proposed bulk drugs & bulk drug...
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1
FORM-1
FOR
PROPOSED BULK DRUGS & BULK DRUG
INTERMEDIATES MANUFACTURING UNIT
OF
M/s. KRISHNA CHEMTECH
Plot No. 2213, GIDC Estate,
Panoli-394116, Dist: Bharuch, Gujarat
Prepared by:
Aqua-Air Environmental Engineers Pvt. Ltd.
(Pollution Control Consultants & Engineers)
Reg. Office: 403, Centre Point, Nr. Kadiwala School, Ring Road,
Surat – 395 002, Gujarat, India Fax: +91 261 2707273 / 3987273 Tel: + 91 261 3048586 / 2460854 / 2461241
E-mail: [email protected] Visit us at: www.aqua-air.co.in
2
APPENDIX I
(See paragraph - 6)
FORM 1
Sr.
No.
Item Details
1. Name of the project/s M/s. Krishna Chemtech
2. S. No. in the schedule 5 (f)
3. Proposed capacity/area/length/tonnage
to be handled/command area/lease
area/number of wells to be drilled
Proposed area = 1,500 sq. mt.
4. New/Expansion/Modernization New
5. Existing Capacity/Area etc. For detail Please refer Annexure – I
6. Category of Project i.e. ‘A’ or ‘B’ ‘A’
7. Does it attract the general condition? If
yes, please specify.
Yes. Located within 5 km of critically polluted
area (Ankleshwar).
8. Does it attract the specific condition? If
yes, please specify.
No
9. Location
Plot/Survey/Khasra No. Plot No. 2213
Village Panoli
Tehsil Ankleshwar
District Bharuch
State Gujarat
10. Nearest railway station/airport along
with distance in kms.
Railway Station: Ankleshwar (4.5 km)
Airport: Surat (60 km)
11. Nearest Town, city, District Headquarters
along with distance in kms.
Panoli Village (3.5 km)
Bharuch (16.9 km), Ankleshwar (4.0 km)
12. Village Panchayats, Zilla Parishad,
Municipal Corporation, local body
(complete postal address with telephone
nos. to be given)
Notified Area Authority, Panoli
13. Name of the applicant M/s. Krishna Chemtech
14. Registered Address Plot No. 2213, GIDC Estate, Panoli-394116,
Dist: Bharuch, Gujarat
15. Address for correspondence: Plot No. 2213, GIDC Estate, Panoli-394116,
Dist: Bharuch, Gujarat
Name Mr. Arvind Gevariya
Designation (Owner/Partner/CEO) Proprietor
Address 205, Shyamal Building, Kohinoor Road, Mini
Bazar, Varachha Road, Surat-395006, Gujarat
3
Pin Code 395006
E-mail [email protected]
Telephone No. --
Fax No. --
Mobile No. +9198796 55109
16. Details of Alternative Sites examined, if
any.
Location of these sites should be shown
on a topo sheet.
NA
17. Interlinked Projects No
18. Whether separate application of
interlinked project has been submitted?
No
19. If yes, date of submission No
20. If no, reason No
21. Whether the proposal involves
approval/clearance under: if yes, details
of the same and their status to be given.
(a) The Forest (Conservation) Act, 1980?
(b) The Wildlife (Protection) Act, 1972?
(c) The C.R.Z. Notification, 1991?
No
22. Whether there is any Government
Order/Policy relevant/relating to the
site?
No
23. Forest land involved (hectares) No
24. Whether there is any litigation pending
against the project and/or land in which
the project is propose to be set up?
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if any
and its relevance with the proposed
project.
No
• Capacity corresponding to sectoral activity (such as production capacity for
manufacturing, mining lease area and production capacity for mineral production, area for mineral exploration, length for linear transport infrastructure, generation capacity for power generation etc.,)
4
(II) Activity
1. Construction, operation or decommissioning of the Project involving actions, which will cause physical changes in the locality (topography, land use, changes in water bodies, etc.)
Sr.
No.
Information/Checklist confirmation Yes/No Details thereof with approximate
quantities frates, wherever possible)
with source of information data
1.1 Permanent or temporary change in land use, land cover or topography including increase intensity of land use (with respect to local land use plan)
No Proposed project activity is within the Panoli GIDC Industrial Estate.
