneparviflora

67. Caralliaintegerrima 68. Garciniamorella

69. Millingtoniahortensis 70. Sapiuim insigne

71. Bauhinia racemosa 72. Delonixregia

73. Crataevareligiosa 74. Anthocephaluscadamba

75. Adenantherapavonina 76. Pterospermusacerifolium

77. Kigelia pinnata 78. Ixora parviflora

79. Embticaofficinalis 80. Myristicamalabarica

81. Ficusbengalesis 82. Heritieralittotalis

83. Alnusnepalensis 84. Acacia melanoxylon



85. Cassia auriculata 86. Cinnamomumcamphora

87. Brideliaretusa 88. Mallotusphillippinensis

89. Shorearobusta 90. Artocarpushirsuta

91. Aesuclus indica 92. Carissa carundas

93. Strychnosnux-vomica 94. Jatrophacurcas

95. Toddaliaasiastic 96. Bassialatifolia

97. Ficusetastica 98. Strychnosnux-vomica

99. Premnatomentosa 100. Coffeaarabica

101. Spathodeacompanulata 102. Canariumstrictum

103. odinawodier 104. Bauhinia racemosa

105. Garciniacambogia 106. hardwickiabinata

107. morus alba 108. Ficustomentosa

109. Macaranga roxburghii 110. Ficustomentosa

111. Bauhinia variegata 112. Gardenia latifolia

113. Hydnocarpuswightiana 114. Careyaarborea

115. Terminaliapaniculata 116. Gmelinaarborea

117. Erythrinastricta 118. Strychnosnuxvomica

119. Gmelinaarborea 120. Cassia grandis

121. Geloniumlanceolatum 122. Cassia marginata

123. Holarrahenaantidysenterica 124. Casuarinaequisetifolia

125. Diospyros embryo pleris 126. Citrus aurantium

127. Matiotusphilippinensis 128. Boehmerianivea

129. Curpressustorulosa 130. Hopeaparviflora

131. Phyllanthusdistricus 132. Ficusretusa

133. Dendrocalamussinctus 134. Acacia farnesiana

FAUNA:

No wildlife sanctuaries are situated within the study area. No endangered faunal

species are found in the proposed project area.

Mammals: During the preliminary survey, the sighting of wild animals was

negligible in the entire study area. Hence the assessment of wild life fauna has been

carried out on the basis of information collected from the secondary sources (Forest

Officer, and local inhabitants). The study area has mammals like Hanuman Monkey or

Langur, Fruit Bat, Leopard or panther, Indian Fox, Indian Wild Boar (Wild Pig), etc.



Birds: Species like Eagle (Spilornischeela), Bhagule (Ardeapurpurea), Myna

(Sturnuspagodarum), dove (Streptopeliasenegalensis), Kingfisher (Alcedoatthis),

Magpie robin (Copsychussaularis), Racket tailed drongo (Dicrucrusparadiseus)

peacock, Partridgesetc are highly frequent in the village area.

TABLE-3.15: LIST OF FAUNA IN THE AREA

Sl. No. Common Name Scientific Name

Mammals

1. Monkey Presbytisphayrei

2. Bat Rhinolopus spp.

3. Common Mongoose Herpestesedwardii

4. Jackal Canisaureus

5. Three Striped Squirrel Funambuluponnati

6. Rats Rattusrattus

7. Indian Hare Lapusnigricallis

8. Indian Wild Boar (Wild Pig)

Susscrofa

9. Bison Bosgaurus

10. Spotted deer Erethizondorsatum

11. Black bucks Antilopecervicapra

12. Porcupines Axis axis

13. Foxes Vulpesvulpes

14. Jackals Canis

Birds

1. Spotted Sandpiper Tringaglareola

2. Common Sandpiper Tringahypoleucos

3. Pheasant-tailed Jacana Hydrophasianuschirurgus

4. Little Ringed Plower Charadriusdubius

5. Common Teal Anascrecca

6. Grey Heron Ardeacinerea

7. Pond Heron/Paddy Bird Ardeolagrayii

3.6 SOCIO-ECONOMIC ENVIRONMENT

The proposed project is modification of bulk drug, which is located at Kolhar

village, Bidar Taluk, Bidar District, Karnataka covering 14,038 Sqmt of land. The site is

notified in Industrial area and is not inhabited hence rehabilitation and resettlement of

people in the region due to the proposed project is located in the designated Kolhar



Industrial area. The nearest habitation Kolhar Village (W) is 2.3km away from the

proposed project site.

The socio-economic study includes various facets, viz. demographic structure,

availability of basic amenities such as housing, education, health and medical services,

occupation, water supply, sanitation, communication power supply and places of

tourist attraction, monuments of archaeological importance; and identifying, predicting

and evaluating the likely impacts due to the proposed project activity in study area.

RECONNAISSANCE:

The proposed developmental projects will be commissioned within the

Industrial area premises. The study area covering 10 km radial distances around the

project site fall under Bidar Taluk. Major part of study area is covered with highly

undulated/hilly terrain mostly covered with natural vegetation as well as agro forestry

especially in lower parts of hill slopes. In the study area, this is covered with number of

small/medium scale industries. The infrastructure facilities including road network

consisting SH-105(Bidar-Humnabad road), Bidar Airport and Bidar Railway (network)

are well developed in project region. Keeping in view the existing

industrial/commercial activities in Kolhar Industrial area (along SH-105), this belt has

been merged into urban agglomeration of Bidar city in 2011 census.

Baseline Status:

The latest available data has been complied to delineate the baseline socio-

economic profile in study area. The data base thus compiled from secondary sources of

various official records, viz. Census records, District statistical abstract, Primary Health

Centres etc. and primary data collection through field survey as well as the

observations by survey team study period include:

Demographic structure

Infrastructure base road network, communication, electricity,

Education

Health Status

Economic attributes



Socio economic status with reference to quality of life

Awareness and opinion of people about the proposed project

The secondary data is compiled from authentic secondary sources, Viz., District

Primary Census Abstracts - 2011, Bidar District, Karnataka. The primary data was

collected through; field survey as well as field observations were made during the site

visit.

Demographic Structure:

An official Census 2011 detail of Bidar, a district of Karnataka has been released

by Directorate of Census Operations in Karnataka. Enumeration of key persons was

also done by census officials in Bidar District of Karnataka.

In 2011, Bidar had population of 1,703,300 of which male and female were

870,665 and 832,635 respectively. In 2001 census, Bidar had a population of 1,502,373 of

which males were 771,022 and remaining 731,351 were females. Bidar District

population constituted 2.79 percent of total Maharashtra population. In 2001 census,

this figure for Bidar District was at 2.84 percent of Maharashtra population.

There was change of 13.37 percent in the population compared to population as

per 2001. In the previous census of India 2001, Bidar District recorded increase of 19.63

percent to its population compared to 1991.

The proposed modification project site is situated in Kolhar Industrial Area,

Kolhar (V), Bidar Taluk & Bidar District, Karnataka State. The study area is falling in

Bidar Taluk of Bidar District, Karnataka. The demographic details of the study area

were collected from District Primary Census Abstracts - 2011, Bidar District, Karnataka.

There are 86 villages, 2 Town Municipal Council in the study area. The summary of the

demographic details such as number of households, sex ratio, percentage of SC & ST

population and occupational pattern, number of literates, number of households, main

& marginal workers including non-working population etc are presented in Table 3.16.

Village wise demographic details viz., area, population distribution, density, sex ratio

etc are presented in Table 3.17.



TABLE 3.16: SUMMARY OF DEMOGRAPHIC STRUCTURE

Demographic Parameters No’s

No. of Districts 1

No. of Villages 63

No. of City Municipal Council-(CMC) 1

Total no. of Households 89172

Total Population 469941

Sex ratio (No. of female/thousand males) 949

Scheduled Castes 88752

Scheduled Tribes 56488

Literate 304634

Main Workers (among total working population) 142296

Non-Workers 292687

Source: District Primary Census Abstracts-2011, Bidar District, Karnataka.

TABLE-3.17: POPULATION DISTRIBUTION IN BIDAR DISTRICT

Talukas Area Population Rural % Density Sex ratio

Aurad 1227.2 245294 93.55 200 951

Basavakalyan 1202.97 299910 80.40 249 960

Bhalki 1117.2 257042 86.35 230 947

Bidar 925.19 405540 57.77 438 938

Humanabad 987.56 294587 79.31 299 950

Total 5460.12 1502373 77.04 276 949

The people of Bidar District speak many languages and dialects. The erstwhile

rule of Nizams and the geographical location of the district next to Andhra Pradesh and

Maharashtra (Telugu and Marathi speaking States) have influenced the people to adopt

and speak Kannada, Hindi, Marathi, Urdu and Telugu languages. The official language

Kannada is known to majority of the people. Education is imparted mostly in Kannada

but there are Urdu and Marathi medium schools as well. The Kannada language spoken

in the area differs widely from the one spoken in other parts of the State.

LITERACY AND EDUCATION

Bidar district has a good education background. The Mahmud Gavan Madrasa is

an evidence of that background. It has a comparatively better position with regard to

literacy and education. The literacy rate was 60.9 in 2001, which is lower than the state

average of 67.04 but is above that of the other two districts in the region. There are no



wide variations across the Talukas the Maximum-Minimum Ratio is 1.2:1, and

Humnabad, Basavakalyan and Aurad are below the district average. The lowest literacy

rate is in Aurad Taluk i.e. 57.9 per cent. The literacy rate has improved due to the efforts

under the D.P.E.P. programme and the literacy drive campaign. The urban literacy is as

high as 80 per cent in Bidar Taluk. But the quality of education has not improved, which

can be observed from the S.S.L.C. results where the district‟s rank is always the lowest.

It is also evident from the deteriorating teacher-student ratio in the district. The number

of students per teacher has increased from 39 in 1971 to 58, which is well above the ideal

norm of 40. This indicates the increasing enrolment of students but lower increase in the

number of teachers. The average number of students per primary school is 219.

Education:

As per 2011, village directory record excepting Kolhar village of Bidar Taluk all

the villages of study area are having educational facilities in the form of primary school.

Some village having Middle school and Secondary Higher Educational schools facility.

Infrastructure:

The infrastructure resources base of the study area with reference to education,

medical facility, water supply, post & telegraph, transportation & communication,

power supply facility is presented in subsequent sections. The infrastructure resources

details have been abstracted from village Directory CD-2011 of Karnataka state.



CHAPTER 4

4. ANTICIPATED ENVIRONMENTAL IMPACTAND

MITIGATION MEASURES

4.1 INTRODUCTION

Environmental Impact Assessment is one of the tools available with the planners

to understand the impact that would emanate from the proposed expansion project.

The objective of Impact Assessment is to foresee the potential environmental problems

that would arise out of a proposed development and address them in the project‟s

planning and design stage. Generally, the environmental impacts can be categorized as

either primary or secondary. Primary impacts are those which are attributed directly by

the project, secondary impacts are those which are indirectly induced and typically

include the associated investment and changed patterns of social and economic

activities by the proposed action.

Environmental Impact is any change in the environmental attributes, adverse or

beneficial, caused or induced by the proposed action or set of actions. The predicted

adverse impacts during each stage of project development are superimposed over the

baseline status of the existing environmental quality to infer the scenario of

environmental conditions in the post-project stage. The main purpose of identifying the

impacts is that it helps in adopting appropriate mitigation measures for the adverse

consequences if any. This chapter focuses on predicting and evaluating the various

significant impacts that are likely to occur. The impacts on the environmental indices

viz. air, water, soil, noise, biological and socioeconomic conditions are scrutinized

methodically and assessed. The most likely impacts on the environment due to the

proposed project need to be appraised during the two different phases of the project

namely pre-operation/construction phase and operation phase. The particulars on

impacts that could be triggered on the environmental attributes by the activities of the

proposed project are discussed below.



IMPACT NETWORK

The purpose of identifying the impacts is that it aids in making appropriate

decision to mitigate the adverse consequences if any. It may be pointed out that the

distinction between magnitude and importance of impact should be appreciated. Thus

the degree of extensiveness and scale of impacts and consequences based on value

judgments are generalized while identifying impacts. As it is imperative that the impact

will normally lead to a chain of reactions. The construction of network charts brings out

to certain extent the appropriate levels of risks that may occur due to the interventions

while interacting with hydrological, biological and social system. The identified impacts

for various components of environment viz. air, noise, water, land and socio-economic

aspects.



FIG-4.1: IMPACT NETWORK FOR AIR ENVIRONMENT

Proposed Project

Construction phase Operation phase

Release of Air Pollutants

Change in

air quality

Impact on

visibility

Particulate

deposition on

soil, water, land

Aesthetic

impact Impact on

Agricultural

Impact on

Human Health

Impact on

Economic output

Release of heat

Climate changes

Impact on

Flora Fauna

Impact on Socio

cultural Environment

Activity

Primary Impacts

Secondary Impacts

Tertiary Impacts



FIG-4.2: IMPACT NETWORK FOR NOISE ENVIRONMENT

Activity

Primary Impacts

Secondary Impacts

Tertiary Impacts

Proposed Project

Construction Operation

Impact on

Economic output Impact on Socio


Noise emission

Change in Ambient Noise level

Health Risks Impact on Work

output &Efficiency

Migration of Binds

reptiles population



FIG-4.3: IDENTIFICATION OF LIKELY IMPACTS FOR WASTEWATER

Effect of wastewater

from proposed

project

DIRECT INDIRECT

Land ecosystem Water ecosystem Water ecosystem Land ecosystem

Change in soil

texture

Shift in group of

desired organism

Injurious to existing

plant community

Ecological

Imbalances

Change in water

resources quality

Shift in the dynamic

population of aquatic

Flora & Fauna

Deleterious to water

living bodies

Socio Economic

Imbalances

Fertility of Land

Pattern of crops

Groundwater

Tables its quality

Community

health

Shift in

Dynamics Flora

& Fauna



FIG-4.4: IMPACT NETWORK FOR LAND ENVIRONMENT

Activity

Primary Impacts

Secondary Impacts

Tertiary Impacts

Proposed Project

Construction Phase Operation Phase

Impact on

Economic output Impact on Socio


Abstraction of

Water

Impact on

landscape

Soil salinity Impact on Flora

& Fauna

Disturbance of

land

Disposal of wastewater

sludge on land

Change in soil texture &

permeability

Change in ground

water regime salt

water intrusion

Substances on land

particulate

deposition on land

Impact on

Agricultural produce Impact on

Live stock



FIG-4.5: IMPACT NETWORK FOR SOIL MICRO FLORA AND FAUNA

Proposed Project

Air emission Solid waste

Soil Matrix

Soil Acidification

Wastewater

Affect Native soil Biota

Nitrogen Fixing Nitrifying Other p

H sensitive

micro flora

Decomposition mineralization of organic matter

Reduction in soil fertility & productivity



4.2 IDENTIFICATION OF ENVIRONMENTAL IMPACTS

An impact can be defined as any change in physical, chemical and biological,

cultural and/or socio-economic environment that can be attributed to activities related

to alternatives under study for meeting the project needs.

Overall environmental impact is divided into two categories i.e. during

Construction Phase and Operation Phase. The environmental impact assessment is

accomplished by identification and prediction of impacts and their assessment.

Potential impacts of proposed project on various environmental attributes given below

are predicted;

Air Environment

Water Environment

Land Environment

Noise Environment

Health & Safety

Ecology

Socio Economic Environment

Aesthetics

The following project related activities identified as sources having potential to cause

impact upon various environmental attributes;

4.2.1 CONSTRUCTION PHASE

Site cleaning

Levelling and road laying

Earthwork comprising of excavation, grading, trenching

Transportation of construction materials

Civil construction

Mechanical erection

Employment

Greenbelt development



4.2.2 OPERATION PHASE

Transportation of raw materials and finished products

Raw material and product storage & handling

Manufacturing process & utility operations (consumption of resources &

emission of liquid effluent, off-gases from stack, generation of Hazardous waste

and Noise)

Emergencies or disaster

Breakdown of critical systems

Employment

Green Belt Development

Infrastructure development & CSR activities

The identification of environmental impacts has been made, based on the

understanding of cause-condition-effect relationship between an activity and the impact

component. The activities identified as sources having potential to cause impact upon

above stated environmental parameters due to proposed project during the

construction& operation phase are given in Table 4.1(a) and Table 4.1(b) respectively.



TABLE 4.1(A): IDENTIFICATION OF IMPACTS DURING CONSTRUCTION PHASE

Parameter

Activity Air Water Land Noise Ecology

Health &

Safety

Socio Economic

Site cleaning x x

Leveling and road laying x x x x

Earthwork comprising ofexcavation, grading, trenching

x x x

Transportation of Constructionmaterials

x x

Civil construction Civil construction x x x

Mechanical erection x x x x x

Employment x x x x x

Greenbelt development

Note: (): Possibility of Impact (x): No impact will occur

TABLE 4.1(B): IDENTIFICATION OF IMPACTS DURING OPERATION PHASE

Parameter

Activity

Air Water Land Noise Ecology

Health

&

Safety

Socio

Economic


x x x x x

Transportation of raw materials and finished products

x x

Production& utilities x

Emergencies or disaster x

Breakdown of critical systems x x

Employment x x x x x

Greenbelt Development x

Infrastructure development & CSR activities

x x x x x

Note: (): Possibility of Impact (x): No impact will occur



4.3 PREDICTION OF ENVIRONMENTAL IMPACTS

Prediction of impacts involves determination of nature and extent of impacts due

to the various activities to be involved in the proposed project. Generally, impacts are

classified as follows;

1. Positive or Negative

2. Short term or Long term

3. Direct or indirect

4. Reversible or irreversible

5. Quantifiable or non-quantifiable

6. Acceptable or conditionally acceptable or unacceptable

The proposed project is for expansion in existing manufacturing activities and

looking to themagnitude of project and pollution potential, impacts have been predicted

for following two classifications;

1. Positive or Negative

2. Short term or Long term

Based on Environmental Impact Analysis, the Environmental Impacts are

quantitatively and qualitatively assessed. Prediction of impacts for the both

construction &operation phase is given in Table 4.2(a) and Table 4.2(b).



TABLE 4.2(A): PREDICTION OF IMPACTS DURING CONSTRUCTION PHASE

Parameter Activity

Air Water Land Noise Ecology Health & Safety

Socio Economic

Site cleaning (-ve) ST

- (-ve) ST

(-ve) ST

(-ve) ST

(-ve) ST

-

Leveling and road laying

(-ve) ST

- - (-ve) ST

- (-ve) ST

-

Earthwork comprising of excavation,

grading, trenching

(-ve) ST

- (-ve) ST

(-ve) ST

- (-ve) ST

-

Transportation of Construction materials

(-ve) ST

- (-ve) ST

(-ve) ST

(-ve) ST

-

Civil construction Civil construction

(-ve) ST

(-ve) ST

- (-ve) ST

- (-ve) ST

-

Mechanical erection (-ve) ST

- - - - (-ve) ST

-

Employment - - - - - (+ve)

ST (+ve)

ST

Greenbelt development (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT

Note: (+ve): Positive Impact; (-ve): Negative Impact; ST: Short Term; LT: Long Term

TABLE 4.2(B): PREDICTION OF IMPACTS DURING OPERATION PHASE

Parameter Activity

Air Water Land Noise Ecology Health & Safety

Socio Economic


(-ve) ST

- - - - (-ve) ST

-

Transportation of raw materials and finished

products

(-ve) ST

(-ve) ST

(-ve) ST

(-ve) ST

- (-ve) ST

-

Production & utilities (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT -

(+ve) LT

-

Emergencies or disaster (-ve) ST

(-ve) ST

(-ve) ST

(-ve) ST

(+ve)

LT -

Breakdown of critical systems

(-ve) ST

(-ve) ST

(-ve) ST

(-ve)

ST -

(-ve)

ST -

Employment - - - - - (+ve)

LT (+ve)

LT

Greenbelt Development (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT (+ve)

LT -

(+ve) LT

Infrastructure development & CSR

activities

- - - - - (+ve)

LT (+ve)

LT

Note: (+ve): Positive Impact; (-ve): Negative Impact; ST: Short Term; LT: Long Term



4.4PREDICTION OF IMPACTS DURING CONSTRUCTION PHASE

TABLE-4.3: IMPACTS DURING CONSTRUCTION PHASE

Sl.

No.

Environmental

parameter

Impacts Mitigative measures

1 Water Short term

negative impacts

due to water

consumption &

sewage disposal

Water requirement for construction phase will be

very minor and for short period and that will be

fulfilled by same source as utilized for existing unit,

i.e. from through tankers. Thus, there will not be

any significant impact on water environment.

• The wastewater generation will be from the

domestic activities. Domestic effluent will be

disposed of through septic tank into soak pit.