1.2 Clearance of existing land, vegetation
and Buildings?
Yes Minor site clearance activities shall be carried out to clear shrubs and weed.
1.3 Creation of new land uses?
No The project site is located on level ground, which does not require any major land filling for area grading work.
1.4 Pre-construction investigations e.g. bore Houses, soil testing?
No
1.5 Construction works?
Yes Please refer Annexure – II.
1.6 Demolition works? No There will be not any demolition work at the site.
1.7 Temporary sites used for construction
works
or housing of construction workers?
No
1.8 Above ground buildings, structures or
earthworks including linear structures,
cut
and fill or excavations
Yes Please refer Annexure – II.
1.9 Underground works mining or
tunneling?
No
1.10 Reclamation works?
No
1.11 Dredging?
No
1.12 Off shore structures?
No
1.13 Production and manufacturing
processes?
Yes Please refer Annexure –III.
5
1.14 Facilities for storage of goods or
materials?
Yes For Proposed Project Activity, raw material & finished products storage area will be developed.
1.15 Facilities for treatment or disposal of
solid waste or liquid effluents?
Yes For Facilities for treatment or disposal of liquid effluents is referred as Annexure-V. For Hazardous waste detail please refer Annexure – VI.
1.16 Facilities for long term housing of
operational workers?
No
1.17 New road, rail or sea traffic during
Construction or operation?
No
1.18 New road, rail, air waterborne or other
transport infrastructure including new or
altered routes and stations, ports,
airports etc?
No
1.19 Closure or diversion of existing transport
routes or infrastructure leading to
changes in
Traffic movements?
No
1.20 New or diverted transmission lines or
Pipelines?
No
1.21 Impoundment, damming, culverting,
realignment or other changes to the
hydrology of watercourses or aquifers?
No
1.22 Stream crossings? No
1.23 Abstraction or transfers of water form
ground
or surface waters?
Yes Water requirement will be met through GIDC water supply.
1.24 Changes in water bodies or the land
surface
Affecting drainage or run-off?
No
1.25 Transport of personnel or materials for
construction, operation or
decommissioning?
Yes Transportation of personnel or raw material and products will be primarily by road only.
1.26 Long-term dismantling or
decommissioning or restoration works?
No
1.27 Ongoing activity during
decommissioning which could have an
impact on the environment?
No
1.28 Influx of people to an area either
temporarily or permanently?
No
1.29 Introduction of alien species? No
1.30 Loss of native species or genetic
diversity?
No
1.31 Any other actions? No
6
2. Use of Natural resources for construction or operation of the Project (such as land, water, materials or energy, especially any resources which are non-renewable or in short supply):
Sr.
No.
Information/checklist confirmation Yes/No Details thereof (with approximate
quantities /rates, wherever possible)
with source of information data
2.1 Land especially undeveloped or agricultural
land (ha)
No Proposed project activity will be within
GIDC Industrial Area, Panoli, Dist:
Bharuch.
2.2 Water (expected source & competing users)
unit: KLD
Yes Water Source: Panoli GIDC Water
Supply
For details please refer Annexure – IV.
2.3 Minerals (MT) No
2.4 Construction material - stone, aggregates,
and / soil (expected source - MT)
Yes Construction materials, like steel,
cement, crushed stones, sand, rubble,
etc. required for the project shall be
procured from the local market of the
region.
2.5 Forests and timber (source - MT) No.
2.6 Energy including electricity and fuels
(source, competing users) Unit: fuel (MT),
energy (MW)
Yes
FUEL:
Agrowaste = 5 MT/Day
Diesel = 5 Lit/Hr (Emergency case)
ENERGY:
250 KVA (DGVCL)
1 DG Set = 100 KVA (Emergency case)
2.7 Any other natural resources (use
appropriate standard units)
No
3. Use, storage, transport, handling or production of substances or materials, which could be harmful to human health or the environment or raise concerns about actual or perceived risks to human health.
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
3.1 Use of substances or materials, which are
hazardous (as per MSIHC rules) to human
health or the environment (flora, fauna,
and water supplies)
Yes Please refer Annexure –VIII.
3.2 Changes in occurrence of disease or affect
disease vectors (e.g. insect or water borne
diseases)
No
3.3 Affect the welfare of people e.g. by
changing living conditions?
No
7
3.4 Vulnerable groups of people who could be
affected by the project e.g. hospital
patients, children, the elderly etc.
No
3.5 Any other causes No
4. Production of solid wastes during construction or operation or decommissioning (MT/month)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever
possible) with source of
information data
4.1 Spoil, overburden or mine wastes No
4.2 Municipal waste (domestic and or
commercial wastes)
No
4.3 Hazardous wastes (as per Hazardous Waste
Management Rules)
Yes Please refer Annexure – VI.
4.4 Other industrial process wastes Yes Please refer Annexure – VI.
4.5 Surplus product No
4.6 Sewage sludge or other sludge from
effluent treatment
No
4.7 Construction or demolition wastes No
4.8 Redundant machinery or equipment No
4.9 Contaminated soils or other materials No
4.10 Agricultural wastes No
4.11 Other solid wastes Yes
Please refer Annexure – VI.
5. Release of pollutants or any hazardous, toxic or noxious substances to air (Kg/hr)
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
5.1 Emissions from combustion of fossil fuels
from stationary or mobile sources
Yes Please refer Annexure – VII.
5.2 Emissions from production processes Yes Please refer Annexure – VII.
5.3 Emissions from materials handling storage
or transport
No
5.4 Emissions from construction activities
including plant and equipment
No
5.5 Dust or odours from handling of
materials including construction
materials, sewage and waste
No
8
5.6 Emissions from incineration of waste No
5.7 Emissions from burning of waste in open
air e.g. slash materials, construction
debris)
No
5.8 Emissions from any other sources Yes Please refer Annexure – VII.
6.Generation of Noise and Vibration, and Emissions of Light and Heat:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data with
source of information data
6.1 From operation of equipment e.g.
engines, ventilation plant, crushers
Yes The Noise level will be within the
prescribed limit. At noisy areas
adequate preventive & control
measures will be taken. No significant
noise, vibration or emission of light &
heat from the unit.
6.2 From industrial or similar processes Yes -Do-
6.3 From construction or demolition No
6.4 From blasting or piling No
6.5 From construction or operational traffic No
6.6 From lighting or cooling systems No
6.7 From any other sources No
7. Risks of contamination of land or water from releases of pollutants into the ground or into sewers, surface waters, groundwater, coastal waters or the sea:
Sr.
No.
Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates, wherever possible)
with source of information data
7.1 From handling, storage, use or spillage of
hazardous materials
Yes Please refer Annexure – VIII.
7.2 From discharge of sewage or other
effluents to water or the land (expected
mode and place of discharge)
Yes For details please refer Annexure – V.
7.3 By deposition of pollutants emitted to air
into the and or into water
No
7.4 From any other sources No
9
7.5 Is there a risk of long term build up of
pollutants in the environment from these
sources?
No
8. Risk of accidents during construction or operation of the Project, which could affect human health or the environment
S.No. Information/Checklist confirmation Yes/No Details there of (with approximate
quantities/rates,wherever possible)
with source of information data
8.1 From explosions, spillages, fires etc from
storage, handling, use or production of
hazardous substances
Yes Please refer Annexure – VIII.
8.2 From any other causes No
8.3 Could the project be affected by natural
disasters causing environmental damage
(e.g. floods, earthquakes, landslides,
cloudburst etc)?
No
9. Factors which should be considered (such as consequential development) which could lead to environmental effects or the potential for cumulative impacts with other existing or planned activities in the locality
Sr. No.
Information/Checklist confirmation
Yes/No
Details there of (with approximate
quantities / rates, wherever
possible) with source of
information data
9.1 Lead to development of supporting.
utilities, ancillary development or
development stimulated by the project
which could have impact on the
environment e.g.
• Supporting infrastructure (roads,
power supply, waste or waste water
treatment, etc.) • housing development • extractive industry • supply industry • other
Yes Please refer Annexure – IX.