• Greenbelt development will have positive impact

on ground water table.

• Measures will be implemented to prevent seepage

of liquid materials into ground where it could

contaminate groundwater and soil.

Ensure prompt cleaning up of accidental spillages

Measures will be followed to prevent the contamination of hydrological features by diesel, grease, oil, etc. derived from the working area

The machinery / equipment will be maintained in a good operating condition

Specially designated areas will be created for vehicle maintenance

• Provisions will be made to ensure the construction

vehicles stick to the access track to prevent mud &

dirt being deposited on roads.

• All mud & dirt deposited on the roads from the

construction activities will be cleaned.

• Adopting good construction and engineering

practices will help in mitigating the water pollution.

2 Air Sort term

negative impacts

because of dust

emission due to

site cleaning,

road laying,

earthwork,

As this is the modification project, changes will be

carried out within the existing premises, very

negligible site cleaning will be required.

• Construction confined to proposed project site

will be carried out as per the requirement.

• The emissions will be temporary and confined

within proposed project boundary. It is not expected



transportation &

construction

to contribute significantly to the ambient air quality.

• However, the unit will take following measures

for control of dust emissions:

Use of plastic cover sheet while transporting raw material at site

The heights, from which materials will be dropped, will be the minimum practical height to limit fugitive dust generation.

Use of water sprinkling system at site for dust suppression

Provision of barricade sheet of steel sheet/ tin sheet of minimum 3 m heights to protect the surrounding area from the dust

All transportation vehicles will be suitably covered with tarpaulin & overloading of the vehicles will be avoided.

PUC certified vehicles will be used to avoid the exhaust emission.

• The construction activity will be carried out

during day time only.

• Existing greenbelt will have significant impact in

reduction of dust dispersion. Proposed Greenbelt

development will be started from the construction

phase.

3 Land Short term

negative impact

due to change in

top layer of soil

Modification will be carried out within the existing

premises. Therefore no change will occur in land

use pattern as well as there will not be any

significant topographical change. However,

temporary change in top layer of soil will be

occurred but the construction activity will help in

fixation of soil, thereby reducing the soil erosion.

• Top soil to be generated during construction

activity will be preserved and used for the green

belt development. Other excavated earth from the

construction activity will be used for the backfilling

and leveling in low laying area.

• Greenbelt development will have significant

impact in reduction of the soil erosion.

4 Noise Short term

negative impact

due to increase

in noise level by

site cleaning,

The noise impacts due to construction activities will

be local; limited to the premises and for very short

period of time.

• The noise generated from construction machinery

will be kept low by keeping the moving parts



4.5PREDICTION OF IMPACTS DURING OPERATION PHASE

Prediction of environmental impacts is the most important part of EIA study as it

provides quantitative information related to projection of possible environmental

consequences/impacts from a proposed modification project well in advance, i.e. prior

to its implementation based on the estimated pollution loads and surrounding local

conditions, viz. topography, existing environmental quality, type of effluent etc. Several

mathematical/statistical techniques and methodologies are available for predicting

impacts from any proposed developmental project on the surrounding physico-

chemical, ecological and socioeconomic components of environment.

The quantitative impacts derived through predictions are also essential to

delineate pragmatic environmental management plan, especially pollution mitigation

measures required to be implemented at different stages of proposed modification

project, i.e. detailed engineering stage, construction and operation phases for

minimizing the possible adverse impacts on the surrounding environment.

road laying,

earthwork,

transportation &

construction

activities

serviced and properly lubricated.

• The construction activity will be carried out

during day time only.

• Vehicular movement carrying raw materials will

be avoided during night time.

• The vehicles will be regularly maintained and

optimum use of the same will be made.

• Adequate PPE‟s (ear plugs, ear muffs, helmet,

mask etc) will be provided to the workers.

• PUC certified vehicles will be used.

• Greenbelt development will have significant

impact in reduction of the noise.

5 Socio-economic

environment

Short term

positive impact

by employment

generation

Temporary employment will be generated due to

construction activities and related services like

transportation of construction materials, mechanical

erections etc.

6 Ecology Long term

positive impact

due to green belt

development

Unit has already provided greenbelt area in existing

premises and the same will be increased after the

proposed modification which will have positive

impact on local flora & fauna.



The following activities related to operation phase will have various impacts on

the environment and are considered for impact assessment:

• Topography and Climate

• Air quality

• Noise levels

• Liquid Effluent Generation

• Solid / Hazardous Waste Generation

• Ecology

• Demography and Socio-economics

• Transportation

• Public Health and Safety

4.5.1IMPACT ON TOPOGRAPHY AND CLIMATE

The major topographical changes envisaged would be manmade structures like

erection of production blocks, raw material storage space, civil structures, water /

wastewater storage tanks, etc. However, it will also invite some positive benefits in the

form of developed greenbelt in the plant premises. From the proposed modification

project the impact on the climate due to the exhaust gas temperature will be envisaged.

The maximum temperatures of the exit gas from the stack will be restricted to 150°C

during normal conditions. Normally, this will not cause any thermal imbalance. Impact

on the climatic conditions from the proposed plant will be marginal which can be

nullified / reduced by existing green belt.

4.5.2 AIR ENVIRONMENT

The main raw materials required for the proposed project are various chemicals,

solvents, etc., for production of Synthetic Organic Chemicals, Coal for boilers & and

Diesel for DG sets. The main sources of pollution envisaged from the proposed project

are as follows.

• Fugitive emissions

• Process emissions

• Boiler & DG set emissions (Flue Gas)



4.5.2.1 FUGITIVE EMISSIONS FROM SOLVENTS HANDLING & RECOVERY AND

MITIGATION MEASURES

Various types of solvents are used in the Synthetic Organic Chemicals process.

Fugitive emissions are expected from the reactors in the workroom, storage tanks area

and as well as from handling area. Product wise solvent usage, losses and recovery are

estimated based on the material balance. The solvent wise usage, its losses and recovery

are presented in Table 4.4.

TABLE-4.4: PROPOSED PRODUCT WISE SOLVENT USAGE, LOSSES AND RECOVERY



1. Etodolac Stage-1 Methanol 450 440 10

Stage-2 Activated Carbon 3 3 --

2. Oxolamine Citrate Stage-1 Acetone 180 165 15



3 Dosulepin(Dothiepin) Hcl

Stage-1 Toluene+ Tetrahydrofuran 550 490 60

Stage-2 Dichloromethane Acetone Methanol

665 475 200

530 430 180

135 45 20

4 Oxolamine Phosphate Stage-1 Acetone 180 165 15


Stage-3 Acetone 500 475 25

5 Diacerein

Stage-3 N, N-Dimethylacetamide


580 2

20 --

6 Capecitabine Stage-1 Acetonitrile 1500 1470 30



8 Efavirenz Stage-1 n-Hexane 2000 1890 110

Stage-2 Ethyl acetate 1000 950 50

9 Leviteracitam Stage-1 Acetonitrile 1500 1450 50

Stage-2 Di methylformamide 1500 1450 50

10 Moxifloxacin

Stage-2 Di methylformamide Triethylamine

800 400

770 370

30 30

11 Nebivolal Stage-1 Methanol 2000 1950 50


12 Nevirapine Stage-1 Toluene 1500 1450 50




Stage-3 O-Xylene 2000 1980 20

Stage-4 n-Heptane 500 480 20

13 SaquinavirMesylate Stage-1 Toluene 500 450 50

Stage-2 Ethanol 500 480 20

Stage-3 THF Triethylamine

400 500

360 450

40 50




1500 1000

1450 960

50 40


800 600

760 500

40 100


600 50 400

550 50 370

50 -- 30

15 Zidovudine Stage-1 n-Hexane 1000 980 20

Stage-2 Acetic anhydride 100 90 10

Stage-3 HCl 100 100 --

16 TerbinafienHcl Stage-1 Dimethyl sulfoxide 400 370 30


17 Ezitamibe Stage-1 Di Isopropyl ether 3000 2900 100

Stage-2 Pd.Carbon Acetone

25 1500

25 1450

-- 50

Industry proposed several steps to minimize the solvent vapour emanations and

recovery procedures. However, leak detection system will be provided at storage/day

tank and loading/unloading operations. Vent solvent vapours will be identified and

precautionary measures will be taken for leak proof operations. Identified vent solvent

vapours (storage, reactor & day tanks etc.) sent to effective condensing system on

multiple stage basis to recovery effectively. Recovery of solvents from spent solvents

will be effectively by distillation unit for purity and can be reused. In case of mixture of

spent solvent, fractional distillation may be made to recovery on stage wise basis.

Other source of fugitive emissions, coal handling places and related dust

emanation is to be minimized by storing in the covered area and water spray system if

required especially during loading / unloading operations and at stock yard.



Apart from these, spillover of raw material in production units is to be avoided,

if any, relevant specific procedure to be followed to clean up the spill over material and

disposed environmental friendly after neutralizing or diluting effectively.

The solvents will be stored in drums and bulk quantities will be stored in above

storage tanks of suitable capacities. Solvents are handled in closed conditions thereby

reducing the losses in the form of evaporation. The industry will take measures for

reduction of fugitive emissions and further reduction will be achieved by providing

vent condensers to the tanks. Chilled brine circulation will be carried out to condensate

the solvent vapor and to the receivers of the solvent vapors which ensures the

maximum recovery and also controlled by closed operations and handling methods.

Good ventilation will be provided to reduce the workroom concentrations. The reactor

generating solvent vapors will be connected to double condensers with receivers.

Solvent vapours from the Centrifuge and Catch pots will be connected to vent

condensers. Vent condensers will be provided to the solvent receiver tank and height of

the vent is above production block roof level and the diameter is 20 mm. The solvent

loss is depending on the boiling point of the solvent.

Solvent management for effective recovery:

Reactor will be connected to double condensers with Cooling and chilled

water/brine condenser system

Reactor and solvent handling pump will have mechanical seals to prevent

leakage.

Condensers will be provided with sufficient Heat Transfer Area (HTA) and

residence time so as to achieve maximum recovery

Solvents will be stored in a separate space specified with all safety measures.

Proper earthling will be provided in all the electrical equipment wherever

solvent handling is done.

Low boiling solvents storage tanks are insulated



Entire plant where solvents are used, the equipment‟s/pumps/fittings will be of

flame proof. The solvent storage tanks will be provided with vent condensers

and breather valve with nitrogen blanketing system to prevent losses.

FIG-4.6: SOLVENT RECOVERY BY DISTILLATION COLUMN

Mitigation Measures

To control the fugitive emissions generated during various operations in the

industry, the following mitigation measures will be adopted.

Dedicated pipe lines for transfer of solvents from respective solvent storage tanks

to day tanks and then to reactors in the production blocks.

All solvent storage tanks will be provided with vent condensers having cooling

or chilled water circulation.

All reactors will be provided by double condensers.

Mechanical seals will be provided for all the reactors for improving emission

control measures.

Mother liquors will be collected in closed drums.

Standby scrubbers will be kept ready for emergency use.



Wherever possible pressure nutsche filters (PNF) will be used in place of

centrifuges to contain the solvents thereby reducing the solvent emissions.

4.5.2.2 PROCESS EMISSIONS AND MITIGATION MEASURES

Manufacturing of Synthetic Organic Chemicals will result in gaseous emissions.

Maximum Process emissions with their quantities and treatment method are presented

in Table 4.5. Gaseous emissions will be scrubbed in multi stages with water /caustic /

dilute HCl solution based on the characteristics of gases.

Mitigation Measures

The quantities of these gases will be insignificant and are not generated

continuously. These emissions are only product based and will be emitted only when

the specific product is under production. The acid mist emissions are liberated from the

process. The scrubbed solutions are sent for ETP for further treatment and reuse. The

vents of the scrubber‟s gases will be dispersed into atmosphere through a stack above

the production block.

FIG-4.7: SCHEMATIC FLOW DIAGRAM OF SCRUBBER SYSTEM



4.5.2.3 FLUE GAS EMISSIONS AND MITIGATION MEASURES

During operational stage of the plant, Particulate Matter (PM), Sulphur dioxide

(SO2) and Oxides of Nitrogen (NOx) emissions would be the major criteria air

pollutants. However, the emission concentrations are insignificant. The impact on

ambient air quality is assessed hereunder considering the following:

Air quality impacts have been predicted assuming that the pollution load due to

the existing activities covered under baseline environmental monitoring Site-specific

meteorological parameters have been recorded by using continuous recorders. Short-

term 24 hourly GLC's incremental values were estimated using the site-specific

meteorological data.

Multicyclone separators and bag filters with a suitable stack height of 30m is

installed for controlling the Particulate emissions within statutory limit of 100 mg/Nm3

from the proposed coal fired boilers of 2TPH.

Stack emissions in this unit are from boilers and DG sets, which will be released

to atmosphere at elevated level at considerable level. DG sets will be used as standby

during power failure.

TABLE-4.5: DETAILS OF FLUE GASES EMISSIONS AND CONTROL MEASURES

Sl. No.

Source of air Pollution Type of

Fuel Sulphur content

Chimney height

(in m) AGL

Constituents to be

controlled


provided

Existing

1 Coal fired Boiler

- 2 TPH Coal 0.8% 30 m AGL PM, SO2, NOx Dust collector

2 250 kVA DG Set HSD -- 5 m AGL SO2 Acoustic Measures

3 Process emission -- -- 20 m AGL Acid mist Scrubber

As possible as low sulphur coal ≤0.5% sulphur may be used without any

compromise with supplier.

High efficiency particulate control system such as multi cyclone followed by bag

filter may be applied with guaranteed efficiency of 99.5% design, where in

appropriate cone length for efficient control of coarse particles in Multi cyclone

andbag filter design filtration velocity will be less than 1.5 m3/min/ m2 area.



Regarding NOx emissions apart from low NOx burner, flue gas recirculation

system and stage based burning system may be applied, so that 25-30% of

further reduction of NOx can be achieved.

4.5.2.4 AIR QUALITY MODELING

The mathematical model stimulates the relationships between air pollutants

emitted from the source and their impact on surrounding air quality. Prediction of

impacts on air environment has been carried out employing mathematical model based

on a steady state Gaussian plume dispersion model designed for multiple point sources

for short term.

In the present case, the software provided by „M/s Lakes Environment‟, Canada

ISC-AERMOD view is used for prediction of pollutants. It is a complete and powerful

air dispersion modelling package which seamlessly incorporates the popular U.S.EPA

models ISCST3, ISC Prime and Aermod into one interphase without any modifications

to the models.

AERMOD dispersion model is a steady state Gaussian plume model which can

be used to assess pollutant concentrations from a wide variety of sources associated

with an Industrial Source Complex.

POLLUTANTS/MODEL OPTIONS CONSIDERED FOR COMPUTATIONS

The model simulation deal with major pollutant emitted from the proposed

stack. The model options used for computation is as follows

i) The plume rise is estimated by Briggs formulae, but the final rise is always

limited to that of the mixing layer;

ii) Stack tip down-wash is not considered;

iii) Buoyancy Induced Dispersion is used to describe the increase in plume

dispersion during the ascension phase;

iv) Calms processing routine is used by default;

v) Wind profile exponents is used by default, 'Irwin';

vi) Flat/elevated terrain is used for computations;

vii) It is assumed that the pollutants do not undergo any physico-chemical



transformation and that there is no pollutant removal by dry deposition;

viii) Washout by rain is not considered;

ix) Cartesian co-ordinate system has been used for computations; and

x) The model computations have been done for 10-km with 500-m interval.

PLAN AND FRAME WORK OF COMPUTATIONS

SELECTION OF LOCATIONS:

The locations have been selected around the proposed project covering an area of

10 km radius from the centre of proposed project. The entire area has been put on grid

network and grid spacing has been taken. The receptors where the baseline data is

analysed have also been selected.

PLAN OF COMPUTATION:

It was planned to compute the following:

The 24 hourly averaged incremental concentration with hourly data.

The identification of grid point having peak concentration for the incremental

values.

Preparation of isopleths of various pollutants.

MODEL INPUT DATA

*** MODEL SETUP OPTIONS SUMMARY ***

**Simple Terrain Model is selected

**Model Is Setup For Calculation of Average Concentration Values.

-- SCAVENGING/DEPOSITION LOGIC --

**Model Uses NO DRY DEPLETION. DDPLETE = F

**Model Uses NO WET DEPLETION. WDPLETE = F

**NO WET SCAVENGING Data Provided.

**NO GAS DRY DEPOSITION Data Provided.

**Model Does NOT Use GRIDDED TERRAIN Data for Depletion Calculations

**Model Uses RURAL Dispersion.

**Model Uses Regulatory DEFAULT Options:



1. Final Plume Rise.

2. Stack-tip Downwash.

3. Buoyancy-induced Dispersion.

4. Use Calms Processing Routine.

5. Not Use Missing Data Processing Routine.

6. Default Wind Profile Exponents.

7. Default Vertical Potential Temperature Gradients.

8. "Upper Bound" Values for Super squat Buildings.

9. No Exponential Decay for RURAL Mode

**Model Assumes Receptors on FLAT/ELEVATED Terrain.

**Model Assumes No FLAGPOLE Receptor Heights.

**Model Calculates 2 Short Term Average(s) of: 1-HR 24-HR and Calculates PERIOD

Averages

The Ground level concentrations of the different pollutants have been calculated

using EPA recommended Air quality Model. The model used is the AERMOD

dispersion model developed by EPA and computed Ground Level Concentration

(GLC‟s) from point sources is given in the Table 4.6

TABLE-4.6: GROUND LEVEL CONCENTRATIONS OF DIFFERENT POLLUTANTS

THE FIRST HIGHEST 24 HR AVERAGE CONCENTRATION VALUES

(µg/m3)

Location code Location NOx SO2 SPM

A1 Chorus Labs Limited 2 0.9 0.4

A2 Chauli 3 0.8 0.6

A3 Atwala 0.8 0.3 0.4

A4 Anadur 4 0.8 0.98

A5 Sikandrapur 0.9 0.3 0.5

A6 Bellura 1.6 0.3 0.4

A7 Amlapur 1.1 0.3 0.7

A8 Chidri 0.5 0.1 0.2

A9 Chikpet 0.8 0.1 0.1

HIGHEST 24 HR RESULT



Conc

NOx 5 (300m East)

SO2 1 (100m East)

SPM 1 (150m East)

FIGURE – 4.8: 24-HR AVERAGE CONCENTRATION VALUES OF SO2 IN micrograms/m3

FIGURE – 4.9: 24-HR AVERAGE CONCENTRATION VALUES OF NOX IN micrograms/m3



FIGURE – 4.10: 24-HR AVERAGE CONCENTRATION VALUES OF PM IN micrograms/m3

Mitigative Measures

Presently unit uses coal as a fuel. An adequate stack height of 30.0 meter is

provided for proper dispersion of pollutant, which will also be adequate.

The adequate scrubbing system like water scrubber followed by alkali scrubber is

proposed to control the process gas emission from manufacturing activity.

In addition to the above, unit will take following adequate measures for the control

of fugitive emissions:

The entire manufacturing activity will be carried out in closed reactors/vessels

and regular checking and maintenance of the same will be carried out to avoid

any leakages.

All the motors of pumps for the handling of hazardous chemicals will be

flameproof and provided with suitable mechanical seal with stand-by

arrangement.

The control of all parameters on a continuous basis will be done by adequate

control valves, pressure release valves and safety valves etc.



All the flange joints of the pipe lines will be covered with flange guards.

All the raw materials will be stored in isolated storage area and containers will

be kept tightly closed.

Precautionary measures will be taken while handling various hazardous

chemicals.

There will also provision of adequate ventilation system in process plant and

hazardous chemical storage area.

A regular preventive maintenance will be planned to replace or rectify all

gaskets, joints etc.

The unit will also expand green belt area within the factory premises to control

the fugitive emissions from spreading into surrounding environment.

Hence, there will not be any significant impact on air environment due to

proposed project.

4.5.3 WATER ENVIRONMENT

With respect to water environment; three aspects are generally considered in

EIA, availability & requirement of fresh water, wastewater generation and its disposal.

Fresh Water Requirement:

Total water requirement for the proposed project is 31.5 KLD which will be met

from KIADB.

Unit will regularly check and maintain water consumption records after

proposed modification. The area falls in industrial zone, specifically chemical &

pharmaceutical industries and looking to the lot of sub-surface pollution in and around

the area and proposed handling of hazardous chemicals by the unit, it is not advisable

to recharge aquifer directly through the recharge well. However, recharge through

pond/tank or plantation is preferred in this area because in that case soil will act as

purifying media. Rain water can also be stored and utilized for plantation and other



purposes. Thus, it is suggested to collect, store and utilize the rain water for plantation

and other industrial purposes and/or to recharge aquifer through pond /tank.

Hence, there will not be any adverse impact on water environment due to water

availability and water requirement for the proposed project.

Wastewater generation:

Two different streams of effluent will be generated that is 1.3 KLD of domestic

waste water, 12.61 KLD of industrial effluent and cooling towers from the project.

Disposal of Effluent:

Two different streams of effluent will be generated and will be treated in

different treatment plant. Domestic sewage will be treated in biological treatment.

Effluent will be treated in ETP followed by MEE and AFTD.MEE flow diagram is

attached as ANNEXURE-10.

The unit has proposed to install their own Effluent treatment plant (ETP)

comprising of primary, secondary & tertiary treatment which will be adequate to

achieve the discharge norms prescribed by KSPCB. Treated water will bemused for

secondary purposes such as gardening purposes within the premises.

Separate drains for storm water and wastewater collection. Open drains for

storm water should be provided and be kept neat and clean all the time and free of any

cross connection from process source.

TABLE 4.7: WASTEWATER TREATMENT DETAILS

Effluent generated from Treatment units provided Final disposal

points(land/sewer/river)

Domestic Biological treatment system Reused

Industrial

1.Process Feed tank to MEE system and

MEE system followed by agitator

thin film drier (ATFD)

MEE condensate to biological

treatment system for further

treatment 2.Washings

3.Boiler blow down

Collection tank Biological treatment system

4. RO reject

5. Cooling Recycled Recycled



FIG-4.11: ZLD EFFLUENT TREATMENT FLOW SCHEME

The effluent generated from the industrial production process was treated using

forced evaporator. Forced evaporator is the system where the water heated up to the

temperature of 1150C to 1200C, than concentrated wastewater is cooled to room

temperature and filtered through nutch filter and then solid waste sent to the hazardous

waste disposal site. The filtrate generated is once again sent back to the forced

evaporator. And now wastewater generated from the industrial process and utilities is

taken to the treatment unit which is Multiple Effective Evaporator with Stripper and

ATFD. This individual effluent will be pumped to the RCC lined tanks for storage and

neutralization then sent to ETP-ZLD of 20 KLD capacity within the plant premises. The

wastewater contains some organic residues which will be stripped at the stage of

stripping and taken in to further stage. The stripped wastewater will be sent to solvent

recyclers for recovery of the solvent.



As the industry is required to operate and maintain the effluents quality within

the limits specified by the CPCB/SPCB, the effects of the industrial effluents may be

negligible. Regular monitoring of these parameters in effluent generated by industry

will help in keeping check in any contamination or surpassing of any set standard and

thus treated quality of water will be maintained. Thus, it can be concluded that there

will not be any adverse and negative impact on the surrounding environment due to

the treated effluents from the industry.

There will not be any discharge of wastewater on the land. Besides, there will be

separate storm water and industrial wastewater drains to eliminate chances of mixing

of rainwater with wastewater. Hazardous wastes will be stored, managed and handled

as per hazardous wastes rules. All bulk chemicals and fuel storage areas will be

provided with dyke wall/bunds to eliminate chances of any spillages/leakages

entering into the storm water drain. No significant adverse impact on the surface and

ground water or soil quality is envisaged in view of the proposed mitigation measures.

4.5.4IMPACT ON LAND USE

The modification unit has been proposed in existing area consist of Built-up area,

greenery, BT/CC roads area, Parking area and Open / lawn area etc., which is under

possession of project proponent. Hence, there are no R&R issues involved in the

proposed project as it is Notified Industrial area. About 40% of the land area will be

developed as greenbelt.

There is no ecologically sensitive area within 10 km of radial distance from

proposed project boundary. No wildlife sanctuaries, National parks, Tiger or elephant

reserves exist in10 km radius. Also no migration route of avifauna present in 10 km

radius. 4 reserved forests blocks are at a distance of within6 km from project boundary

of the project site.

4.5.4.1 IMPACT ON SOIL

Spillages such as wastewater/solid wastes/raw materials are expected /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. Hence, there is no impact on the top soil.

The Hazardous / solid waste generated will be stored in the covered area till it is

disposed the SPCB authorized Cement industries/ TSDF. Hence, apart from very few

localized construction impacts at the plant site, no significant adverse impact on soil in

the plant premises area is anticipated.

4.5.4.2 IMPACT DUE TO HAZARDOUS / SOLID WASTE GENERATION

All process waste is considered as hazardous waste and segregated into process

organic residues, Inorganic salts and spent carbon. The organic residues and spent

carbon disposed to cement units, agreement copy is attached as ANNEXURE-7 for use

as alternate fuel either in the solid or liquid form as recommended by CPCB. Inorganic

salts are sent to landfill at TSDF. Solid waste generated from the different sections of

proposed Synthetic Organic Chemicals plant is presented in Table 4.8. 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 till its

disposal. Boiler ash will be sold to brick manufacturers. All wastes including hazardous

& non-hazardous wastes will be disposed through the method approved/permitted by

the competent authority.

Hence, issues of impacts on land due to the solid/hazardous waste are not

envisaged. In addition to these mitigation measures, proponent will be dedicated to

maintain healthy greenbelt, which can have beneficial impact to land use, land cover

and for prevention of erosion of topsoil.

TABLE 4.8: SOLID &HAZARDOUS WASTE GENERATION AND HANDLING

Source Description Quantity in Kg/day Disposal method

Process

Inorganic solid waste 1,080 Sent to TSDF

Spent carbon 100 Sent to cement industries

MEE salts 1122 Sent to TSDF

Raw Material Storage & Handling

Detoxified containers 200 nos./Month KSPCB authorized agencies for reprocessing/

recycling LDPE bags 500 nos./month HDPE drums 200 nos./month



Plant and Machineries

Waste oil 2 KL/Annum

Coal ash from boiler 300 Kg/day Sent to Brick manufactures

Solvent distillation

bottom residue.

25 kg/day Sent to TSDF

Fly ash utilization with its action plan:

In the present case generation fly ash from boiler is around 0.3MTPD. Hence,

collection and storage system may be given due importance i.e. not to emanate to

atmosphere and contaminant to water and soil. Stored bulk material should be utilized

in brick manufacturing units through respective users and disposed accordingly.

Industry has entered into an agreement with Brick manufacturing industries

(Annexure-8).

Development of Green Belt

The unit has been developing green belt in the area admeasuring 5615 Sqmt

(40%) within the existing premises. The green belt area will not only improve the

landscape and environment but also enhance soil conditioning, prevent soil erosion

which gives slight beneficial impact on the land usage.

4.5.5 IMPACT ON NOISE LEVEL

In general any industrial complex has several sources of noise in clusters or

single. These clusters/single sources may be housed in buildings of different

dimensions made of different materials or installed in open or covered sheds. The

material of construction implies different attenuation co-efficient. The major sources of

noise pollution are from the proposed modification plant is due to stationary sources.

There is no major noise generating operations envisaged in the plant. The only

noise generating sources are DG sets, motors and rotating machinery like

pumps/blowers/compressors etc. DG sets will be installed with inbuilt acoustic

enclosures.

Low noise and noise reduction will be a part of design specification for all future

plant equipment‟s. The limiting noise level of 85-90 dB (A) will be binding for all



machinery under inspection and is an integral part of the routine preventive

maintenance. Noise generating units are isolated and sensitive areas like canteen,

administration building and plants are provided with enclosure doors. The noise levels

at the plant boundary with Greenbelt are significantly below 55 dB (A). There is a

considerable distance between the surrounding community and the plant boundary to

effect adequate noise attenuation.

The findings indicate that no significant impacts due to noise pollution are

expected, due to the enhancement in production capacity. Besides this other noise

control measures are as follows:

Noise attenuating devices like earplugs and earmuffs have been provided to the

workers exposed to high noise level area like DG Sets.

Sufficient green belt is being maintained in & around the plant premises.

Regular monitoring of noise level is being carried out and corrective measures in

concerned machinery are being adopted accordingly.

4.5.5.1 IMPACT ON COMMUNITY

Greenbelt developed around the periphery of the premises will also act as a

barrier to the propagation of noise from the factory premises. This will further reduce

the noise levels from the generation sources. The cumulative impact of all noise sources

at boundary will be less than 55 dB (A). There will not be much effect on the nearest

village (habitation), which is 1 km distance from the project boundary. Hence, no

significant impact is envisaged.

It is, therefore, expected that noise level at the plant boundary will be within the

prescribed norms of CPCB due to operation of the proposed modification project and

hence no significant adverse impact on noise environment is expected.

4.5.5.2 IMPACT ON OCCUPATIONAL HEALTH (WORK ZONE)

The noise sources include boiler, cooling tower, DG sets and compressors etc. It

is observed that noise levels inside the process units will not exceed 65 dB (A).

However, impacts on the working personnel are not expected to be significant on



account of the regular maintenance of the plant, which means that workers will be

exposed for short duration only and that too intermittently. However, exposure to noise

to individual workers will be below 90 dB (A) (for 8 hours shift) because of use of

earmuffs.

The noise generation during operation phase would be at source itself through

different measures such as inspection, operation and maintenance at regular intervals.

The noise control measures described in environmental management plan will be

followed. The occupational noise exposure to the workers in the form of 8-hourly time

weighted average will be maintained well within the prescribed Occupational Safety

and Health Administration (OSHA) standards (<90dB(A)). Hence, the impact on

occupational health of workers would be insignificant.

4.5.6 ECOLOGICAL ENVIRONMENT

The impact due to the proposed project on the ecological parameters like natural

vegetation, crops, forests and species diversity is summarized in below texts:

The proposed modification is carried out within the existing industrial premises.

Hence, there will not be any cutting of natural vegetation due to proposed

modification. On the contrary, the industry will expand its green belt area within

and surrounding periphery.

Necessary environmental protective measure have been planned under EMP for

air, water and hazardous waste management systems and regular environmental

surveillance will be carried out so as to prevent any short-term or cumulative

effect on the crops and natural vegetation of the area.

Industrial treated effluent conforming to the discharged norms by KSPCB will be

utilized for greenbelt development within the premises.

There is no national park or sanctuary within the study area.

No rare and endanger flora & fauna is reported within the study area.



4.5.7 SOCIO-ECONOMIC ENVIRONMENT

The proposed project is in a well-established and industrial notified estate. Thus,

the said project will not have any significant impact on Socio-economic pattern of the

surrounding region. The project shall generate indirect employment opportunities,

which will contribute to social upliftment of the people in surrounding area.

a) Employment Opportunity:

Prediction of the socio-economic impacts of site would be totally a positive

mainly due to the employment opportunities. At present total 20 nos. of workers are

placed for management and production department for existing unit, which there will

be no increased in population after modification. The preference will be given to local

population for employment in the semi-skilled and unskilled category; this will increase

the employment opportunity in the surrounding area. Secondary jobs are also bound to

be generated to provide day-to-day needs and services to the work force. This will also

increase the demand for essential daily utilities in the local market and ancillary

business development to some extent for the local population. Thus, the proposed

project is expected to create a beneficial impact on the local socio-economic

environment.

b) Industries:

During the operation activities, the required resources are consumed maximum

from the local area and same practice will continue after the modification. The

increasing industrial activity will boost the commercial and economical status of the

locality, to some extent.

c) Public Health:

Same as the existing plant, workers will be provided after proposed

modificationwith basic amenities like safe water supply, low cost sanitation facilities,

first aid, required personal protective equipments, etc.; otherwise there could be an

increase in diseases related to personal hygiene. Moreover unit is carrying out CSR

activities in nearby villages in the field of medical facilities, public health and green belt



development; this has contributed to improve the public health in the region to some

extent. The unit also intends to continue such activities with the increased budget in the

region after the modification project.

4.5.8 LAND ENVIRONMENT AND ASTHETICS

The required plant & machinery for the full production capacity will be installed

within the said premises. No new land is to be acquired for the proposed project. Thus,

no adverse impact is likely to be generated on the land environment and general

aesthetics of the area.

Construction Phase is for small period during erection and installation of

machineries and therefore there is no question of impacts on land use pattern. During

operational phase, there will not be any effect on land.

Adequate air pollution control equipments at various pollutant generation

sources shall be proposed. Adequate height of the stack will help in dispersing the

pollutants emitted from the stacks effectively into the atmosphere.

TRANSPORTATION AND PUBLIC AMENITIES

The impact of economic development on civic amenities will be substantial as the

industry is located in Notified Industrial Area. The area has already experienced a good

network of roads and communication. Industry is about 700m from State Highway No.

105. Many villages have been electrified during the last decade. Although the level of

existing communications and support services in the area are adequate, modification of

the proposed unit would further strengthen these services. After modification vehicle

movement of the industry will be no increase in numbers of vehicles. Industry

earmarked the adequate parking area for the above vehicles separately. Hence, it can be

said that the proposed modification project will have a positive impact on the study

area.

Traffic management

The project site is connected to the SH-105 at the West side of the project site. The

project site is having well established internal road with the tar finishing and they are in



good condition. Traffic movement is controlled within the project site by monitoring the

movement of the vehicle and proper signage boards are provided for smooth running

of the vehicle. To analyze the traffic level, traffic survey has been carried out on the SH-

105 and details as follows.

ROADCONNECTIVITY

TRAFFIC SURVEY DETAILS: SH-105- BIDAR HUMNABAD ROAD

TRAFFIC FLOW TOWARDS HUMNABAD:

S. No.

Vehicle type During Lean Hrs (No. of vehicles/hr)

Vehicles in PCU’S

During Peak Hrs (No. of vehicles/hr)

Vehicles in PCU’S

1 Two Wheeler 40 20 72 36

2 Three Wheelers 10 8 24 18

3 Cars 36 36 60 60

4 Buses/Lorry 14 42 30 90

Total 100 106 186 204

TRAFFIC FLOW TOWARDS BIDAR:

S. No.

Vehicle type During Lean Hrs (No. of vehicles/hr)

Vehicles in PCU’S

During Peak Hrs (No. of vehicles/hr)

Vehicles in PCU’S

1 Two Wheeler 52 26 98 49

2 Three Wheelers 22 17 36 27

3 Cars 48 48 80 80

4 Buses/Lorry 24 72 40 120

Total 146 163 254 276

Lean Hrs: Before 8 hrs (morning), 1 to 5 hrs (afternoon)& after 9 hrs (evening)

Peak Hrs: After 8 hrs & 5 to 9 hrs in the (evening)



TRAFFIC SCENARIO:

Road Towards V C Existing V/C LOS

SH-105 BIDAR HUMNABAD

ROAD

Humnabad 204 1100 0.18 A

Bidar 276 1100 0.25 B

V/C LOS Performance

0.0-0.2 A Excellent

0.2-0.4 B Very good

0.4-0.6 C Average

0.6-0.8 D Poor

0.8-1.0 E Very poor

1.0 & Above F Worst

Note: Capacity as per IRC-106; 1990 for guideline, for capacity, for urban roads page 11 table-2.

V= Volume in PCU‟s/hr & C= Capacity in PCU‟s/ hr LOS = Level of Service Existing traffic scenario is in very good condition; even though the LOS remains same.

4.5.9 ODOUR CONTROL MEASURES

All operations will be carried out in closed system, vents of the batch tanks and

solvents will be connected to scrubber to avoid every possibility of odour

escaping into atmosphere.

Green belt will be developed covering 40% of the total project area, around the

plant boundary as dust preventive barrier and help to reduce odour.

The operation of centrifuging/ filter will be done in closed system to avoid any

vapors coming out in the local atmosphere. The vents of centrifuges/filters will

be connected to scrubbers.

Most effective way of controlling odour is by storing volatile materials in closed

containers to prevent volatile emission and carrying out chemical reactions in

closed chambers.



CHAPTER 5

5. ANALYSIS OF ALTERNATIVES

M/s. Chorus Labs Limited is an existing industrial unit and the proposed project

will take place within the existing premises having all the infrastructure facilities, land,

water sources, material transportation, power etc. After the proposed project existing

infrastructure facilities will be utilized with the addition of new machineries and

therefore, no alternative for the site was considered. This is existing unit and therefore

Alternate sites are not considered for the proposed modification project. Availability of

the supporting facilities include skilled manpower is available in abundance since plant

is close to Bidar. Rehabilitation and Resettlement is not applicable to this project site as

the modification site is existing industrial land. Land is in possession of project

proponent.

Unit proposes to manufacture various Bulk Drugs & Drug Intermediates

(Synthetic Organic Chemical) and manufacturing process involves various chemical

reactions and physical operations. For the proposed products, unit will adopt latest and

best technology available so far in the market.

Moreover, the unit is very concerns and conscious about the product quality and

equally about the environmental protection and resource conservation; and hence they

put their efforts for replacing/ upgrading their existing plant and machineries from

time to time with the best available technology.



CHAPTER 6

6. ENVIRONMENTAL MONITORING PLAN

6.1 INTRODUCTION

Environmental monitoring is an essential tool for sustainable development

&ensuring effective most implementation & monitoring of environmental management

plan& mitigation measures. It is also very essential to keep updating the environmental

management system for effective conservation of environment along with ongoing

project activities/operation. The environment monitoring plan enables environmental

management system with early sign of need for additional action and modification of

ongoing actions for environment management, improvement & conservation. It

provides exact idea for mitigation measures to be implemented as it is linked with

actual distraction of environmental quality due to the project activities. Hence,

monitoring of critical parameters of environmental quality is very essential in the

routine activity schedule of project operation. An Environmental Monitoring

Programme shall be scheduled for the following major objectives:

Assessment of the changes in environmental conditions, if any, during the

project operation/activities.

Monitoring & tracking the effectiveness of Environment Management Plan&

implementation of mitigation measures planned.

Identification of any significant adverse transformation in environmental

condition to plan additional mitigation measures

The primary aim of environmental monitoring program is to formulate a

systematic, site-specific plan for monitoring the environmental parameters within the

impact area, during and after commissioning of the project, which would aid in

assessing the effectiveness of mitigation and environmental protection measures



implemented for the proposed project based on the existing environmental scenario and

the probable environmental impacts appraisal.

For each of the environmental attributes, the monitoring plan specifies the

parameters to be monitored, location of monitoring sites, frequency and duration of

monitoring and it also denotes the applicable standards, implementation and

supervising responsibilities.

6.2 OBJECTIVES OF MONITORING

Ensure day to day operational activities are conducted in a manner in

compliance with the applicable regulatory approvals including legislation and

industry standards

Evaluate the adequacy of mitigation and pollution control measures

implemented for reducing the adverse impacts caused during the construction

and operation stage and suggest additional mitigation measures, if appropriate,

in the light of the results

Define a detailed framework to monitor and document for achieving full

compliance with statutory requirements

Encourage good environmental management practices through planning,

commitment and continuous improvement

Develop clearly defined environmental monitoring program designed to assess

the nature and extent of environmental impacts of the proposed operations and

progressively refine such programs against the targets.

To handle hazardous wastes as per the Hazardous Waste (Management and

Handling) Rules, 1989 and subsequent amendments

Define roles and responsibilities of site personnel and ensure that all people

onsite are fully informed of their responsibilities and accountabilities with regard

to the environment



To comply with all regulations stipulated by the State Pollution Control Board

(SPCB) related to air emission and liquid effluent discharge as per air and water

pollution control act/ laws

Review, improve and update environmental management procedures and

standards

Perspective budgeting and allocation of funds for environmental management

expenditure, Continuous development and search for innovative technologies

for a cleaner and better environment

6.3 MONITORING SCHEDULE

Environmental Monitoring Schedules are prepared covering various stages of

project advancement such as constructional phase and regular operational phase.

6.3.1 MONITORING SCHEDULES DURING CONSTRUCTIONAL PHASE

Environmental impacts during the construction phase can be attributed to the

site preparation activity and the mobilization of workforce. The impacts of the

construction phase on the environment would be basically of transient nature and are

expected to wear out gradually on completion of the construction programme.

However, once the construction of the project is completed and its operations started,

these operation stage impacts would overlap the impacts due to the construction

activities.

In order to mitigate such impacts and restrict them within tolerable levels, the

following measures shall be adopted:

Proper and prior planning of approach and access roads, and appropriate

sequencing and scheduling of all major construction activities.

Adoption of appropriate soil conservation programme and its timely

implementation in the proposed project site.

Initiation of an appropriate landscape programme including plantation of trees

and flowering plants in and around the project site particularly, at all available



spaces which would serve the dual purpose of controlling fugitive dust and

abatement of noise levels in addition to improving the aesthetics of the area.

Water sprinkling in the vulnerable areas to suppress the dust generated during

leveling and other operations.

Use of properly tuned construction machinery & vehicles in good working

condition with low noise & emission and engines turned off when not in use.

Control of quality of construction wastewater within the construction site

through suitable drainage system with traps for arresting the sediment load for

its proposed disposal into the main natural drainage system around the site.