9.2 Lead to after-use of the site, which
could have an impact on the
environment
No
9.3 Set a precedent for later developments No
9.4 Have cumulative effects due to
proximity to other existing or planned
projects with similar effects
No
10
(II) Environmental Sensitivity
Sr.
No.
Areas Name/
Identity
Aerial distance (within 15 km.)
Proposed project location boundary
1 Areas protected under international
conventions, national or local legislation for
their ecological, landscape, cultural or other
related value
No Proposed project site is within the GIDC
Industrial Estate, Panoli.
2 Areas which important for are or sensitive
Ecol logical reasons - Wetlands,
watercourses or other water bodies, coastal
zone, biospheres, mountains, forests
No
3 Area used by protected, important or
sensitive.Species of flora or fauna for
breeding, nesting, foraging, resting, over
wintering, migration
No No protected area or sensitive species
within 15 km from the proposed project
boundary.
4 Inland, coastal, marine or underground
waters
No River Narmada – 13.7 kms
5 State, National boundaries No N.A.
6 Routes or facilities used by the public for
access to recreation or other tourist, pilgrim
areas
Yes Public transportation
7 Defense installations Yes Ankleshwar
8 Densely populated or built-up area Yes Panoli village 3.5 km and Ankleshwar City
around 4.0 km from the proposed project
site.
9 Area occupied by sensitive man-made land
uses Hospitals, schools, places of worship,
community facilities)
No
10 Areas containing important, high quality or
scarce resources (ground water resources,
surface resources, forestry, agriculture,
fisheries, tourism, minerals)
No
11 Areas already subjected to pollution
environmental damage. (those where
existing legal environmental standards are
exceeded)or
Yes Ankleshwar
12 Areas susceptible to natural hazard which
could cause the project to present
environmental problems (earthquake ,
subsidence ,landslides, flooding erosion, or
extreme or adverse climatic conditions)
No NA
IV). Proposed Terms of Reference for EIA studies:Please refer Annexure - X
11
I hereby given undertaking that, the data and information given in the application and
enclosures are true to the best of my knowledge and belief and I am aware that if any
part of the data and information submitted is found to be false or misleading at any
stage the project will be rejected and clearance give, if any to the project will be revoked
at our risk and cost.
Date: 22/6/2017
Place: GIDC Panoli
Signature of applicant
NOTE:
1. The projects involving clearance under Coastal Regulation Zone Notification, 1991 shall
submit with the application a C.R.Z. map duly demarcated by one of the authorized agencies,
showing the project activities, w.r.t. C.R.Z. (at the stage of TOR) and the recommendations of
the State Coastal Zone Management Authority (at the stage of EC). Simultaneous action shall
also be taken to obtain the requisite clearance under the provisions of the C.R.Z. Notification,
1991 for the activities to be located in the CRZ.
2. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere
Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map
duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project
location and the recommendations or comments of the Chief Wildlife Warden thereon (at the
stage of EC).
3. All correspondence with the Ministry of Environment & Forests including submission of
application for TOR/Environmental Clearance, subsequent clarifications, as may be required
from time to time, participation in the EAC Meeting on behalf of the project proponent shall
be made by the authorized signatory only. The authorized signatory should also submit a
document in support of his claim of being an authorized signatory for the specific project.
12
LIST OF ANNEXURES
SR. NO. NAME OF ANNEXURE
I List of Products and Raw materials along with their Production Capacity
II Layout Map of the Plant
III Brief Manufacturing Process Description
IV Details of water consumption & waste water generation
V Details of Effluent Treatment Scheme
VI Details of Hazardous Waste Generation and Disposal
VII Details of Stacks and Vents, Fuel & Energy Requirements
VIII Details of Hazardous Chemicals Storage & Handling
IX Socio-economic Impacts
X Proposed Terms of Reference
13
ANNEXURE - I
____________________________________________________________________________
LIST OF PRODUCTS ALONG WITH THEIR PRODUCTION CAPACITY WITH RAW MATERIALS
SR.
NO. PROPOSED PRODUCTS CAS NO.