Implementation of suitable disposal methods of sediment at designated places to

avoid water logging at construction site.

Provision of protective gears such as ear mufflers etc. for construction personnel

exposed to high noise levels and locating the temporary labour sheds for housing

the construction laborers away from the construction site.

TABLE 6.1: ENVIRONMENTAL MONITORING DURING PROJECT CONSTRUCTION STAGE

Sr. No.

Potential Impact

Action to be Followed Parameters for

Monitoring Frequency of Monitoring

1 Air

Emissions

All equipments are operated within specified

design parameters.

Random checks of equipment

manuals/logs Periodic

Vehicle trips to be minimized to the extent

possible Vehicle logs

Periodic during site clearance &

construction activities

Any dry, dusty materials stored in sealed containers

Open containers of dusty materials.

Periodic during construction activities

Ambient air quality within the premises of the proposed unit to be

monitored.

The ambient air quality will conform to the standards for PM10, SOx& NOx

As per CPCB/ KSPCB requirement or on monthly basis whichever is earlier.

2 Noise

List of all noise generating machinery onsite along with age to be prepared.

Equipment to be maintained in good

working order.

Equipment logs, noise reading

Regular during construction activities



Night working is to be avoided.

Working hour records

Daily records

Implement good working practices to minimize noise and also reduce its impacts

on human health Site working

practices records, noise reading


No machinery will be running when not

required.

Acoustic mufflers / enclosures to be provided

in large engines

mufflers / enclosures shall be

in place

Prior to use of equipment.

Noise to be monitored in ambient air within the

plant premises. Spot noise recording

As per CPCB/ KSPCB

All equipment operated within specified design

parameters.

Random checks of equipment logs/

manuals


Vehicle trip[s to be minimized to the extent

possible Vehicle logs


3 Soil Erosion

Minimize area extent of construction site by staying

within the defined boundaries

Construction site boundaries not

extended / breached as per

planned document.


4 Waste

Management

Implement waste management plan that

identifies and characterizes every waste arising

associated with proposed construction activities &

which identifies the procedures for collection,

handling& disposal of each waste arising.

5

Non-routine events and accidental releases

Plan to be drawn up, considering likely

emergencies and steps required to prevent/ limit

consequences.

Mock drills and records of the same




6 Health Employee and migrant labour health check ups

All relevant parameters

Regular check ups

7 Flora and

Fauna Vegetation development as

per Forest Guidelines No. of plants,

species During site clearance

phase

6.3.2 MONITORING SCHEDULES DURING OPERATION PHASE

The control measures that will be undertaken during the operation phase to

mitigate the impacts that may be caused during the operation of the project are as

follows: Periodic monitoring of the environmental attributes to check the adequacy and

effectiveness of the pollution control measures employed

The major sources of emission are D.G sets, boiler stack, production block

(reactor) scrubber stacks which will be of adequate height to disperse the

pollutants. Adequate green belt has been developed to mitigate the pollution

arising due to movement of vehicles. Regular monitoring of DG-Stack and

Ambient air quality will be carried out.

Appropriate treatment of liquid effluents generated at the site-Domestic

wastewater will be treated in biological treatment system. The high TDS

wastewater generated from the process will be subjected to MEE Plant for

treatment.

Noise pollution will be curbed by using proper acoustic enclosures for D.G sets

and reactors; thereby the ambient noise levels will be maintained below the

CPCB limits of 75 dB for industrial areas. Personal protective equipments will be

provided to those workers who work in areas of high noise.

Rainwater harvesting system has been designed to utilize the underground

water system sustainably.

Proper maintenance of greenbelt will be ensured.

Adequate safety measures conforming to the occupational health and safety

policy will be taken to prevent accidents/hazards to the workers.



The following routine monitoring programme as detailed in table-6.2 shall be

implemented at site. Beside to this monitoring, the compliance to all environmental

clearance conditions and regular permits from KSPCB/MoEF shall be monitored and

reported periodically.

TABLE 6.2: ENVIRONMENTAL MONITORING DURING PROJECT

OPERATIONAL STAGE

Sr. No.

Potential Impact

Action to be Followed Parameters for

Monitoring Frequency of Monitoring

1 Air Emissions

Stack emissions from process stacks to be

optimized and monitored.

Gaseous emissions (NOX, SO2, SPM,

RSPM)

Once in a month as grab sampling

Stack emissions from DG Set to be monitored

Gaseous emissions Periodic during operation phase

Ambient air quality within the premises of the

proposed unit and nearby habitations to be

monitored Exhaust from vehicles to be minimized

by use of fuel efficient vehicles and well

maintained vehicles having PCU Certificate

NOX, SO2 and PM10

Vehicles logs to be maintained

As per CPCB/ KSPCB

requirement.

Measuring onsite data of meteorology

Wind speed, Wind direction,

Temperature, Relative Humidity

and Rain fall

Periodic monitoring

during operation phase

2 Noise

Noise generated from operation of DG set and

cooling towers to be optimized and monitored

Spot noise level recording

Periodic during operation phase

3 Waste

Management

Implement waste management plan that

identifies and characterizes every waste arising

associated with proposed operational activities &

which identifies the procedures for collection,

handling& disposal of each

Record of solid waste generation,

treatment and disposal

Periodic Waste Management

during operation phase



waste arising.

4 Soil Quality Maintenance of good soil

quality

Physico-chemical parameters and

metals

Periodical monitoring at ash

pond site

5 Health Employee and migrant

labour health check ups All relevant parameters

Regular check ups

6.4 ENVIRONMENTAL MANAGEMENT SYSTEM

For the effective and consistent functioning of the proposed complex, an

Environmental Management System (EMS) should be established at the site. The EMS

should include the following:

Environmental Management Cell

Environmental Monitoring program

Personnel Training

Regular Environmental Audits and Corrective Action plan

Documentation - Standard operating procedures Environmental Management

Plans and other records

The major roles and responsibilities of Environmental Management system will

be as follows:

To implement the environmental management plan

To ensure regular operation and maintenance of pollution control devices

To assure regulatory compliance with all relevant rules and regulations

To minimize environmental impacts of operations by strict adherence to the EMP

To initiate environmental monitoring as per approved schedule

Review and interpretation of monitored results and corrective measures in case

monitored results are above the specified limit

Maintain documentation of good environmental practices and applicable

environmental laws

Maintain environmental related records

Co-ordination with regulatory agencies, external consultants and monitoring

laboratories



CHAPTER 7

7. ADDITIONAL STUDIES

7.1 RISK ASSESSMENT

Hazard analysis involves the identification and quantification of the various

hazards (unsafe conditions) that exist in the plant. On the other hand, risk analysis deals

with the identification and quantification of risks, the plant equipment and personnel

are exposed to, due to accidents resulting from the hazards present in the plant.

Risk analysis involves the identification and assessment of risks to the

neighbouring populations is exposed to as a result of hazards present. This requires an

assessment of failure probability, credible accident scenario, vulnerability of population

etc. Much of this information is difficult to get or generate. Consequently, the risk

analysis is often confined to maximum credible accident studies.

In the sections below, the identification of various hazards, probable risks

involved in the chemical industry, maximum credible accident analysis, consequence

analysis are addressed which give a broad identification of risks involved in the

process. Based on the risk estimation for fuel and chemical storage, Disaster

Management Plan (DMP) has been prepared.

There is always possibility of occurrence of incidents in an industry which

requires properrisk assessment and proper safety preparedness. Activities requiring

assessment of risk due to occurrence of most probable instances of hazard and accident

are both onsite and off-site.

On-site:

Exposure to fugitive dust, Chemicals, noise, and other emissions

Housekeeping practices requiring contact with solid and liquid wastes

Emission/spillage etc. from storage & handling



Off-site:

Exposure to pollutants released from offsite/ storage/related activities

Contamination due to accidental releases or normal release in combination with

natural hazard

Deposition of toxic pollutants in vegetation/other sinks and possible sudden

releases due to accidental occurrences

Risk assessment often requires the synthesis of risk profiles, which represent the

probability distribution of total annual loss due to a certain set of events or activities.

These assessments usually involve estimation of losses for several sub-classifications of

the overall process and synthesis of the results into an aggregate risk profile.

An important element of mitigation is emergency planning, i.e. identifying

accident possibility, assessing the consequences of such accidents and deciding on the

emergency procedures, both on site and off site that would need to be implemented in

the event of an emergency.

Impact of the project

Major risks involved in the chemical industry are:

Fire in Electric Panels, oil room and chemical storage.

Waste treatment processes.

Cleaning of barrels, which have held chemical substances.

Cable rooms, transformer, unit, auxiliary transformers, oil tanks, etc. within the

plant are the likely areas for which disaster management plan is to be made to deal with

any eventuality of fire. Stores, workshop, canteen and administrative building will be

included.

7.2 DISASTER MANAGEMENT PLAN

A major emergency in an activity/project is one which has the potential to cause

serious injury or loss of life. It may cause extensive damage to property and serious



disruption both inside and outside the activity/project. It would normally require the

assistance of emergency services to handle it effectively.

An important element of mitigation is emergency planning, i.e. identifying

accident possibility, assessing the consequences of such accidents and deciding on the

emergency procedures, both on site and off site that would need to be implemented in

the event of an emergency.

Emergency planning is just one aspect of safety and cannot be considered in

isolation from the proposed project and hence before starting to prepare the plan, works

management will ensure that the necessary standards, appropriate to safety legislation,

are in place.

OBEJECTIVE

The overall objectives of the emergency plan will be:

To localize the emergency and, eliminate it; and

To minimize the effects of the accident on people and property.

Elimination will require prompt action by operations and works emergency staff

using, for example, fire–fighting equipment, water sprays etc.Minimizing the effects

may include rescue, first aid, evacuation, rehabilitation and giving information

promptly to people living nearby.

Safety Measures for Storage & Handling of Chemicals:

The chemicals will be directly fed to the bottling unit mechanically and no

manual handling will be involved which will reduce the risk of spillage in the storage

area. Following precautionary measures would be taken for safety:

HANDLING AND STORAGE: Keeping away from heat, sparks and open flame, care will

be taken for avoidance of spillage, skin and eye contact, well ventilation, Use of

approved respirator if air contamination is above acceptable level will be promoted. For

Storage and handling following precautions will be taken:

Keeping away from oxidizers, heat and flames.



Avoidance of plastics, rubber and coatings in the storage area.

Cool, dry, & ventilated storage and closed containers.

Grounding of the container and transferring of equipment to eliminate static

electric sparks.

In case of any emergency following measures would be taken:

First Aid Measures: For Skin contact, Eye contact, & Inhalation.

Fire Fighting Measures:

Use of extinguishing media surrounding the fire as water, dry chemicals, Sand, etc

Foam system for fire freighting will be provided to control fire from the chemical

storage tank. The foam thus produced will suppress fire by separating the chemical

from the air (oxygen), and hence avoiding the fire & explosion to occur in the tank.

Foam would blanket the fuel surface smothering the fire. The fuel will also be

cooled by the water content of the foam.

The foam blanket suppresses the release of flammable vapors that can mix with the

air.

Special Fire Fighting Procedures; Keeping the fire upwind. Shutting down of all

possible sources of ignition, keeping of run-off water out of sewers and water

sources. Avoidance of water in straight hose stream which will scatter and spread

fire. Use of spray or fog nozzles will be promoted, cool containers will be exposed

to flames with water from the side until well after the fire is out.

RISK MITIGATION MEASURES:

The material handled at the proposed installation is inflammable and reactive

substance and based on the consequence analysis; the following measures are suggested

as risk mitigation measures

Smoke and fire detectors should be suitably located and linked to fire fighting

system to reduce the response time and ensure safe dispersal of vapours before ignition

can occur.



Training in fire fighting, escape action, operation of emergency switches etc. is

vital. Emergency procedures should be well rehearsed to achieve state of readiness.

7.3 EMERGENCY PLANNING

General: Disaster Management Plan for an industrial unit is necessarily a

combination of various actions which are to be taken in a very short time but in a

present sequence to deal effectively and efficiently with any disaster, emergency or

major accident with an aim to keep the loss of men, material, plant/machinery etc. to

the minimum.

The main functions of the Disaster Management Cell are to prepare a detailed

Disaster Management Plan, which includes:

Identification of various types of expected disaster depending upon the type of the

industrial unit.

Identification of various groups, agencies, departments etc. necessary for dealing

with a specific disaster effectively.

Preparation– by intensive training of relevant teams/groups within the

organization to deal with a specific disaster and keep them in readiness.

Establishment of an early detection system for the disaster.

Development of a reliable instant information/communication system.

Organization and mobilization of all the concerned

departments/organizations/groups and agencies instantly when needed.

A major disaster that can be expected due to fire in this proposed distillery.

Objective of the plan: The plan is developed to make best possible for the proposed

plant were:

Rescue the victims and treat them suitable.

Safe guard others (evacuating them to safer places).

Contain the incident and control it with minimum damage.

Identify the persons affected.



Preserve relevant records and equipment needed as evidence incase on inquiry.

Rehabilitate the affected areas.

IDENTIFICATION OF MAJOR HAZARDOUS: From the preliminary risk assessment study

presented in above chapter of this report, some of the possible hazards are Methanol.

OBJECTIVES OF THE PLAN: The plan will set into action immediately after a fire occurs

inside the plant. However fire hazard will be restricted to fuel tank storage area only

and hence to major disaster is envisage.

GENERAL RECOMMENDATIONS:

All non-routine work etc. should be carried out under a permit system.

Adequate number of caution boards high lighting the hazards of chemicals to be

handled, eye bath and emergency showers should be provided at critical location.

Adequate number of absorbents should be placed at accessible locations in the tank

farm area as well as in the pump house that would enable to contain spills

immediately.

Adequate color coding and labeling of the pipelines should be provided for easy

identification of products proposed to be handled through them.

The damage distance due to any failure could be reduced, by reducing the time

required to stop the leak, which in turn would reduce the quantity of spillage. The

response time could be reduced by installing/maintaining instruments, effective

communication system, etc.

It is recommended that rubber mats be provided in front of electrical panel of the

entire plant with a view to prevent employees from receiving electric shocks.

It is suggested that all type of fire extinguishers be placed at appropriate places for

easy access in case of emergency.



The availability, organization, and utilization of resources for emergency:

The organizational set-up necessary for chain of commands during emergency

situation, which may arise in the premises, is given in Figure 7.1. The system is

described in following subsections

FIGURE-7.1: ONSITE DISASTER MANAGEMENT PLAN

FUNCTIONS AND RESPONSIBILITIES:

Factory Manager:He shall be the main guiding person for direct emergency operations.

Safety officer:The main responsibility of safety officer is safety management.The Safety

management includes the implementation of prevention methods to avoidincident or

accident and handling of emergency in case of accident.

Skilled person:

He shall be responsible for the operation and maintenance.

He shall be arranging the safety equipment accordingly.

He shall be followed the instruction of supervisor and officer.

Factory Manager

Safety officer

Skilled person & unskilled person

Factory Manager

Safety officer

Skilled personals Unskilled personals



Emergency Response Room (Safety officer room):

The place identified as Emergency Response Center will be considered as the

SecurityGate Office. The location of the Emergency Response Center may change in

future as perconvenience. The facilities available at the Emergency Response Center

shall include:

Internal Telephone

External Telephone

Manual Fire/Emergency Siren

Siren Actuation Switch

Important Address and Telephone Numbers

Emergency Vehicles

Confined Space Entry Procedure

List of Antidote/actions to be taken in case of hazardous chemical/materials.

Material Safety Data Sheets of chemicals

A copy of On-Site Disaster Management Plan

All communications after General Shift working hours and on

Sundays/Holidays are tobe routed through the Security Gate Office.

General Rules

Follow sense of discipline and do not pain.

Do not rush and endanger your personnel safety

Use personnel protective equipment according to the situation

Do not block any passages, which may hinder the movement of emergency vehicles.

In case you have to shut down your plant operation, do it in an orderly manner as

perstandard operating procedures.

In situation when you have to leave your work and evacuate to identify places out

ofoperating areas, do it in an orderly manner.

Follow instructions of the Safety officer.

Understand the Disaster Management Plan well and take interest in practice mock drill.



Other Key Personnel:

All key personnel will wear red helmet for their identification and easy recognition.

The responsibilities and duties of key personnel include.

1. Safety:

The safety officer/ supervisor will carry out the following:

To provide necessary equipment like firefighting equipment (FFE) and

personalprotective equipment (PEE).

To accompany factory inspector during investigation of the emergency.

To train workers/ supervisors in safety and safe operating procedures.

To assist the site main controller, incident controller in preparing a briefreport of

theincident.

2. Assembly Points:The assembly points for gathering non-essentials workers / persons

will be fixed andwill be clearly marked as per the wind direction.

3. Fire Control Arrangement:

Fire fighting trained personnel will be made available in all the shifts.

Theresponsibilities and duties include:

To fight the fire with available internal firefighting equipment and to stop

leakage ofliquid etc.

To provide personal protective equipment to the team.

To cordon the area and inform incident controller or site main controller about

thedevelopment of emergency.

To train personnel (essential workers) to use personal protective equipment

andfirefighting equipment.

4. Medical Arrangement:The responsibilities and duties include:

To provide first aid to the affected persons, and, if necessary, send them to

hospitals forfurther treatment.

To keep a list of blood groupings ready and update.

1. Transport Evacuation Arrangement:For transportation of people, company‟s

vehicles, cars, rickshaws etc. will be utilized.



7.4 FIRE PROTECTION

Elaborate firefighting system will be available for fighting fires in any corner ofthe

plant. A comprehensive fire detection and protection system is envisaged for

thecomplete power station.

Fire water storage tanks of adequate capacity

Automatic circuit breakers activated by over current.

Smoking should be strictly prohibited.

Fire water pump house containing combination of diesel and electrically driven

pumps

Hydrant system complete with suitable size piping, valves, instrumentation,

hoses,nozzles, hose boxes/stations, monitors etc.

Portable and mobile extinguishers, such as pressurized water type, carbon

dioxide type,foam type, dry chemical powder type located at strategic locations

throughout the plant Complete instrumentation and control system for the entire

fire detection and protectionsystem for safe operation of the complete system.

7.5 ENVIRONMENTAL MANAGEMENT CELL

Apart from having an EMP, it is also necessary to have a permanent

organizational setup charged with the task of proposed plant will create a department

consisting ofofficers from various disciplines to co–ordinate the activities concerned

with themanagement and implementation of the environmental control measures.

Basically this department will undertake to monitor the environmental

pollutionlevels by measuring stack emissions, ambient air quality, water and effluent

quality,noise level etc. either departmentally or by appointing external agencies

wherevernecessary.

In case the monitored results of environmental pollution are found exceeding

theallowable values, the environmental management cell will suggest remedial

actionand get these suggestions implemented through the concerned plant authorities.



Theactual operation and maintenance of pollution control equipment of each unit will

beunder the respective plant managers.

The Environmental Management Cell (EMC) will handle of all the related activitiessuch

as collection of statistics of health of workers and population of the region,afforestation

and green belt development.

7.6ON-SITE EMERGENCY PLAN

7.6.1 INTRODUCTION:

The views of the possible hazards that can arise out of the daily operations in

thechemical industry, various measures are adopted to prevent the occurrence of

amajor accident. This comprises of:

Built in safety measures, alarms, trips and interlocks etc.

Standard safe operating and maintenance procedures permit system etc.

Training of all the involved staff in normal and emergency operatingprocedures.

Training of all employees in safety, fire fighting and first aid.

However, in spite of these precautions, it is required to foresee situation of

majoraccident and plan for taking timely action to minimize the effects of such incident

onthe safety and health of persons working in the plant as well as those living

aroundthe premises.

7.6.2 PREPARATION OF PLAN:

Alarm System: A siren shall be provided under the control of Security office in the

plant premises togive warning. In case of emergencies this will be used on the

instructions to shift incharge that is positioned round the clock. The warning signal for

emergency shall beas follows:

Emergency Siren: Waxing and waning sound for 3 minutes.

All clear signal: Continuous siren for one minute.

Communication: Walkies & Talkies are located at strategic locations; internal telephone

systemEPBX with external P&T telephones would be provided.



7.6.3 FIRE PROTECTION SYSTEM:

Fire Fighting System: The fire protection system for the unit is to provide for

early detection, alarm,containment and suppression of fires. The fire detection and

protection system hasbeen planned to meet the above objective an all–statutory and

insurance requirementof Tariff Advisory Committee (TAC) of India. The complete fire

protection system willcomprise of the following.

(a) Fire brigade

Automatic / manual fire detection & alarm system

(b) Fire Hydrant

Fire hydrant will be provided at all around in the plant as per TAC Norms.

(c) Portable fire extinguishers

Various areas of the plant will have one or more of the above system depending

uponthe particular nature of risk involved in that area.

(d) Portable Chemical Fire Extinguishers

These are intended as a first line of defense, and hence will be stationed at

strategiclocations in different buildings and also for outdoor facilities. Portable

fireextinguishers will be foam type; carbon dioxide type and multipurpose dry

chemical(MPDC) type.

(e) Fire Detection and Alarm System

Fire detection and alarm system an effective means of detection, visual indication offire

location and audible alarm of any fire at its incipient stage. This system willcomprise

fire alarm panels, automatic fire detectors, manual call points and fire siren(hooter).

The main fire alarm panel will provide both visual and audible alarm of fire in

anyprotected areas of the plant.Manual break glass type fire alarms will be provided at

strategic locations where highhazards exits. Automatic fire detectors will be provided

for chemical handling areasand in plant areas such as control rooms, switchgear rooms,

cable galleries etc.



7.6.4 FIRST AID:A first aid centre with adequate facilities shall be provided. It shall be

maintainedround the clock by a compounder cum dresser and a doctor. An Ambulance

shall alsobe provided at site to carry affected people to hospital.

7.6.5 SECURITY:

The security requirements of the company premises shall be taken care of by

CSOassisted by a Fire In charge. The team, apart from the normal security functions

willmanage the role required during a disaster management operation as a part of

thecrisis control team.

7.6.6 SAFETY:

The safety wing led by a Safety Manager will meet the requirement of

emergenciesround the clock. The required safety appliances shall be distributedat

differentlocations of the plant to meet any eventualities. Poster/placards reflecting

safetyawareness will be placed at different locations in the plant area.

7.6.7 EMERGENCY CONTROL CENTER

Provision is made to establish an Emergency Control Centre (ECC) from

whichemergency operations are directed and coordinated. This centre is activated as

soonas on–site emergency is declared.The ECC consists of one room, located in an area

that offers minimal risk beingdirectly exposed to possible accidents.

During an emergency, the Emergency Management Staff, including the site

controllerwill gather in the ECC. Therefore, the ECC is equipped with adequate

communicationsystems in the form of telephones and other equipments to allow

unhamperedorganisations and other nearby facility personnel.

The ECC provides shelter to its occupants against the most common accidents;

inaddition, the ECC‟s communication systems are protected from possible

shutdown.The ECC has its own emergency lighting arrangement and electric

communicationsystems operation.

The ECC is always ready for operation and provided with the equipment and

suppliesnecessary during the emergency such as:



Updated copies of the On–site Disaster Management Plan.

Emergency telephone numbers.

The names, phone number, and address of external agencies,

responseorganizations and neighbouring facilities.

The adequate number of telephone (more than two).

Emergency lights, Clocks, Personal protective equipment.

List of fire extinguishers with their type no. and location, capacity, etc.

Safety helmets – List of quantity & location.

Status boards/message board.

Material safety data sheets for chemicals handled at the facility.

Several maps of the facility including drainage system for surrounding

areashowing:

Areas where hazardous materials are stored.

Plot plans of storage tanks, routes of pipelines, all water permanent lines etc.

The locations where personal protective equipment are stored.

The position of pumping stations and other water sources.

Roads and plant entrances.

Assembly areas & layout of Hydrant lines.

7.7 COMMUNICATION EQUIPMENTS AND ALARM SYSTEMS

This kind of equipment is absolutely vital for notifying accident; make the

emergencyknown both inside and outside of the facility, and coordinating, the response

actionsamong the various groups involved in response operations.

In particular, this equipment is used to communicate within the facility;

communicatebetween the facility and outside organizations; and inform the public.

Different communications systems can vary in effectiveness, depending on the

task.The most common types installed in the plant are given below.



7.7.1 SIRENS:

These are audible alarm systems commonly used in facilities. In case of any

emergency siren will be operated short intermittently for 1.5 minutes.An alarm does

more than just emergency warning. It also instructs people to carry outspecific

assignments, such as reach to assembly point for further instructions andactions, or

carry out protective measures; this can be achieved only if the people arefamiliar with

the alarm systems and are trained to respond to it.

7.7.2 PERSONAL PROTECTIVE EQUIPMENTS

This equipment is used mainly for three reasons; to protect personnel from a

hazard while performing rescue/accident control operations, to do maintenance and

repair work under hazardous conditions, and for escape purposes. The list of

PersonalProtective Equipment provided at the facility and their locations are available

in ECC.Effective command and control accomplish these functions necessitates

personaltrained in this On–site Disaster Management Plan with adequate facilities

andequipments and equipment to carry out their duties and functions.

Theseorganizations and the facilities required to support their response are summarized

inthe following subsections.

7.7.3 PROCEDURE FOR TESTING & UPDATING THE PLAN

Simulated emergency preparedness exercises and mock fire fighting

exercisesincluding mutual aid scheme resources and in conservation with district

emergencyauthority to be carried out time to time.

7.7.4 DISCLOSURE OF INFORMATION TO WORKER & PUBLIC AWARENESS

SYSTEM IN EXISTENCE& ANTICIPATED

Safety awareness among workers by conserving various trainingprogrammes

and Seminars, competition, slogans etc.

Practical exercise.

Distribution and practices of safety Instructions.

Safety Quiz contests.

Display of Safety Posters & Safety Slogans.



Developing Safety Instructions for every Job and ensuring

theseinstructions/booklets or manuals by the workers.

7.8 OFF-SITE EMERGENCY PLAN

The Offsite emergency plan is made based on events, which could affect people

andEnvironment out side the premises. The off site plan is largely a matter of ensuring

theco-ordination of proposed services and their readiness as far as possible, for

thespecific hazards and problems, which may arise in as incident. Briefly two

mainpurposes of the plan are as under:

To provide the local district authorities, police, fire brigade, doctors etc. the

basicinformation of risk and environmental impact assessment and to appraise

them ofthe consequences and the protection / prevention measures and control

plans andto seek their help to communicate with the public in case of major

emergency.

To assist the district authorities for preparing the off site emergency plan for

thedistrict or particular area. We have made our key personnel and other fully

awareabout this aspect. The function of the off site plans are as under:

Structure of the off site emergency plan includes the following:-

Organizational set up-Incident controller /Site main controller, Key personnel, etc

Communication facilities - List of important telephones

Specialized emergency equipment - Fire fighting equipment

Specialized Knowledge - Trained people

Voluntary Organization - Details of organization

Chemical information - MSDS of hazardous substances

Meteorological information - Weather condition, Wind velocity etc

Humanitarian arrangement - Transport, First aid, Ambulance

A DETAILED STUDY REPORT ON HAZARD IDENTIFICATION & RISK

ASSESSMENTREPORT IS ATTACHED AS ANNEXURE –11



CHAPTER 8

8. PROJECT BENEFITS 8.1 GENERAL

Project benefit focused on those points which become beneficial to the

surrounding area or community in terms of infrastructural development, social

development, boosting employment and other tangible benefits due to upcoming or

proposed activities in form side benefits.

The proposed modification project will bring overall improvements in the

locality, neighborhood and to the state by bringing industry, roads, water supply,

drainage facility, power supply, employment for skilled, semi skilled and unskilled

labour, thereby uplifting the living standards of local communities and economic

growth as well as it also stimulates the growth in small and medium scale industries

like residential developments, hotels, shopping complexes, retail shops, health centre‟s,

educational institutes, recreational centers etc., may be further developed as a

consequence.

8.2IMPROVEMENT IN PHYSICAL INFRASTRUCTURE

The proposed modification project is expected to yield a positive impact on the

socio-economic environment. It helps in sustainable development of this area including

further development of physical infrastructural facilities.

The following physical infrastructure facilities will improve due to proposed

project:

Road transport facilities

Water supply and sanitation



8.3 IMPROVEMENT IN SOCIAL INFRASTRUCTURE

Due to proposed project activity social infrastructure will improve by means of

civilization, standard of living, education, vocational training, and basic amenities.

Additional benefits will be arrived from the proposed project like: residential

apartment, healthcare, educational facilities to the community, community hall,

industrial developments, and public services in the surrounding area.

Better education facilities, proper health care, road infrastructure and drinking

water facilities are basic social amenities for better working standard of human being.

Proposed project will further increase the above amenities directly/indirectly either by

providing or by improving the existing facilities in the area, which will help in uplifting

the living standards of local communities. Due to this project development adaptation

of new technologies and other infrastructural facilities will improve which will

indirectly boost the civilization of the surrounding people.

The project is going to have positive impact on consumption behavior by way of

raising average consumption and income through multiplier effect. The following

change in socio-economic status is expected to take place with this project.

Education facilities

Banking facilities

Post offices and communication facilities

Medical facilities

Recreational facilities

Business establishment

8.4EMPLOYMENT POTENTIAL

As the proposed project bring employment generation for skilled, semi skilled

and unskilled, it is obvious to assume that, all the economic activities in the project area

would induce considerable improvement in the socio-economic levels of people. The

impact of human settlement is expected to be positive, as apart from some people being

directly employed; many others will get indirect employed.



The employment of local people in primary and secondary sectors of project

shall upgrade the prosperity of the region. This in turn will improve the socioeconomic

conditions of the area.

DURING CONSTRUCTION PHASE:

This project will provide temporary employment to many unskilled and semi

skilled laborers in nearby place. This project will also help in generation of indirect

employment to those people who render their services for the personal directly working

in the project. The project will fulfill the job requirements for all kinds of people in

various sectors, which increase the employment opportunity and improve the living

standards.

DURING OPERATION PHASE:

The impact of the project on the economic aspects can be clearly observed. The

proposed project activities will provide employment to persons of different skills and

trades.

8.5OTHER TANGIBLE BENEFITS

The following benefits are expected due to the implementation of the said

project:

The easy availability of infrastructure, man power, raw materials will reduce the

production cost as well as demand supply gap. The same will bring revenue to

the state exchequer by way of Duties and Taxes.

The development of green belt in and around the plant premises will improve on

the aesthetics of the area. Moreover, it will help in reducing the noise levels

within the plant boundary.

The setting up of the proposed plant will help in providing employment to local

people.

There will be an increase in indirect employment & earnings of the small time

shop owners like tea vendors, transporters, etc.



The implementation of Rain Water Harvesting Scheme will help in increasing the

ground water level of the area.

8.6CORPORATE SOCIAL RESPONSIBILITY

Corporate social responsibility is the commitment of businesses to contribute to

sustainable economic development by working with the employees, their families, local

community & society at large to improve their lives in ways that are good for business

as well as overall development. It is a voluntary activity of a company that supports

social interests & environmental issues. It is a principle through which the business

houses contribute to the welfare of the society & not only maximize their profits. CSR,

in fact, is about business giving back to the society.

The project proponent has planned to contribute in socio-economic development

of the area and will organize Education Programmes, Health awareness programmes

etc. and will continue to do so.



CHAPTER 9

9. ENVIRONMENTAL COST BENEFIT ANALYSIS

Chorus Labs Limited is existing industry and is engaged in manufacture

ofIntermediates and API. The proposed project is modification of Bulk Drugs

andintermediate manufacturing unit located at at Plot No. 23-B, KIADB Kolhar

IndustrialArea, Nizampur Hobli, Bidar Taluk & District, Karnataka,. All the basic

requirements forthe production are in placed including infrastructure availability. The

increase inproduction of chemicals will be available to the needy industries. It will

definitely boostthe economic growth of the country; develop region and quality of life

of the people in asustainable manner without creating any environmental damage.

The project site is well connected to railways, roadways and airways. The

proposedmodification is planned in the notified Industrial area, Bidar. Therefore, it will

not involveloss of vegetation and biodiversity. The vegetation is similar in the whole

area with nosensitive ecosystem or rare and endangered flora or fauna, hence no

environmental losswill be there in terms of net productive value. However plantation in

and around thecompany premises will increase the aesthetic view apart from restricting

and pollutionlevel.

The total project cost is estimated to be Rs. 6.5 Cr. and expenditure on

implementation ofthe Environmental Management Plan (EMP) is presented in Chapter

10 of this report.Besides tangible benefits, the proposed modification has got number of

intangible benefitslike minimum emission of the generated gases, no adverse impact on

environment as faras air, noise and water environmental components are concerned.

With theestablishment of proposed modification, there will be socioeconomic

development in thearea and thereby the improvement in the quality of life of the

people. More employmentopportunities will be there for the local people, moreover the

proposed modification willhelp for enhancement of the economy of the country. The



proposed modification willprovide temporary and permanent job opportunities to the

local people in theneighboring area. The industry management has complete focus on

quality, quantity, promptness, safe delivery and best services through 3 M‟S – Man,

Machine and Materialmanagement.

The establishment of proposed modification when in operation will definitely

providesignificant supply of products to the industries, not only in the region, state but

also inIndia and help to increase the economic status of the country.

The developmental activities due to modification will increase economy of the

country andalso help to increase the economy of the state through products

transportation, taxes,supporting economy for nation‟s growth.

ENVIRONMENTAL BENEFITS:

Proposed modification project shall benefit environment in following ways:

To create an environment that could support the culture of good standards.

To emphasize the policy of afforestation/landscape and rainwater harvesting

tocreate a better micro-climate in the area

A well designed drainage system to control flooding/ overflow of water during

therainy season

The continuous inflow of people will require local transport system like autos,

taxis,etc. which would help local transport business.

Considerable number of people will be benefited by provision of job opportunity

tolocal people. Thus, direct and indirect employment generation by this project.



CHAPTER 10

10. ENVIRONMENTAL MANAGEMENT PLAN

10.1 INTRODUCTION

The Environmental Management Plan (EMP) is required to ensure sustainable

development in the study area of the proposed modification plant, hence it needs to be

an all encompassing plan for which the plant authorities, Government, regulating

agencies like Pollution Control Board etc., working in the region and more importantly

the population of the study area need to extend their cooperation and contribution.

The details/data provided by project proponent about the proposed

modification project (technical data, approach to environmental protection etc.) and the

pre-project (baseline) environmental status monitored through field surveys by M/s

ENVIRO RESOURCES Mumbai and Lab teams during post - monsoon season (October

2018 to December 2018) have formed the basis to predict the impacts on all individual

componentsof environment. In view of the above, project proponent will maintain the

specifications/details/ data as provided for preparation of this report or may try to

improve further towardsenvironmental betterment protection during various phases of

implementation of proposedmodification project. The environmental management plan

relevant to construction andoperation phases is delineated in the following sections:

The management action plan aims at controlling pollution at the source level to

the maximum possible extent with the available and affordable technology followed by

treatment measures before they are discharged/recycled/reused. Specifically, the EMP

lays stress on key environmental aspects with mitigation measures and issues of the

modification project during construction and operation phase by:

Identifying potential environmental impacts.

Recommending mitigation measures for the negative impacts.

Identifying opportunities for enhancement measures.



Upgrading the organizational framework for operating environmental

management system and other functions of the modification project by assigning

roles and responsibilities for existing environmental monitoring and

management.

Formulating Environmental Action Plans (EAPs) which specify mitigation,

periodic and annual monitoring activities during modification project

implementation and operation.

The potential environmental impacts from the proposed modification project are

identified and the magnitude of these impacts also predicted. The potential

environmental impacts to be regulated from the proposed modification plant are

summarized below:

Air pollution due to the emission of particulate matter, sulphur dioxide & oxides

of nitrogen mainly from boilers, DG sets and process emissions from

manufacturing products.

Fugitive emissions for material / solvent handling.

Noise pollution due to various noise generating equipment.

Wastewater generation from processing units as well as from domestic activities.

Hazardous/Solid waste generation from manufacturing/utilities/warehouse etc.

In order to minimize these adverse impacts and to ensure that the environment

inand around the project site as well as the neighboring population is well protected;

aneffective EMP is developed for construction phase as well as operation phase of the

project.

10.2 CONSTRUCTION PHASE

10.2.1 AIR ENVIRONMENT

The construction activities and vehicular traffic contribute increase in PM, SO2

and NOx concentrations. The mitigation measures recommended to minimize the

impacts are:



Water will be sprinkled on loose topsoil to re-suspension of dust in to ambient

air due to movement of vehicles etc.

Proper maintenance of vehicles and construction equipment.

Since electrical power is available in the project site, attempts will be made to

utilize the electrically powered machinery to the extent possible to minimize the

gaseous emissions during construction and

As far as possible, construction activities will be restricted to daytime only to

minimize disturbance during night time.

10.2.2 WATER ENVIRONMENT

The wastewater from construction equipment will contribute to increase in

pollutant concentration like oil and grease. However, the following mitigation measures

are recommended to minimize the impacts:

Provision of sanitation facilities in the modification project for the workforce

with a provision of sending sewage to effluent treatment plant (ETP) and

Waste oil collected in the oil trap will be sold to authorized recyclers for off-site

recycling.

Utilizing the wastewater back into the utilities/construction purpose.

10.2.3 SOLID WASTE

Solid waste generation during construction work will be construction debris like

rubble, brick bats, debris, steel scrap, wooden scrap, sand gravels etc. However these

materials are inert in nature and will not leaching of any substances or constituents.

These materials will be properly stored and will be used with in premises for

filling of low lying area. Wooden scrap, steel scrap will be given to scrap dealers. On

completion of civil work, all debris etc. will be completely removed from site to avoid

any incompatibility with future use.



10.2.4 NOISE ENVIRONMENT

Operation of construction equipment and vehicular traffic contribute to the

increased noise level. The noise effect on the nearest inhabitants during the construction

activity will be negligible, as the noise levels will be dissipated within the project site

area itself. Nevertheless, the following mitigation measures will be adopted:

Good maintenance of vehicles and construction equipment.

Restriction of construction activities to day time only.

Trees planted around the plant boundary to attenuate the noise and

All construction workers working in high noise area will be provided

appropriate Personal Protective Equipments like ear muffs and to wear them

during working hours.

10.2.5 LAND ENVIRONMENT

Following steps are proposed to task to take care of impact of construction

activity on project land area.

On completion of civil work, all debris etc. will be completely removed from site

to avoid any incapability with future use.

Other materials like paints, diesel etc. will be properly stored and handled by

prevent any spillage on land.

All the wastes are stored at a designated site within the premises to prevent

scattered discharge on land.

10.2.6 ECOLOGY

The proposed project shall come up in the existing premises. Hence, no tree

cutting exercise will be there and no major impact on ecology is anticipated.

However possibility of rising of green-belt along with construction activity will

be explored so that greening of area can be started at the beginning of project.

10.2.7 SITE SECURITY AND MIGRANT LABOURERS

The modification site is secured with compound wall and manned entry points.

Mainly local labourers will be employed for construction activities. No labour camps



are envisaged for the modification project. The following facilities will be provided to

the construction work force:

First Aid: At work place, first aid facilities will be provided at accessible place.

Potable Water: Adequate quantity of cool potable water fit for drinking will be

provided at suitable places at the construction site.

Rest Shelters: Rest shelter will be provided to workforce.

Facilities for Women: Facilities as per applicable rules will be provided to the women

workforce. Separate toilets for women are provided and marked in a vernacular

language with conspicuous letters for women only. A poster showing the figure of a

man and woman will also be exhibited at the entrance to toilets.

10.3 OPERATION PHASE

During operation stage the major pollution from the proposed modification is

from liquid effluents from process, utilities and domestic facilities. Air pollution from

combustion of fuels (Boilers & DG sets) and production process. The effluent treatment

system will separate most of the solids from liquid effluents by way of evaporation salts

and ETP sludge.

The management action plan aims at controlling pollution at the source level to

the extent possible, with the available facilities and affordable technology, followed by

treatment measures before they are recycled/discharged.

The majority of effluent generated will be from process and it will have

considerable amount of COD & TDS load and suspended solids, which has treated in

ETP. The air pollution is caused due to combustion of fuels and product process

reactions.

10.3.1 WATER POLLUTION CONTROL SYSTEM


from KIADB. Daily water requirement during operation phase is estimated as 31.5

KLD, out of which approximately 1.5 KLD of water required for domestic consumption,

4 KLD is for gardening and remaining 26 KLD for industrial use. Water balance chart is



shown in Chapter-2. In 26 KLD of industrial usage, cooling tower water requirement is

4 KLD, process water 11.5 KLD, Boiler feed 8 KLD, washing 2.5 KLD. From the

industrial usage, the total wastewater generated will be 12.61 KLD. This generated

wastewater will be diverted in to the MEE plant and flow diagram shown below. From

the MEE, condensate water istaken in to the cooling tower makeup and dried solid will

be sent to TSDF. Totalcapacity of the Multiple Effective Evaporator proposed for the

project will be20KLD andMEE drawing is attached as ANNEXURE-10.