PRODUCTION
CAPACITY
(MT/MONTH)
1 1,4-di bromo Butane , 99% 110-52-1
50
2 1-(4-fluoro phenyle piperazine) , 99% 2252-63-3
3 1-benzylepiperazine 2759-28-6
4 N,N-Bis 2-chloro ethyle amine 821-48-7
5 Cyclo propyl methyl ketone 765-43-5
6 Chlorozoxanone 95-25-0
7 Aceclofenac 89796-99-6
8 Fluconazole 86386-73-4
9 Niclosamide 50-65-7
10 1-(4- Methoxyphenyl)-1-(4-nitrophenyl)
piperazine 74852-61-2
11 1-(4-Methoxyphenyl) piperazine
38212-30-5
12 6-Methyl pyridine-3 yl-2,4-Methylsulfonyl
phenyl Etanone (Ketosulfone)
221615-75-4
13 4 Bromo methyl 2 Cyano biphenyl (Bromo
OTBN) 114772-54-2
Total 50
14
LIST OF RAW MATERIAL
Sr.
No. Proposed Product Raw material Capacity(MT/MONTH)
[1] 1,4-Di bromo Butane,
99%
1,4-Butanediol 20.87
Hydrobromic acid (48%) 78.06
Toluene 50.00
[2] 1-(4-fluoro phenyle
piperazine) ,99%
4-Fluoroaniline 30.82
Bis(2-
Chloroethylamine)hydrochloride 49.51
Isopropyl alcohol 57.50
Potassium carbonate 200.00
[3] 1-benzylepiperazine Benzyl chloride 35.91
Piperazine 24.43
Toluene 50.00
Sodium hydroxide 11.34
[4] N,N-Bis 2-chloro ethyle
amine Diethanol amine 30
Thionyl chloride 34
Hydrochloric acid 11
Ammonium hydroxide 12.5
Toluene 200
[5] Cyclo propyl methyl
ketone 5-chloro-2-pentanone 83
Caustic Lye 85.5
[6] Chlorozoxanone 4-Chloro-2- Amino Phenol 47.5
Urea 47.5
Hydrochloric acid 102
Methanol 150
Activated Carbon 5.5
Sulphuric acid 5
Acetic acid 25
Sodium Hydrosulphite 2.5
15
[7] Aceclofenac Chloro Acetyl Chloride 27.5
Tertiary Butyl Alcohol 18
Dimethyl Aniline 32.5
Soda Ash 0.5
Caustic Lye 48% 22.5
Diclofenac Sodium 51.5
Formic Acid 35.5
Toluene 51.5
[8] Fluconazole 1,2,4-Trizole 26
Potassium Hydroxide 37.5
Tri Methyl Sulfonium Iodide 26
Di-floro acetophenone 58
Toluene 19.5
CP HCL 41.5
MDC 78
Citric acid 1.5
Carbon 3
Hyflow 1
[9] Niclosamide Xylene 142.86
Ortho Chloro Para Nitro Aniline 25.71
Thionyl Chloride 19.29
5-Nitro Salicyclic Acid 25.00
[10] 1-(4- Methoxyphenyl)-
1-(4-nitrophenyl)
piperazine
1-(4-Methyxy) Piperazine 32.82
Para Nitro Chlorobenzene 26.89
Potassium Carbonate 29.12
Dimethyl Formamide 38.33
Methanol 76.77
Acetone 77.68
Carbon 0.64
[11] 1-(4-Methoxyphenyl)
piperazine 4-Methoxy Aniline 57.47
Bis HCL-65% (As 100%) 102.59
16
Caustic Lye-48% 22.99
Sodium Carbonate 11.49
Sodium Hydrosulfite 1.44
Charcoal 0.57
HCL Solution-30% 20.69
[12] 6-Methyl pyridine-3 yl-
2,4-Methylsulfonyl
phenyl Etanone
(Ketosulfone)
4-Methyl Thiophenyl
Acetonitrile 32.00
Toluene 48.00
Sodium Methoxide 16.00
Methyl 6 Methyl Nicotinate 29.60
Methanol 30.00
Sodium Tangustate 0.60
Hydrogen Peroxide 32.00
Conc. Sulfuric Acid 1.00
[13] 4 Bromo methyl 2
Cyano biphenyl (Bromo
OTBN)
OTBN 45.45
Bromine 22.73
Methylene Dichloride 295.45
Hydrogen Peroxide (30%) 37.27
4-Bromo Methyl 2-
Cyanobiphenyl (Bromo OTBN) +
MDC
370.45
Ethyl Acetate 113.64
17
ANNEXURE - II
___________________________________________________________________________
LAYOUT OF MAP OF THE PLANT
18
1,4-ButanediolHydrobromic acid 1,4-Dibromobutane Water
H2O
Toluene
azeotropic
distillationHO OH HBr Br Br
ANNEXURE - III
___________________________________________________________________________
MANUFACTURING PROCESS, CHEMICAL REACTION & MASS BALANCE
[1] 1,4-Dibromobutane
MANUFACTURING PROCESS:
1,4-Butanediol is reacted with hydrobromic acid (48%) in the presence of an organic solvent
such as toluene at reflux temp and slowly remove water by azeotropically distillation
contineously till end of reaction. After completion of the raction distilled out solvent. The
final product 1,4-Dibromobutane is dried under vaccum to remove traces of moisture.