The effluents generated in the process, separation techniques and during

purification contain organic residues and inorganic raw materials, solvents and

products. Hence the effluents contain both organic and inorganic salts in various

quantities leading to high COD and TDS levels. Estimated effluents are 14.61 KLD from

process, washings, Scrubbing media; Segregated effluent will be collected by gravity

into a collection tank separately. Flow diagram of the HTDS wastewater treatment

system is shown below

FIG-10.1: FLOW DIAGRAM OF THE HTDS WASTEWATER TREATMENT SYSTEM

Trade effluent

inlet

Neutralization

tank

Holding

Tank

Nu

tsch

e

filt

er

MEE

system Condenser

Condenser Stripped

solvents for

Recovery

Condensate to

cooling tower

make-up

Salts to TSDF

Str

ipp

er

Collection cum

equalization

tank



Organics process effluent, scrubber will be segregated and will sent to ETP-ZLD

facility with primary (equalization and neutralization), secondary (stripper with MEE,

ATFD & biological) and tertiary treatment (PSF, ACF & R.O) will be provided. Design

report of biological treatment system with 15 KLD capacity.

Domestic wastewater is treated in biological treatment system 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 it will be sent to TSDF.

The measures recommended for minimising the impacts and conservation of fresh

water are:

Proposed to recycle treated effluent as makeup water for utilities like cooling

tower to reduce fresh water consumption.

Separate provision for storm water collection system and send the run-off water

during rainy season to rain water harvesting tanks. This stored water will be reused to

reduce the fresh water requirement.

Rainwater harvesting structures

Rain Water harvesting system:

Rainwater harvesting system will be adopted within the project site to manage the

rainwater with in the premises. Separate collection system will be implemented for the

rooftop water to conserve the water. Potential of the rainwater harvesting within the

site is calculated as follows.

Major building block within the project site includes Production block one and

two,Admin block, with the total area of 774sqm.

Rainfall intensity in Bidar – 885mm/year

By considering 60 days of rainfall average rainfall = 885/60days= 14.75 mm/day

By considering maximum two hours of rainfall event

Harvestable rainfall from the rooftop area Q =C I A

Where, C is runoff coefficient. I is intensity of rainfall in mm. A is area in sqm.

Therefore, Total rainfall = 0.9x774 x 14.75= 10.3 m3 say 11 m3.



Project activity involves transportation of chemicals from one place to another place and

unloading and loading at different location may lead to the leakage of the chemicals

which may mix with the rainwater. Following measures has been adopted to avoid the

same.

All the raw material including solid and liquid storage area should be covered

shed and the floor should be lined so that there will not be any percolation of the

same in to the ground.

If any chemical spill occurs that has to be washed and separate collection system

should be provided so that the water can be taken into the treatment unit.

Separate drains shall be provided to carry the rain water and percolation pits

shall be provided at the suitable place.

10.3.2 AIR POLLUTION CONTROL SYSTEM

The manufacturing process consists of reaction, separation and purification. The

reaction is conducted in closed reactors, while the separation is conducted in closed

centrifuge, filtration equipment etc. The purification would be conducted in reactors or

filtration equipment. The transfer of materials will be through closed pipelines. Various

sources of emissions are identified from process operations.

The main source of air pollution will be flue gas emission and process gas

emissionfrom the proposed project. There will be also chances of fugitive emission due

tomanufacturing activities and storage, handing & transportation of raw materials

&products. Various potential of air pollution are described hereunder;

10.3.2.1EMISSIONS FROM UTILITIES

The gaseous emissions will be from fuel burning, which consists of common

pollutants like SO2, NOx and PM10, would be discharged into atmosphere through

Multicyclone separators and bag filters with a suitable stack height for controlling the

particulate emissions within statutory limit of 115mg/Nm3 from the proposed &

existing coalfired boilers of 2 TPH.



Multicyclone separator with 30 m stacks will be installed for coal fired boiler.

Stack will be provided to the proposed DG sets of 1x250 KVA. DG sets will be used

asstandby during power failure.

10.3.2.2PROCESS EMISSIONS

The sources of process emissions are reactors, where gaseous products are

released, or excess gaseous raw material used in production, which mainly contain

inorganic gases. The emissions are generated from the process. H2 emissions vents from

the reactor will be connected to multi stage scrubber with suitable chilled or room

temperature liquid water/caustic/dil. HCl to scrub the emissions effectively and the

scrubbing liquid sent for further treatment. H2 will be diffused with flame arrestor. The

scrubbed solutions will be sold/captive consumption/sent for recycle and ETP for

further treatment. Proposed gaseous emissions will bescrubbed in stages with suitable

liquid based on the characteristics of gases.

10.3.2.3FUGITIVE EMISSIONS

Fugitive emissions are the air pollutants released in the air other than those from

stacks or vents; Any chemical or mixture of chemicals, in any physical form, which

represents an unanticipated or spurious leak from anywhere on an industrial site.

Solvents are used for extraction of products and as reaction medium.

Solventsconstitute major consumable material of synthetic organic chemicals, mainly

used as reaction medium. The used solvents constitute major wastestream of synthetic

organic chemical manufacturing. Hence it is proposed to recycle thesolvents by

distillation for reuse in process, thereby reducing total solvent consumption in theplant

and reducing the waste quantity to be disposed. The distillation column is mainly

provided to remove moisture and impurities from spent single solvents and mixed

solvents.

The recycled single solvents are reused in the process, while the mixed solvents

are sold toend users. Distillation process generates residues which are mainly organic in



naturecontaining significant calorific value and can be sent to cement plants as alternate

fuel forco-processing.

To control fugitive emissions from process/ reaction, all reactors will be

equipped withtwo condensers – primary condenser and secondary condenser. All vents

of condensers will be connected to the scrubber to minimize loss of solvents/process

emissions in to the atmosphere. All the receiver tanks will be provided with

ventcondensers using chilled water circulation.

Storage of all solvents/ chemicals will be in drums/ storage tanks. Vent

condensers willbe provided to all storage tanks. Drums will be kept in covered roof

with elevated platform toreduce the direct contact of sunlight thereby reducing the

internal pressure and reducing thefugitive emissions from storage area while handling

of any solvents in dispensing area. Transferof solvents will be in closed conditions to

further reduction of fugitive emissions as well as toreduce solvent losses during

handling of solvents. Fugitive dust emissions due to trafficmovement will be controlled

by providing paved internal roads, regular cleaning of internalroads, proper

maintenance of vehicles etc.

Fugitive emissions are anticipated from equipment leakage and transfer spills.

Theperiodic maintenance program will ensure integrity of equipment mitigating the

equipmentleakage. The spills however will be managed by adopting the spill

management scheme asmentioned in the respective material safety data sheet (MSDS),

spill control kit will beprovided in storage and production blocks. The fugitive

emissions will be reduced by closedtransfer and handling of all solvents and chemicals.

The ventilation system provided willreduce health impact on the employees by way of

dilution of workroom air and alsodispersion of contaminated air.

Coal for Boiler will be stored in covered shed and fly ash generated from the

boilerthrough pollution control system will be handled through pneumatic pipelines

and stored inclosed / covered areas. Ash will be sent to Brick manufacturers.



Measures to Reduce Fugitive Dust Emissions

All transportation vehicles carry a valid PUC (Pollution under Control) Certificate

All the Roads inside the plant premises are concreted or asphalted.

Regular sweeping of all the roads & floors will be done.

Green belt developed in an area of 40% of the total plant area along theperiphery

and will be maintained.

Ambient air quality is regularly monitored and effective control exercised, so as

tokeep emission within the limits.

Local exhaust unit provided at source of emission.

10.3.2.4DIFFUSE EMISSIONS

Emissions are also released from various operations viz., centrifuge, distillation,

extraction, etc. These emissions mainly contain volatile contents of the materialsent for

processing. The emissions are normally passed through vents equipped

withcondensers/ scrubber before releasing into atmosphere to mitigate odour. The

emissionsfrom distillation are passed through condensers, which mitigate odour /

VOCs emissionsrelease. The transfer pumps will be provided with mechanical seals.

10.3.2.5ODOUR MANAGEMENT

Odour can be defined as the “perception of smell” or in scientific terms as “a

sensation resulting from the reception of stimulus by the sensory system”. Whether

pleasant or unpleasant, odour is induced by inhaling air-borne volatile organics or

inorganics. Physical & chemical characteristic of specific odour are largely affected by

the types of odour sources.

Sources of Odour:

• Wastewater Treatment Plant

• ETP Sludge

• Industrial Processes

• Volatile (organic & inorganic)chemical



Control of odour :

• Reduction of odour at generation source: Most effective way of controlling odour.

This is done by storing volatile material in closed containers to prevent volatile

emission and carrying out chemical reactions in closed chambers.

• Removal of odour from collection air stream: Effective air cleaning technology like

Scrubbers

• Green Belt development: can help to mitigate the odour

Odour Control Measures

• Exhaust gases are released through stack of appropriate height

• Scrubber installed to adsorb odour emitting gases

• Proper ventilation system is provided to remediate the odour problem

• Incineration of hazardous odour emitting waste is done to eliminate odour

• Activated carbon filter installed to adsorb odour emitting particles from treated water.

• Full-fledged green belt development

Odour is caused mainly by diffuse and fugitive emissions of low boiling

organicchemicals/ compounds releasing VOCs. The above mentioned measures for

mitigation andcontrol of diffuse and fugitive emissions will reduce release of VOC‟s

into atmosphere andthe resultant odour.

10.3.3 HAZARDOUS WASTE MANAGEMENT SYSTEM

Hazardous/Solid wastes are generated from the process, solvent distillation,

wastewater treatment and utilities. Process residue contains mainly un-reacted raw

materials. These are collected from the reactors and other process equipment and stored

in drums. Solvent residue is generated from distillation units; the residues are tarry

substances with good calorific value and are stored in drums. The other major waste is

salts from MEE withATFD system. These salts are stored in HDPE lined bags. All solid

waste storage containers/drums/bags are labeled showing the source, nature of hazard

and type of wastes. All the hazardous wastes are stored in a covered shed with fire

safety measures, and the shed is provided with a garland drain connected to the



effluent treatment system. The process residue and solvent residue are sent to cement

plants for co-processing.

Hazardous/solid waste will be generated during production from the plant.

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 before sending to the Cement industries. Solid waste like

boiler ash will be sent to Brick manufacturers.

The organic residues & spent carbon is sent to cement plants as recommended by

CPCB for use as alternate fuels either in the solid or liquid form. Inorganic salts are to

be sent for landfill at TSDF. Hazardous/Solid waste will be segregated, stored and

disposed using manifest system. Mixed solvents will be sent to cement plant for co-

processing, while spent solvents are recovered within plant premises. The other solid

wastes expected from the unit are containers, empty drums which are returned to the

product seller or sold to authorized buyers after detoxification.

Boiler ash will be stored in the Silos and will continue to be sent to Brick

manufacturing units. Empty containers will be collected from all the sources of

processing / warehouse area and will be kept in the covered raised platform with

leachate collection and detoxification area. All containers will be detoxified under

expert supervision. Detoxified containers will be used for storing the hazardous waste

and the balance will be sold to scrap vendors. Wash water from the detoxifying area is

sent to ETP for further treatment.

Used oil generated from the DG sets, Gear boxes, Vacuum pumps etc., will be

collected separately in MS/HDPE drums and stored in the designated area for further

disposal to SPCB authorized Used/Waste oil re-processers using 7-copy manifest

system. Used Batteries will be replaced with the new batteries and sold to suppliers on

buy-back basis.

Name boards will be provided in all dedicated areas for Hazardous/solid waste

storage and maintain records for waste generation quantity, handling& storage and

disposed quantity. All records will be summarized and sent to SPCB monthly for



information and records. Form IV statement comprising of all Hazardous waste

disposal details for the financial year will be submitted to SPCB annually as per

Hazardous & other wastes (M & TM) Rules, 2016 and its amendments there under.

Industry will be ensured for disposal of the Hazardous waste on priority.

10.3.4 NOISE CONTROL MANAGEMENT SYSTEM

Noise is anticipated from motors, compressors, boiler area, pumps, cooling tower

andDG sets. The DG sets will have in built-in acoustic enclosures. The motors and

compressors will be provided with guards and will be mounted adequately to ensure

the reduction of noise and vibration. The employees working in noise generating areas

will be provided with earmuffs. The employees will be trained in the mitigation

measures and personal protection measures to be taken to avoid noise related health

impacts.

An effective hearing conversation program will be undertaken where exposure to

industrial noise is capable of producing hearing loss. The objective is to ensure that an

employee hearing is not affected during his working life to an extent greater than that

usually occurring with age and to preserve it at a level sufficient for normal speed

perception. The following control aspects are identified for further implementation to

reduce noise levels/exposure:

Noise generating sources like motors and compressors will be provided with

Casings and guard to reduce the noise levels

Placing attenuating screens between the operators and the sources

Adequate spacing between noise sources and operators will be provided. In free

field conditions the sound levels roughly varies with the square of the distance.

Reflected noise is reduced by use of absorbent materials on roofs, walls and

floors.

By proper maintenance, which corrects vibrations and other imbalances, will be

taken up



Training would be imparted to plant personnel to generate awareness about the

damaging effects of noise.

Personal protective equipment‟s (PPEs) such as earplugs and ear muffs

consisting of fine glass wool, ear muffs consisting of ear cups with a soft seal,

fitted with a spring or adjustable headband. Comfort, maintenance and cleaning

are important aspects of use.

Planted trees of tall as well as short trees in and around the plant area will

protect the outside environment from any noise and dust nuisance.

As per the Factories Act, the general health check-up of the workers will be

checked for any Noise Induced Hearing Loss (NIHL) by a competent ENT

doctor.

By these measures, it is anticipated that noise levels in the plant will be maintained

well below 75dB (A). The noise levels at the periphery of the plant are likely to be less

than55 dB (A).

Proposed modification project site is located in Kolhar Industrial Area, Kolhar

Village, Bidar Taluk & District, Karnataka. Plant boundary with greenbelt is about 1 km

from nearest habitation; no impact of noise will be felt at this habitation. The noise

levels in the work place environment will be monitored periodically and action will be

taken in the form of regular maintenance schedule to reduce noise and vibration in

generating sources. Noise attenuation targeted & achieved with greenbelt of pure

Species Monoculture.

10.3.5LAND ENVIRONMENT

Chorus Labs has social obligation to recreate the environmental status by

providing thick green cover to suppress fugitive emission and provide aesthetic beauty.

Trees form the important part of the biosphere in the Eco-system. This will help in

reducing the concentration of pollutants and will also be effective in attenuating noise

levels.



GREENBELT DEVELOPMENT

The tree plantation is one of the effective remedial measures to control the air

pollution and noise pollution. It also causes aesthetics and climatologically

improvement of area as well as sustains and supports the biosphere. It is an established

fact that the trees and vegetation acts as a vast natural sink for the gaseous as well as

particulate air pollutants. Due to enormous surface area of the leaves, it also helps to

attenuate the ambient noise level. The plantation around the pollution sources control

the air pollution by filtering the air pollutant and interact with gaseous pollutant before

it reaches to the ground. The tree plantation also acts as buffer and absorber against

accidental release of pollutants.

The selection of tree species suitable for plantation at the industry shall be

governed by guiding factors as stated below.

The tree shall tolerant to air pollutants present in the area

The tree is able to grow and thrive on the soil of the area, be evergreen,

inhabitant, having minimum of leaf fall.

The tree is tall in peripheral curtain plantation and with large and spreading

canopy in primary and secondary attenuation zone.

The tree posse‟s extensive foliar area to provide maximum impinging surface for

continued efficient adsorption and absorption of pollutants.

The tree are fast growing and indigenous, and shall maintain ecological, land

and hydrological balance of the region.

10.3.6SOCIO-ECONOMIC ENVIRONMENT

M/s. Chorus Labs, Bidar has generated direct and indirect employment for 20

persons including the existing after modification. The modification project provides an

opportunity for the local people to get employment directly or indirectly and helps in

the up-liftment of the socio-economic status of the area. The project proponents propose

to involve in social activities of the stakeholders/surrounding community by planning

the betterment of neighboring social conditions through awareness and welfare



programs will ensure an improved relation, useful in the long run. The goodwill of the

local populace can never be ignored. Another important facet of social environment

identified by the project proponent is a green appearance; hence the management will

develop a green belt towards aesthetic beautification as the same is necessary to be

considered as a responsible, social neighbor.

Corporate Social Responsibility:

M/s. Chorus Labs, Bidar, under the Corporate Social Responsibility (CSR),is

carried out the requirements to the surrounding villages in association with

otherindustries of the industrial area and the same will be continued for the

surroundinghabitations by identifying their requirements to get local people into

confidence amongst thelocal people about the modification project activities. Adequate

funds are earmarked towards enterprise social commitment. The

followingrequirements will be met in phased manner for minimizing the adverse

impacts on socioeconomicand parameters of human interest:

Interaction with the local community would be institutionalized and done on

regular basis by the project authorities to provide an opportunity for mutual

discussion.

Project Proponent will initiate/implement the social welfare programmers/

measures for improving vicinity people living standards.

For social welfare activities to be undertaken by the project authorities,

collaboration may be sought with local administration, Gram Panchayat, Block

Development/Tehsil Offices etc., for better co-ordination and also to approach

the public.

Preference will be given for employment of the local people during construction

phase as well as operation/maintenance activities.

Awareness programmers will be organized to make people aware about the

environmental protection, need for water conservation, rainwater harvesting and

methods of preserving water quality.



Conduct awareness campaigns in the community specially related to basic

health, hygiene and sanitation.

Periodical health checkup camps will be organized by project authority for

workers.

To strengthen existing education facilities in the surrounding villages, following

measures are recommended :

- Required support for additional class rooms/schools.

- Providing teaching aids to village schools.

- Installation of suitable scholarship or awards to meritorious students.

As regards aesthetic environment, development of social forestry and road side

plantations will be encouraged through tree plantation drives in the project area.

Provide books, school bags, uniforms and other requirements for financially poor

children, therefore the proposed Project need to focus on education and more on

girl child and women education and adult education facilities.

Provide the vocational trainings for SHGs, youth especially SC and ST

community and poor people.

10.3.7MANAGEMENT AND STORAGE OF RAW MATERIALS

All the raw materials will be first received by the stores department and samples

of raw materials will be sent to quality control (QC) laboratory wherein the quality of

raw material will be tested. Only after confirmation of quality by the QC lab, the raw

material will be transferred / unloaded at the respective storage area in the factory with

proper labeling “Approved”. The raw material in general will be received in bags/

carboys/ drums as well as through tankers. Raw materials transported from the storage

area to the production plant by hydraulic trolley/trolley/lift as applicable. Modes of

transportation of all raw materials to the plant site and finished products from the plant

site are by road.

Raw materials will be received in MS/HDPE/fibre drums, carboys, bags, cartons

and cylinders as well as through tankers. Material received from tanker will be stored



inabove ground tanks. All the storage tanks of hazardous flammable substances will be

located within premises in separate storage area i.e. Tank farm area. Warehouse will

becontaining store office, raw material store, finished product store, etc. Personnel

protectiveequipment‟s like hand gloves, safety shoes, goggles, helmet, clothing, etc.,

whereverrequired, will be provided to the persons. All motors and electrical

connections will be flameproof.

All the liquid raw materials will be stored in storage tanks at separate storage

area.The storage area for hazardous chemicals will be located within the boundary wall

with aconstant watch by security round the clock. All necessary firefighting system and

safetyarrangements will be provided near the storage area to combat any emergency

accident.MSDS will be placed at each Hazardous Raw material for ready information of

the material.The liquid chemicals will be transported through pipes via rack to

production area day tanksfrom storage tanks.

Management, handling and storage of coal

Coal consumption at about 5 TPD will be used in the proposed and existing coal

fired boilers of 2TPH; Diesel will be used at full operation load in the proposed DGsets

of 1x200 KVA. Coal will be procured from the Singareni Colleries Company Limited.

Coal will be stored in covered shed and fly ash generated from the boiler

through pollution control system will be handled through pneumatic pipelines and

stored in closed /covered areas. Ash will be sent to Brick manufacturers.

10.3.8 SPILL CONTROL MANAGEMENT

The guidelines for spill control in protecting and preventing the environment

from contamination will be ensured. The following are required for prevention of

contamination for storage in vessels/ tanks based on the type of materials. They are:

• Retaining wall

• Sump and drainage system

• Diversion system

• Retention tank



• Absorbent Materials

Practice and Requirement for liquid storage

Tank Storage:

Bulk Chemicals, fuels or solvents will provide dyke or retaining wall around the

tank.

Drainage from dyke or walled storage area will be restrained by valves or other

positive means.

Drain valves will remain in closed position except during draining. Draining of

liquid will not be commenced until sampling check is done & found free from

contaminant.