CHEMICAL REACTION:
MASS BALANCE:
Input Qty in kg
Output Qty in kg
1,4-Butanediol 8.347 1,4-Dibromobutane 20.000
Hydrobromic acid (48%) 31.223 Water (from acid & rxn.) 19.570
Solvent (Toluene) 20.000 Solvent (Toluene) 20.000
Total 59.570 Total 59.570
Note: Water generated during the process is as good as distilled water, because in the
process water is removed by azeotropic distillation.
19
4-Fluoroaniline Bis(2-chloroethyl Pottasium 1-(4-Fluorophenyl) piperazine Pottasium Water
amine)HCl carbonate Chloride
F NH2 NH.HCl
Cl
Cl
K2CO3
Isopropyl aclohol
80 deg C for 12 hrs.
N NHF KCl H2O
[2] 1-(4-Fluorophenyl) Piperazine
MANUFACTURING PROCESS:
4-Fluoroaniline is reacted with Bis(2-chloroethylamine)HCl in the presence of an organic
solvent such as IPA & pottasium carbonate at 80 °C for 12 hours to give 1-(4-
Fluorphenyl)pierazine and pottasium chloride. Reaction continue till no more carbon dioxide
is evolved. The by product pottasium chloride is filltered off in pure form (while water
generated during reaction/neutralization will be retained by the wet cake of pottasium
chloride which will be lost during drying). Filltrate taken for distillation to remove the
solvent. The final1-(4-Fluorphenyl)piperazine, 99% is dried under vaccum to remove traces
of moisture/solvent.
CHEMICAL REACTION
MASS BALANCE:
Input Qty in kg
Output Qty in kg
4-Fluoroaniline 3.082 1-(4-Fluorophenyl) piperazine 5.000
Bis(2-Chloroethylamine) HCl 4.951 Potassium chloride 6.203
Potassium carbonate 5.750 Water 0.750
Isopropyl alcohol 20.000 Carbon dioxide 1.830
Isopropyl alcohol 20.000
Total 33.783 Total 33.783
Note: Water generated during the process will be retained by the wet cake of the
potassium chloride which will be lost during the drying.
20
Benzyl chloride Piperazine Sodium hydroxide 1-Benzylpiperazine Sodium chloride Water
CH2Cl HN NHNaOH CH2 N NH NaCl H2O
Toluene70 deg C
[3] 1-Benzylpiperazine
MANUFACTURING PROCESS:
Benzylchloride is reacted with piperazine in the presence of an organic solvent such as
toluene at 70 °C for 8 hours to give 1-Benzylpiperazine hydrochloride. Hydrochloride salt of
the 1-Benzylpiperazine neutralise with sodium hydroxide to give 1-Benzylpiperazine, sodium
chloride and water. The by product sodium chloride is filltered off in pure form (while water
generated during neutralization will be retained by the wet cake of sodium chloride which
will be lost during drying). After filtration organic layer taken for distillation to remove the
solvent. The final product (1-Benzylpiperazine) is dried under vaccum to remove traces of
moisture.
CHEMICAL REACTIONS:
MASS BALANCE:
Input Qty in kg
Output Qty in kg
Benzyl chloride 7.182 1-Benzylpiperazine 10.000
Piperazine 4.886 Sodium chloride 3.314
Solvent (toluene) 10.000 Water 1.022
Sodium hydroxide 2.268 Solvent (toluene) 10.000
Total 24.336 Total 24.336
Note: Water generated during neutralization will be retained by the wet cake of sodium
chloride which will be lost during drying
21
[4] Bis (2-Chloroethyl) Amine Hydrochloride
MANUFACTURING PROCESS:
Stage-1
Di ethanol amine undergoes chlorination with Thionyl chloride in presence of Toluene and
Methanol to give Bis (2-chloroethyl) amine Hydrochloride.
CHEMICAL REACTIONS:
MASS BALANCE:
22
[5] Cyclopropyl Methyl Ketone
MANUFACTURING PROCESS:
5-chloro-2-pentanone is reacted with Caustic Lye (48%) in aqueous medium, cyclization
occurs to form crude CPMK which is further distilled out to get pure cyclopropyl methyl
ketone.
CHEMICAL REACTIONS:
H2O
C5H9ClO + NaOH ----------> C5H8O + NaCl + H2O
5-chloro-2- Caustic Lye cyclopropyl Sodium Water
pentanone methyl ketone Chloride
MASS BALANCE:
Input Qty in
Kg
Output
Qty in
Kg
5-chloro-2-pentanone 1.66 Cyclopropyl Methyl Ketone 1.0
Caustic Lye 48% 1.71 Water 1.63
Water 0.5 Sodium Chloride 1.20
Residue 0.04
Total 3.87 Total 3.87
23
[6] Chlorzoxazone
PROCESS DESCRIPTION:
Charge Urea, Acetic acid and Hydrochloric acid with 4-Chloro-2- Amino Phenol In the reactor
and heat up to 95 0C and maintain for 1 hr. Check TLC then centrifuge crude material at 30
0C, then wash with water till neutral pH.Add Charcoal and heat to reflux for 2 hr at 55 0C
Filter hot through Sparker, collect clear filtrate in crystallizer.Collect clear filtrate in
crystallizer and keep temp 45 0C in crystallizer. Wash sparklers carbon bed with Acetone
and transfer it to crystallizer.Add Hydrose with water then fast add DM Water 15 minutes at
70 0C. Slowly cool to 400C.Apply chilling and chill the material up to 10 oC and maintain for
1 hrs.Centrifuge the material at 10 0C and collect for Acetone Recovery.Wash the cake with
DM water till chloride free, unload material and dry at 90 0C, check LOD and unload from
dryer.
CHEMICAL REACTION:
24
MASS BALANCE:
Input Qty in
Kg
Output
Qty in
Kg
4-Chloro-2- Amino Phenol (4CAP) 0.95 Recoered Methanol 2.85
Urea 0.95 Methanol Loss 0.15
Hydrochloric acid 2.04 ML to ETP (Spent Acid) 2.5
Methanol 3.00 Chlorzoxazone 1.00
Activated Carbon 0.11 Effluent to ETP 1.2
Sulphuric Acid 0.10
Acetic acid 0.50
Sodium Hydrosulphite 0.05
Total 7.7 Total 7.7
25
[7] Aceclofenac
PROCESS DESCRIPTION:
Charge N Dimethyl Amine , Tertiary Butyl Alcohol stirr 1/2 Hrs & unload in clean drum,again
charge Chloro Acetyl Chloride in same reactor chill to 8-10OC.Add mix solution of NNDMA +
T Butanol at 8-10 OC addition time 8-10hrs. Maintain 5 hrs at 8-10 OC, slowly raise Temp up
to 35 OC.Charge water, stirr 1.0 Hr & settle, seperate organic layer from bottom aqueous
layer for NN DMA recovery, organic Layer charge in GLR add water, stirring & separate
bottom organic to give soda ash solution wash to make ph 8.5 to 9.5. Stirr & separate in
organic layer, charge sodium sulphate & filter through 5 Micron cloth. Collect all organic in
GLR and Distilled out product at 85 to 105 OC under vacuum.Charge Reaction mass from
Step 2 with crude Diclofenac Sodium, heat the reaction mass to 80-85 OC, maintain 5 Hrs
and cool to 55 to 60 OC, charge formic acid heat to 48 to 55 OC maintain 8 hrs check TLC,
cool to 40 OC, charge water and Toluene stirring 2 Hrs Centrifuge wash with water.
centrifuge and Unload cake & Dry.