All dykes or wall built will be liquid tight and will be checked periodically.

Standby Empty tanks (dump tanks) will be available for transferring the liquid

during any leakage of tank/reactor in Tank form area and near to each

production blocks.

Materials stored in tank will be compatible to the condition of storage such as

corrosion, temperature and pressure rating.

Valves and pipelines will be audited regularly by technical and operation

personnel. The job will include visual inspection for defects and deterioration,

leakage, liquid accumulation, piping joints and supports etc.

Truck Tanker / Drum and Vessel Contaminant: The spill control is meant to cover only

the general precaution and measure throughout the whole process operations.

However, each area will be individually supplemented by its own detailed procedure.

Training: The team members will be trained to handle spill or leak incidents. Refresher

training will be conducted regularly. Mock drill will be conducted at prescribed

frequency to check & ensure sites readiness to respond in case of emergency.

10.3.9HOUSEKEEPING, PREDICTIVE AND PREVENTIVE MAINTENANCE

Maintaining a clean and orderly site is part of the environmental management

policy. All areas will be cleaned routinely and wastes will be disposed as per waste



disposal procedures. Floor washing is avoided and wet mopping will be adopted to

minimize liquid waste generation. Housekeeping in each area is required to be audited

to ensure meeting the plant standards.

A sound preventive and predictive maintenance program will be established to ensure

the integrity of the piping, joints and gaskets. Pumps seal and other rotating equipment

will be periodically inspected, replaced, serviced and maintained so that leak and spill

will be prevented.

10.4OCCUPATIONAL SAFETY AND HEALTH ASPECTS

Many workers health and safety hazards are posed by synthesis operations. They

include safety hazards from moving machine parts, pressurized equipment and pipes;

heavy manual handling of materials and equipment; steam, hot liquids, heated surfaces

and hot workplace environments; confined spaces and hazardous energy sources (e.g.,

electricity); and high noise levels.

Acute and chronic health risks may result from worker exposures to hazardous

chemicals during synthesis operations. Chemicals with acute health effects can damage

the eyes and skin, be corrosive or irritating to body tissues, cause sensitization or

allergic reactions or be asphyxiants, causing suffocation or oxygen deficiency.

Chemicals with chronic health effects may cause cancer, or damage the liver, kidneys or

lungs or affect the nervous, endocrine, reproductive or other organ systems. Worker

exposure to chemicals can occur during manufacturing when chemicals spill, leak, or

discharge from the process system and contaminate areas where workers are present.

The most frequently reported industrial exposure occurs during the transfer of

materials. The entry of workers into systems, equipment, or enclosures that are

contaminated may occur inadvertently, but routine servicing, nonscheduled

maintenance, and process monitoring appear to be the kind of activities with potential

for significant exposure. Health and safety hazards may be controlled by implementing

appropriate control measures (e.g., process modifications, engineering controls, and

administrative practices, personal and respiratory protective equipment).



The process modification will be a constant exercise of the labs of the

organization, resulting in reduced pollution loads and increased yields. The measures

proposed are selection of alternative solvents/routes of synthesis, avoidance of

hazardous chemicals usage and application of green chemistry principles.

The engineering controls proposed for reducing occupational hazards are;

provision of scrubbers, condenser systems for process equipment, piping systems,

insulation to reactors, usage of transfer pumps with mechanical seals, Air Operated

Double Diaphragm (AODD) pumps, Lifts and trolleys for transfer of drums or bags,

closed hoods for charging raw materials, dip pipe provision for solvent and liquid raw

material charging, level indicators, pressure and temperature indicators, barrier guards

on moving machine parts, optimization of chemical inventory, control switches and

emergency stop devices to mitigate and avoid physical, chemical, electrical and

mechanical hazards.

Administrative practices proposed for improving occupational safety are

induction training programs, safety training programs, rotation of workers,

implementation of proactive maintenance schedule, provision of standard operating

procedures for all plant operations, access to MSDS for all employees, access to

emergency numbers of contact, and avoidance of crowded work place, and

strengthening of existing occupational health centre.

Personal protective equipment will be provided to all the employees including

contract employees. All the employees will be provided with safety shoe/ gumshoe,

helmet, masks and goggles. The other equipment like ear muffs, gloves, respirators,

aprons etc., will be provided to employees depending on the work area allocated to

them. The personal protective equipment (PPE) selection will strictly follow the

prescribed guidelines of MSDS.

Medical Check-up:

The plant will have a medical program of pre-employment screening, periodic

medical examination, emergency treatment, non-emergency treatment, and record



keeping and review. The pre-employment screening and periodic medical examination

will follow the guidelines of factories act. The pre-employment screening will obtain

medical history, occupational history followed by physical examination and baseline

monitoring for specific exposures. The existing occupational health centre will be

strengthened to provide emergency and non-emergency treatment, by way of

emergency first aid on site, liaison with local hospitals and specialists, arranging

decontamination of victims, arranging transport of victims to hospitals, and to transfer

medical records, and to provide details of incident and medical history to next care

provider. The proposed occupational health centre will maintain the health records and

will analyze the records for any common symptoms and common health problems

which may be due to exposure to chemicals, and or due to other occupational hazards.

10.5COST PROVISION FOR ENVIRONMENTAL MEASURES

Total capital cost allocated towards environmental pollution control measures is

Rs. 1.22 Crores including existing and the Recurring cost (operation and maintenance)

will be about Rs. 0.125 Crores per annum

TABLE-10.1: BUDGETARY PROVISION FOR EMP

S. No. Description Amount in lakhs Amount in lakhs

Investment cost

Maintenance cost/annum

1

Pollution Control equipments Such as Scrubber, Cyclone

separators& bag filter with stacks, vent condensers

50.0 5.0

2 Rainwater Harvesting system 10.0 1.0

3 Green Belt Development 5.0 0.5

4 Water Pollution Control (Multiple

Effect Evaporator) 50.0 5.0

5 Occupational health and safety 5 1

8 Corporate Social Responsibility 2 -

TOTAL 122 12.5



10.6 POST – PROJECT ENVIRONMENTAL MONITORING PROGRAMME

10.6.1 INTRODUCTION

Regular monitoring of environmental parameters is of immense importance to

assess the status of environment during plant in operation. With the knowledge of

baseline conditions,the monitoring programme will serve as an indicator for any

deterioration in environmentalquality due to operation of the modification project, to

enable taking up suitable mitigatory steps in time to safeguard the environment.

Monitoring is as important as that of control of pollutionsince efficiency of control

measures can only be determined by monitoring.

The baseline study is carried out for post monsoon season. Hence, post

projectmonitoring programme of the environmental parameters is essential to take into

account thechanges in the environmental quality to ascertain the following:

State of Pollution within the plant site and in its vicinity.

Generate data for predictive or corrective purpose in respect of pollution.

Examine the efficiency of air pollution control system adopted at the site.

To assess environmental impacts.

Monitoring will be carried out at the site as per the norms of CPCB.

Environmental Monitoring Programme will be conducted for various

environmentalcomponents as per conditions stipulated in Environmental Clearance

Letter issued byMoEF&CC/SEIAA& Consent to Operate issued by KSPCB. Six monthly

compliance reportswill be submitted on regular basis, to MoEF&CC, Regional Office,

Bengaluru on 1stof June &1stof December. Quarterly compliance Report for conditions

stipulated in Consent toOperate will be submitted to SPCB on regular basis.

10.6.2 ENVIRONMENTAL MANAGEMENT SYSTEM

In order to maintain the environmental quality within the standards, regular

monitoring of various environmental components is necessary. The company has a

fullfledged environmental management cell (EMC) reporting directly to Managing

Director & Plant Manager / Director Operations for environmental monitoring and



control. The EMC team takes care of pollution monitoring aspects and implementation

of control measures.

A group of qualified and efficient engineers with technicians is deputed for

maintenance, up keeping and monitoring the pollution control equipment, to keep them

in working at the best of their efficiencies. For effective and consistent functioning of the

plant, the EMS at the site will be strengthened further with the following:

Environmental management cell covering EHS (Environment, Health & Safety)

team

Environmental Monitoring

Personnel Training

Regular Environmental Audits and Corrective Action Plan

Documentation – Standard operating procedures, Environmental Management

plans and other records

Environmental Management Cell:

It is necessary to have a permanent organizational set up charged with the task of

ensuring its effective implementation of mitigation measures and to conduct

environmental monitoring. The major duties and responsibilities of Environmental

Management Cell will be as under:

To implement the environmental management plan.

To ensure regulatory compliance with all relevant rules and regulations.

To ensure regular operation and maintenance of pollution control devices.

To minimize environmental impacts of operations by strict adherence to the

EMP.

To initiate environmental monitoring as per approved schedule.

Review and interpretation of monitored results and corrective measures in case

monitored results are above the prescribed standards.

Maintain documentation of good environmental practices and applicable

environmental laws for ready reference.



Maintain environment related records.

Coordination with regulatory agencies, external consultants, monitoring

laboratories.

To improve the capacity building of the Environmental Cell, as a part of the

management hierarchy a separate cell has been created under the Director, operations

in the form of Sr.Manager- Environment, Health &Safety (EHS) who is assisted by

Manager, Executives/Officer, Supervisors/Chemists, Operators/workmen and

Indirect/contract workers. One of the executive will be for documentation, procedures

& Compliances and other will be heading the operations both assisted by operators &

helpers. The Organizational Structure of Environmental Health and Safety is presented

in fig below.

FIG-10.2: ORGANIZATION STRUCTURE OF ENVIRONMENT HEALTH AND SAFETY

The Sr. Manager, Occupational health & safety (OHS) is fully responsible for the

OHS aspects of the employees, workers and will be assisted by Manager - EHS who

monitor the on-site & off-site emergency teams and assisted by the Executives/Officers

for compliances of OHS norms.

Managing Director

Sr. Manager-EHS

Manager Environment

Operation & OHS

Operators

Helpers

Manager Environment

Documentation & Compliance

Environment

Executive



Any non-compliance/violations witnessed by any employee in the organization

can directly communicate the same to the Sr. Manager, who will assess the serious and

not so serious violations /non-compliances and will communicate to the Director /

Managing Director.

Any non-compliances/violations of serious nature will be addressed by the

Director in consultation with the directly involved officials and will report to the Board

of Directors of the company. The primary focus is to comply with the regulations and

work out on action taken report to be placed before the Board of Directors. Similarly a

preventive action for non-recurrence of such violations/non-compliances will also be

worked out and strict monitoring will be done by the Management for implementation

of the same.

10.7 PREVENTIVE & CORRECTIVE ACTIONS FOR WITH PEL

All the preventive and corrective actions to protect the health of all the

employees, from any possible occupational health problems will be undertaken.

Exposure to chemicals: As the company is proposing to handle toxic chemicals, the

specific precautions needed to prevent exposure of employees to the chemicals in

various physical forms will be ensured.

All the reactors, centrifuges, etc., will be operated only in closed condition.

All the liquids will be added only through fixed pipelines.

Solids will be added through closed system.

Centrifuges and catch pots will be connected to vent condensers with chilled

brine circulation and nitrogen blanketing.

All the storage tanks will be provided with vent condensers.

Solvent transfer lines will be provided with mechanical seals.

Primary and Secondary condensers will be provided for all the reactors.

Two stage scrubbers will be provided for process emissions treatment.

Fugitive emissions will be monitored.



Exposure to dust: Addition of solids / powders will be done only through closed

system.Dust collectors will be provided wherever dust generating operations like

milling, shifting,packing etc.

Noise: Maximum noise is generated from DG sets, compressors and boilers. To reduce

thenoise levels, silencers and noise resistant enclosures will be provided. Periodic noise

levelmonitoring will be carried out to ensure the noise levels are maintained within

thepermissible levels.

Illumination: In all the work places, adequate ventilation and illumination will be

ensured.Routine monitoring will be conducted to ensure that illumination in all places

is above 500lux.

Heat: Arrangements will be made to ensure that employees are not exposed

totemperatures above permissible limit. Air conditioning will be provided wherever

activitiesare carried out in closed rooms. Temperature mapping will be carried out on

daily basis.

Musculo-skeletal problems: Employees will not lift weights beyond the limits

prescribedby the Factories Act. Seating facilities will be provided to employees, who

normally standwhile working. Those employees who normally sit while working,

ergonomically designedchairs and tables will be provided.

In addition to the above, the following facilities will be provided in concordance

with IndianFactories Act.

Candidates on recruitment, safety training will be given for one week on

handling ofchemicals

Potable drinking water will be provided

Adequate latrines, urinals and washing facilities will be provided for male and

femaleemployees separately

Ambulance room, rest rooms and lunch room/canteen will be provided



First aid facilities will be provided in production areas, maintenance

workshop,laboratories and at the security office

Training on First aid will be provided to all the employees

All the wastes generated will be properly treated, stored and disposed off

Cleanliness will be maintained throughout the premises

Personal protective equipment‟s (PPEs) suitable for various operations will be

providedto all the employees.

Pre and post-employment medical checkup will continue to be conducted. The

testswill include, but not limited to the following:

Blood test: Blood group and Rh factor, Blood sugar, Fasting and Post Meal

Total count/differential count

Lipid profile

Erythrocyte sedimentation rate

Routine urine test

Liver function tests

Pulmonary function test

ECG

Chest X-ray

Audiometry

Vision test

Complete physical examination.

The results of these tests will be assessed by company's Medical Officer and

hisrecommendations will be implemented. Industry is already entered into the

agreement withthe nearby hospitals in case of emergency and Medical officer is visiting

industry regularly.Latest regular Medical health checkup for employees (one employee

details) is enclosed as ANNEXURE-12.

The post-employment tests will be conducted before recruitment. Company

willemploy qualified paramedical staff so that one person is always available in each



shift. Firstaid training will be given to employees, so that such employees will be

available in all theshifts. The above activities will be undertaken to ensure that the

employees do not sufferfrom any health problems due to their occupation. Employees

also trained for First-Aid /Emergency Response etc., in 1: 10 ratio. List of Emergency

Response Team also displayednear entrance and a Badge placed in Helmet of the

Employee for easy recognition duringemergency.

M/s. Chorus Labs Limited, Bidar will continue to follow the safety norms asper

the guidelines of the National Safety Council for a process industry and will provide

allthe necessary safety equipment for the protection of the Industrial establishment as

well asthe personnel working in the plant premises. Personnel Protective Equipment‟s

(PPEs) willbe provided to all its employees who are involved in the handling of

hazardous activities.The storage and handling of various chemicals will be according to

the norms of MSDS andthe Inspector of Factories. Personnel involved in the production

will be provided withprotective clothing, helmets, goggles, masks, gloves, etc. These

handling operations will becarried out under the strict supervision of the trained and

highly skilled personnel.Supervision will be provided to ensure the usage of these

PPE‟s. Necessary firefightingfacilities like extinguishers, sand buckets etc. will be

provided to meet the on-siteemergencies. A detailed On-site emergency plan will be

prepared for modification projectand implemented as per the provisions of Factories

Act. An agreement has been made witha nearest hospital for treating the employees due

to unforeseen emergencies.

To take care of Occupational Health, the following measures will be

implemented

Existing Occupational Health Centre will be strengthened and this will be

manned bycertified paramedical attendants, round the clock.

Adequate Wash and Toilet facilities will be provided to all employees, separately

formale and female employees.

Canteen facility will be upgraded to meet the requirement of proposed

employment.



Cool, potable, drinking water will be provided at various locations, easily

accessible toall employees.

For people doing their work standing, sitting facilities will be provided to relax

inbetween.

For employees doing their work sitting, ergonomically designed seats will be

provided.

Plan of evaluation of health of workers

By pre-designed format during pre-placement and periodical examinations.

Proper schedule will be devised and followed with help of occupational health

expertand doctors.

Health effects of solvents & chemicals used and health hazard plans based

onmonthly correlation of related diseases and people affected.



CHAPTER 11

11. SUMMARY & CONCLUSION

SUMMARY:

The proposed project is expansion and modification of manufacturing of drug

product & intermediates in the premises; existing product and addition of new drug

products is proposed to manufacture the products. The industry is located at Plot No.

23-B, KIADB Kolhar Industrial Area, Bidar Taluk & District, Karnataka.

The project is falling under item activity 5 (f) of Category-B projects of MoEF as

per the EIA Notification dated 14th September 2006 and the amendments thereof,

proposed manufacturing of bulk drugs requires Environmental Clearance from MoEF

(Ministry of Environment & Forests) for its modification of production capacity.

As per the TOR prescribed by the State Expert Appraisal Committee dated on

15thJune, 2018 and as per the CPCB standard references, EIA (Environmental Impact

Assessment) study has been carried out towards the proposed project.

An environmental Impact Assessment Study has been carried out and assessed

for the proposed project based on the ToR and baseline quality data collected for the

study area. Identification and anticipation of the potential environmental impacts due

to the proposed project with a delineation of appropriate impact mitigation measures in

an Environmental Management plan during both construction and operation phases is

provided in the EIA report prepared.

The proposed project will ensure that the industrial activities relevant to the

project are environmentally sound with no adverse impacts posed on the natural

environment in the surrounding area.

The marginal impacts that might be caused by the proposed activity will be

mitigated by the implementation of the proposed pollution control and environmental

management measures.



In a true and a larger sense, in view of the considerable benefits from the project

with no major impacts, the proposed project is said to be more beneficial to the nation.

With the above summary, the EIA study of the proposed bulk drug

manufacturing has not been identified with any major negative impacts on the site and

on to the local environment.

And while in operation, from the proposed project involved in

processing/manufacturing activities and has proposed new products for the existing

products, whatever the impacts like generation of domestic & industrial wastewater,

solid waste, waste oil, boiler, DG etc., for that proper well planned Environmental

Management Plan has been proposed along with this, for operation phase; other

permanent Environmental Management Plans like well-planned storm water

management, internal transportation management, sufficient parking provision, septic

tank, effluent treatment plant, solid waste management, providing air pollution control

equipment, green belt development plan has been proposed and the same will be

effectively implemented on the proposed project and for the implementation of the

same and its management EMP cell is being framed, along with this environmental

monitoring routine plans are also proposed with estimated budgetary allocations.

The EMP that will be implemented for the construction and operation stages of

the project will include:

• Air Pollution control and Management

• Noise Control and Management

• Hazardous and solid waste Management

• Sewage treatment and Management

• Effluent treatment and Management

• Risk Assessment and Onsite emergency Plan

In order to effectively implement the EMP planned, an environmental

management system will be formulated.



ENVIRONMENT MANAGEMENT PLAN

AIR QUALITY MANAGEMENT

It is proposed to have a green belt plantation along the boundary of the plot,

which will intercept the dispersing particulates.

The sprinkling of water is recommended in areas where dust emission is

expected within the plant.

The internal roads of plant are asphalted and hence dust emission shall be to

minimum.

WATER MANAGEMENT The total effluent generated from process, cooling tower, boiler feed and others

shall be treated in ETP followed by MEE and ATFD and the domestic sewage

will be treated in biological treatment system.

NOISE MANAGEMENT

The occasional noise has been attenuated by the development of green belt

around the industrial complex, and ear-protecting devices will be provided to

personnel working in high noise generating zones.

Acoustic enclosure shall be provided to the DG set.

SOLID WASTE MANAGEMENT

The solid wastes shall be segregated according to their properties, packed,

transported and stored in a separate impervious storage area demarcated for

them. They will then be disposed off according to the requirements of statutory

authorities.

OCCUPATIONAL HEALTH & SAFETY

Masks and other PPE‟s will be provided as additional personal protection

equipment to the workers.

Workers are informed, kept aware and trained about occupational health

hazards, due to such activities and preventive measures.

Workers health related problem if any, will be properly addressed.



PLANTATION DEVELOPMENT AND PROGRAMME

The local species will be planted with consultation of local forest department

/horticulturist and follow the CPCB guidelines.

CONCLUSION:

The baseline study carried out for the study area indicates that all the physical,

chemical and biological characteristics of the environmental attributes in the

surrounding area are well within the permissible limits.

Based on this environmental assessment, the possible impacts during both pre

project and post-project phase are anticipated and the necessary adequate control

measures are formulated to meet the statutory compliances.

With very minute negative impacts, the project positively leads to commercial

business opportunities, Employment opportunities, increased revenue and

infrastructural development.

However, modification and expansion of this project has certain beneficial

impacts/effects during the course in operational phase of the project.

Some of the beneficial impacts/effects are:-

It will result in considerable benefits on physical infrastructures like

transportation system, water supply & drainage system, power supply and social

infrastructures like health centers, banking, education as well as small and

medium scale industries like residential developments, hotels, shopping

complexes, retail shops etc,.

Improvement to the general aesthetics of the surrounding area.

It will also bring employment generation to skilled, semiskilled and unskilled; it

is obvious to assume that, all the economic activities in the project area would

induce considerable improvement in the socio-economic levels of people. The

impact of human settlement is expected to be positive, as apart from some people

being directly employed, many others will get indirect employment.



The impacts are identified and evaluated to reduce their negative impacts and

maximize the positive effects on the surrounding environment.

It raises the living conditions of the citizens of the country.

During operation phase, use of eco-friendly methods such as sewage treatment

plant (Septic tank), effluent treatment plant, solid waste management, process

emission control, rain water harvesting & recharging, scientific disposal of

hazardous waste, bio medical waste and e-waste, green belt development and

corporate social activities around the project site will benefit the environment.

Overall, the proposed project will have positive impact on the Environment if,

the recommended Environmental Monitoring, Health & Safety and

Environmental Management aspects are fully implemented by the project

proponents.



CHAPTER 12

DISCLOSURE OF CONSULTANT

DECLARATION BY CONSULTANT ORGANIZATION DEVELOPING EIA

REPORT

M/s. Enviro Resources, Mumbai is a prominent provider of environmental

consulting to wide range of clients. Our comprehensive range of diversified services

includes obtaining environmental clearance from SEIAA/MoEF, CRZ clearance from

MoEF, preparation of EIA/EMP and approval/authorization from KSPCB.

TABLE-12.1: DISCLOSURE OF CONSULTANT

Project proponent M/s. Chorus Labs Limited

Project site At Plot No. 23-B, KIADB Kolhar Industrial Area, Nizampur

Hobli, Bidar Taluk & District, Karnataka

Type of project Modification and expansion of manufacturing of bulk drugs

with total production capacity of 10.225 TPM

Category of project as per

EIA notification

5 (f) of Category-B, “Synthetic organic chemicals industry”

EIA consultant

organization

M/s. Enviro Resources, Mumbai

Contact information No.1604 Roopnagar CHS S V Road, Kandivali West, Mumbai

- 400067.

Status of accreditation

with NABET

Certificate No. NABET/EIA/1821/IA0038.

COPY ATTACHED AS ANNEXURE-2



CHAPTER - 13

13 ASSESSMENT OF ECOLOGICAL DAMAGE, REMEDIATION

PLAN & NATURAL AND COMMUNITY RESOURCE

AUGMENTATION PLAN

13.1 Introduction:

Any change in the environmental attributes contributing in beneficial or harmful

way is an Environmental Impact, which is caused due to proposed or existing

developmental activities such as construction, demolition, renovation, production,

mining etc. Extending an existing structure, increasing in the rate of production in an

existing industry or proposing a new structure or an industry will have a significant

impact on the environmental attributes. Comprehensively predicting and evaluating the

impacts in various aspects that are likely to occur by comparing the existing quality of

environmental attributes with their condition in the post-project stage will help in

adoption of appropriate mitigation measures to overcome the consequences.

This report presents the assessment and quantification of the damages caused

due to expansion and modification of Bulk drugs and Intermediatesproduction by M/s.

Chorus Labs Limited, possible restoration measures that are required to be adopted to

overcome the damages caused and cost incurred in that.

13.2 Chronology of the Industrial Activity:

KIADB allotted land to M/s. Bidar Drugs Pvt Ltd in the year of 1987.

Karnataka State Financial Corporation (KSFC), Bangalore taken over the plant by

M/s. Bidar Drugs Pvt Ltd in the year of 1989.

M/s. BSN Pharma Limited purchased the plant from KSFC, Bangalore dated

12/9/2005.

M/s. BSN Pharma Limited obtained CFE for Ibuprofen product with capacity 50

TPM with order dated 22/11/2006.



M/s. BSN Pharma Limited changed the name in the year of 6/8/2009 to M/s.

Chorus Labs Limited.

CFO was issued for manufacturing of Ibuprofen product with capacity 50 TPM

and validity was till 30/06/2010.

M/s. Chorus Labs Limited has obtained CFEx for 17 products with the order

dated 20/08/2010. Subsequently CFO was obtained and its validity was till

30/09/2015.

In 11/4/2014, M/s. Chorus Labs Limited proposed to replace 5 projects in the

place of existing products and accordingly filed the application to KSPCB to

obtain CFE.

M/s. Chorus Labs Limited obtained CFEx for change of products with order

dated 8/8/2015.

Subsequently, industry was visited by Secretary, SEIAA, Karnataka and Member

Secretary, KSPCB on 28th& 29th April 2016 as compliant against industrial

activities subject to pollution of groundwater in and around the Kolhar industrial

area is made to legislation petition committee.

KSPCB has issued closure order to the industry to stop the industrial operation.

Presently plant is closed.

M/s. Chorus Labs Limited had applied for an Environmental Clearance and TOR

application is submitted to SEIAA, Karnataka dated on 21.5.2016. (FILE No.

SEIAA 20 IND 2016)

Terms of Reference (TOR) meeting held on 30.8.2016.

SEAC committee members along with KSPCB officers visited the industry for

inspection on 4.10.2016 and reported observation as well as recommendation.

M/s. Chorus Labs Limited submitted the EIA report dated 24.3.2017.

As per Notification No. S.O 804(E) dated 14.3.2017, SEIAA Karnataka decided to

close the file as it is a case of violation and received letter from SEIAA dated on

21.4.2017.



Accordingly we have filed the application to MoEF, Delhi with File No: [J-

11011/257/2017-IA-II(I)]

As per the MoEF new Notification dated 8th March 2018, all the violation cases

have been forwarded to individual state subject to Categorization in EIA

Notification 2006.

13.3 Purpose of the study:

The Terms of Reference (TOR) granted to the project by SEIAA vide letter SEIAA 16

IND (VOIL) 2018 dated 15.06.2018 to conduct the EIA studies to obtain the

Environmental Clearance for projects under EIA notification-2006. SEIAA also

recommended to assess the damages caused to the Environmental Attributes like

Air, Water, Soil, Ecology etc as per the Notification No.S.O.804 (E) dated 14th March

2017, Notification No.S.O.1030 (E) dated 8th March 2018 and preparing a remediation

plan and natural resources augmentation plan corresponding to the damages

assessed. In compliance with the above, impacts on environmental attributes due to

change in product mix and respective remedies and mitigation plans are discussed

in this chapter.

13.4 Project & Violation details:

M/s. Chorus Labs Limited was established in the year of 2009 and had CFO for

manufacturing Ibuprofen with a capacity of 50 MTPM. Also the industry had obtained

CFE and CFO for manufacturing additional 17 products which was expired on

30/09/2015. The industry has not obtained Environmental Clearance for any of the

stated productions. As per the EIA Notification 2006, the industry should have obtained

Environmental Clearance to take up the production, but industry started manufacturing

without obtaining Environmental Clearance.

The project falls in the activities listed under the EIA notification, 2006 hence

does require prior Environmental Clearance under the EIA notification. The proposed

project is covered under activity 5 (f) “Synthetic organic chemicals industry” of

Category-“B” of MoEF as per the EIA notification vide gazette no. S.O. 1533 dated



14thSeptember, 2006. Hence the proposed project has to obtain environmental clearance

from SEIAA, Karnataka, without which it is treated as violation. As per the EIA

Notification No.S.O.804 (E) dated 14th March 2017, Notification No. S.O.1030 (E) dated

8th March 2018; the industries who have taken up change of product mix without

obtaining Environmental Clearance are treated as violation.

13.5 Assessment of the Damages and Remediation Plan:

The impacts on the environmental attributes can be broadly classified into two:

Damages during construction

Damages during operation

13.5.1 Damages during Construction phase:

M/s. Chorus Labs Limited is the existing industry located at Plot No. 23-B,

KIADB Kolhar Industrial Area, Bidar. In the process of assessing the damages to the

environmental attributes, possible environmental impacts during construction phase

have been considered/addressed and detailed in the table below.



Table-13.1: Damages/Impacts during construction phase.

Sl.

No.

Environmental

Impact Probable Damages

Damages

Caused Remarks

1. Loss of Top soil All the construction activities start with site clearance and

levelling, hence top soil of the site will be removed resulting in

reduction of the fertility level of the soil at site.

NA M/s Chorus

Labs Limited is

an existing

industry since

2009, hence no

construction

activity involved

during the

production of

Bulk drugs and

Intermediates.

2. Loss of

Vegetation

All the construction activities start with site clearance and

removal of trees and shrubs; hence green belt of the site will be

removed resulting in loss of vegetation cover at site.

NA

3. Due to change in

land use pattern

Loss of vegetation and impact on Flora and Fauna NA

4. Impact on air

quality

Generation of dust and particulate matter due to construction

activities and vehicular movements.

NA

5. Impact on Noise

levels

Use of excavators, vibrators, compactors and other construction

machines releasing unwanted noise beyond ambient noise levels.

NA

6. Impact on

human health

Effect on environmental attributes will have a significant impact

on human health.

NA

M/s Chorus Labs Limited is the existing unit since from 2009 and the violation activity includes the production of

Bulk drug and Intermediates without obtaining environmental clearance. Therefore, damage during the construction is

insignificant.



13.5.2 Damages during Operational Phase:

M/s Chorus Labs Limited had consents for manufacturing Ibuprofen and other 17

products with a capacity of 50 MTPM. As per the EIA Notification 2006, the industry

should have taken Environmental Clearance before taking up any production, but the

industry started manufacturing activities only by obtaining consents from time to time.

As the industry is established in the year of 2009, environmental management

systems were in place to handle different types of waste including air emissions,

effluent and solid waste generated from the production activity.

Production of Bulk drugs and Intermediates by the industry for the entire period is

within the limits as per consents obtained from KSPCB that is 50 MTPM. Evaluation of

the raw material requirement, production quantity and waste generation has been done

and detailed in tables below. Process description along with material balance is attached

in Annexure-15.



Table - 13.2 Details of production quantity, raw material usage and waste generation from 2009 to 2017

Sl. No.

Year Product name Production

quantity (kg) ETP Salt disposed

to KWMP (kg)

Effluent generation (HTDS) kl

Solid waste generation

(MT)

Solvent residue (kg)

1 2009-10 I Buprofen 48599 0 1042

Total 48599 0 1042

2 2010-11

Neverapine 2250

18770 1539

0.00 1350

Diclofinac Sodium 35000 63.00 4200

Leviteracitam 12340 0.00 4319

Terbinafinac HCL 9481 0.00 1422.2

Total 59071 18770 1539 63.00 11291.2

3 2011-12

Neverapine 232

18160 1100

0.00 139.2

Leviteracitam 24694 0.00 8642.9

Terbinafinac HCL 43355 0.00 6503.3

Total 68281 18160 1100 0.00 15285.4

4 2012-13

Neverapine 1784

11220 2707

0.00 1070.4


Diclofinac Sodium 6000 27.00 720

Total 46131 11220 2707 27.00 15211.9



5 2013-14

Neverapine 1292

13010 993

0.00 775.2


Diclofinac Sodium 2860 128.70 343.2

Total 50084 13010 993 128.70 17194.6

6 2014-15 Neverapine 2558

35909 1746 0.00 1534.8


Total 16603 35909 1746 0.00 6450.6


10880 739 0.00 1756.8


Total 20276 10880 739 0.00 7828.6


10215 260 0.00 30


Total 3235 10215 260 0.00 1144.8



Table-13.3: Details of yearly generation of Effluent and its treatment

Sl.

No.

Production

Year

Total Effluent

generated (KL/A)

Total capacity to

treat Effluent (KL/A)

Excess Effluent

discharged into

Environmental

Attributes (KL)

1. 2009-10 1042 3650 0

2. 2010-11 1539 3650 0

3. 2011-12 110 3650 0

4. 2012-13 2707 3650 0

5. 2013-14 993 3650 0

6. 2014-15 1746 3650 0

7. 2015-16 739 3650 0

8. 2016-17 260 3650 0

Total 0.0

Table-13.4: Details of yearly generation of Solid waste and treatment

Sl.

No.

Production

Year

Total Solid waste

generated (MT/A)

Total capacity to

treat Solid Waste

(MT/A)

Excess Residue

Solid Waste

disposed into the

Environmental

Attributes (MT)

1. 2009-10 0.0 2920.00 0.0

2. 2010-11 63.00 2920.00 0.0

3. 2011-12 0.00 2920.00 0.0

4. 2012-13 27.00 2920.00 0.0

5. 2013-14 128.70 2920.00 0.0

6. 2014-15 0.00 2920.00 0.0

7. 2015-16 0.00 2920.00 0.0

8. 2016-17 0.00 2920.00 0.0

Total 0.0



Table-13.5: Details of yearly Loss of Solvent during distillation

Sl. No. Production Year

Total Solvent loss

during distillation

(MT)

1. 2009-10 0.00

2. 2010-11 11.291

3. 2011-12 15.285

4. 2012-13 15.211

5. 2013-14 17.194

6. 2014-15 6.450

7. 2015-16 7.828

8. 2016-17 1.144

TOTAL 74.403

Table - 13.6Coal used in boiler

Year Quantity (kg)

2009-10 1,13,896.54

2010-11 2,32,965.00

2011-12 2,64,920.00

2012-13 2,65,205.00

2013-14 2,16,850.00

2014-15 1,79,275.00

2015-16 1,31,995.00

2016-17 18,585.00

Total 14,23,691.54



Table - 13.7 Air emission from Coal

Sl. No. Pollutant Quantity Generated (MT)

1. CO2 2334.854

2. SO2 56.948

3. NOx 28.473

4. PM 35.592

Table - 13.8: Analysis of retribution cost for Effluent production:

Sl. No.

Particulars (Pollutants)

Total discharge of effluent from

production carried (KL)

Retribution Rate

(Rs/KL)

Retribution Amount (Rs)

1 Industrial Effluent

0.0 500 0.0

Table - 13.9: Analysis of retribution cost for Solid waste production:

Sl. No.


Total generation from production

carried (MT)

Retribution Rate

(Rs/MT)


1 Solid Waste 0.0 800 0.0

Table - 13.10: Analysis of retribution cost for Solvent evaporation:

Sl. No.


Total solvent evaporation from

production carried (MT)

Retribution Rate

(Rs/MT)


1 Solvent 74.403 640 47,635.2

Table - 13.11: Analysis of retribution cost for Air Emissions:

Sl. No. Particulars (Pollutants)

Total emission for excessive production

carried (MT)

Retribution Rate (Rs/MT)


1. CO2 2334.854 Rs. 640 14,94,306.56

2. SO2 56.948 Rs. 640 36,446.72



3. NOx 28.473 Rs. 640 18,222.72

4. PM 35.592 Rs. 640 22,778.88

TOTAL 15,71,754.88

Note: Carbon credit of 8 Euros per tonnes of carbon considered and accordingly

considered for other pollutants.

Table – 13.12 Total cost of the damages from different wastes generated from the activity.

Sl. No. Type waste Amount is Rupees

1. Industrial Effluent 0.00

2. Solid Waste 0.00

3. Solvent 47,635.20

4. Air Emissions 15,71,754.88

TOTAL 16,19,390.00



Table - 13.13: Environmental Damage Remediation Plan and Costing

Sl. No.

Particulars & their origin

Anticipated Activities leading to

damage

Studies out come with respect to environmental pollutants Remedia

tion Plan

1. Deforestation: At the time of expansion of existing manufacturing unit.

Cutting trees, clearing vegetation cover etc.

M/s Chorus Labs Limited is

the existing industry hence no

construction activity has

damaged the environment, as

the construction activity has

been carried out within the

premises of the industry.

NA

2. Change of Topography: At the time of expansion of existing manufacturing unit.

Levelling of ground, excavation of soil etc.



construction activity has

damaged the natural

topography, as the

construction activity has been

carried out within the


NA

3. Soil Erosion: At the time of expansion of existing manufacturing unit.

Removal of vegetation cover, changing natural drainage pattern etc.



construction activity has lead

to soil erosion, as the

construction activity has been

carried out within the


NA

4.

Loss of Vegetation: At time of establishment of industry in the year 2008

Site clearance, excavation of soil etc.



construction activity has lead

to loss of vegetation cover, as

the construction activity has

been carried out within the


NA

5. Air Pollution:

Manufacturing units

Boilers

Release of Green House Gases into the atmosphere.

Air emissions that have been

generated from the activities

includes Manufacturing,

Boilers, DG Sets have been

NA



DG Sets

Transportation

Emission of particulate matters causing cardiovascular effects including heart attacks and associated mortalities.

controlled by providing the

pollution control equipments

as per the Consent For

operation issued by the

Karnataka state pollution

Control Board. During the

study period air environment

in and around the industry

premises have been analyzed

and not found any traces of

pollutants above the NAAQS.

6. Water Pollution:

High TDS

Low TDS

Used water

Sewage

During the operational phase major concern is domestic sewage and waste water generated from various processes.

The release of waste water contaminates ground water. The waste water having high BOD & COD, if released without treatment reduces the DO level of the receiving water body.

Effluent discharge that have

been generated from the

activities includes process

wastewater, washing,

domestic effluent and

wastewater generation from

the utilities have been

controlled by providing the

treatment units within the

industry as per the Consent

For operation issued by the

Karnataka state pollution

Control Board. During the

study period bore well water

and soil in and around the

industry pre premises have

been analyzed and not found

any traces of pollutants with

respect to the activities.

NA

7. Soil Pollution:

Municipal Solid Waste & Hazardous waste

Improper Disposal of Municipal Solid Waste generated by the inhabitants of the industry.

Disposal of

All the Municipal Solid Waste

& Hazardous waste that has

been generated was stored in

the designated area within the

industry and it has been sent

to respective vendors.

Manifest copy is attached

NA



hazardous wastes generated during the production such as chemical sludge, spent solvent, process residues etc., causing serious damage to the soil environment.

along with the EIA report.

8. Noise Pollution:

Manufacturing units

Vehicles

Boilers

DG Sets

Reactors

Air compressors.

During the operational phase because of machinery and vehicular movements, unwanted noise & vibrations are released in the atmosphere, causing health issues and discomfort to the people living in the surrounding areas.

Since the unit was existing

and located at the KIADB

industrial area with all the

precautionary measures to

mitigate the impact from the

noise pollution, no incidents

that have been occurred about

the health issues and

discomfort to the people living

in the surrounding area

NA

9. Health of Employees.

Employees working for excessive production need more space for their basic amenities, lack of which is causing discomfort to them.

Since the unit was existing

and located at the KIADB

industrial area with all the

precautionary measures to

mitigate the impact from the

noise pollution, no incidents

that have been occurred about

the health issues and

discomfort to the people living

in the surrounding area

NA

Environmental remediation deals with the removal of pollution or contaminants from

environmental media such as soil, groundwater, sediment, or surface water. To help



with environmental remediation, one can get environmental remediation services.

These services help eliminate radiation sources in order to help protect the

environment.

M/s Chorus Labs Limited is an existing industry which is established in the year of

2009.The industry had obtained consents for manufacturing17 products with a total

production quantity of 50 MTPM and from the Karnataka State pollution Control

Board, where the generated wastes and emissions are monitored by the Board.But as

per EIA Notification-2006 the Industry should have obtained Environmental Clearance

before taking up any of these productions. The industry has carried out the production

during the year of 2009 to 2017 under the environmental management systems existed

within the industry to take care of air emissions, effluent and solid waste generations.

During the EIA study period all the environmental attributes have been monitored,

analyzed and results have been interpreted which shows no presence of pollutants/

contaminants in any of the attributes. Since there is no presence of pollutant/

contaminants in any of the attributes, cost has not been allocated for remediation plan

instead cost has been worked out for Natural and Community Resource Augmentation

Plan and shown in the subsequent table.



Table - 13.14: Natural and Community Resource Augmentation Plan

Sl. No

Environmental Attribute

Augmentation Activity Budget

Allocation

1. Air

Developing green belt to reduce air pollution levels.

Monitoring Ambient Air Quality

Arranging free medical checkups to take care of public health.

1,00,000

2. Water

Supplying potable water to the locality

Providing storm water drainage system with natural gradient and sufficient number of recharge pits.

2,00,000

3. Land/Soil

Disposing Municipal Solid Waste at right place and using waste food for cattle feeding.

Disposing hazardous waste materials as per Hazardous Waste Management Rules 1989

1,00,000

4. Noise & Vibrations

Monitoring Ambient Noise levels and maintaining them within the standards.

Constructing acoustic enclosures the machinery creating excessive noise and vibrations.

Supply workers with Personal Protective Equipments (PPEs).

1,00,000

5. Flora and Fauna

Planting trees to reduce the concentration of pollution agents in the air, and developing green belt as a part of landscaping.

Preserving and maintaining the green belt by watering and manuring at appropriate time.

1,00,000

6. Socio economic

Constructing shelters at bus stops and providing signage.

1,00,000

TOTAL 7,00,000/-

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