CHEMICAL REACTION:
MASS BALANCE:
26
[8] Fluconazole
PROCESS DESCRIPTION:
Stage-1
To Di-floro acetophenone material, 1,2,4-trizole, Toluene and TMSI is added slowly and the
mass is maintained for about 4 hours, Adjust pH with KOH flakes and kept under
maintenance at 65o-68
oC,Cool to 5
oC and centrifuge, washed with Toluene.The wet material
is charged in to SS tray drier. The Material is air dried for 1 hour and then at 450C to 50
0C
with steam. Drying is continued till LOD content is less than 0.5% w/w. Dried material is
unloaded and taken for next stage of purification.
Stage 2
The stage I material is taken in a reactor and treated with MDC, Citric acid adjust the pH 3.5
with HCL and charcoal and filtered. The filtrate is distilled to remove MDC and the mother
liquor is collected to recover the MDC and the wet material is dried.
CHEMICAL REACTION:
PROCESS FLOW DIAGRAM:
27
MASS BALANCE:
28
29
[9] Niclosamide
PROCESS DESCRIPTION:
Charge xylene in reactor and then add 5 nitro salicyclic acid at room temperature.This is stir
for 1 hour and chilled to 10 C. then slowly charge thionyl chloride at 15° and maintain for 3
hours
Then slowly charge ortho chloro para nitro aniline then stir for 6 hours at 85C. then cooled
to room temperature and centrifuged
ML is collected and recycled. Then extra water is drained to ETP and product is dried and
packed.
CHEMICAL REACTION:
30
MASS BALANCE:
31
[10] 1-(4- Methoxyphenyl)-1-(4-nitrophenyl) piperazine
PROCESS DESCRIPTION:
Charge dimethyl formamide, potassium carbonate and 1-(4-Methyxy) piperazine into a
reactor. Heat the mass to 60-65°C. Add para nitro chloro benzene for 3-4 hours at same
temperature. After completion of the reaction distill off the dimethyl formamide
completely. Cool the mass and charge methanol add carbon into the reactor. Maintain the
mass for 30 minutes at 50-55°C and filter into another reactor. Cool the filtrate to 10-15°C
and centrifuge. Wash the material in water. Slurry wash the cake with acetone to produce 1-
(4- Methoxyphenyl)-1-(4-nitrophenyl) piperazine.
CHEMICAL REACTION:
MASS BALANCE:
32
Process flow chart:
33
[11] 1-(4-Methoxyphenyl) piperazine
PROCESS DESCRIPTION:
1) 100g of p-aminophenol is taken in a mixture of 280 ml water and 180 ml water and 168 g
Bis (2- Chloroethylamine) hydrochloride added. (Actually Bis HCl solution of 65% strength is
used and water adjusted accordingly)
2) At reflux and under nitrogen 106 ml caustic lye solution is added over 9 hr maintaining pH
between 6-6.1.
3) Sodium hydrosulfite is added to decolorize the reaction mass to pale yellow color.
4) After maintaining for 2 hrs, methanol 100 ml is added and stirred for 1 hr. The acetate
salt that precipitates out is filtered and washed with methanol.
5) The above acetate salt is taken in 500ml water and soda ash solution prepared separately
by dissolving 30 g in 150 ml water, is added gradually to bring pH to around 8-8.2.
6) After maintaining at pH 8-8.2 for around 1 hr the pH of the solution is shifted to 5-5.5
using dil HCl and maintained for 0.5 hr.
7) The M1 crude obtained is centrifuged, washed with water and then with methanol.
8) M1 crude is purified by charcoal treatment in a mix of 3:2 methanol water solution (for
100g K3 crude, 500 ml of methanol- water mix is required). pH is first adjusted to 5-5.5,
sodium hydrosulfite added to decolorize, 10 % active charcoal added and refluxed. After 1
hr the solution is filtered hot and sodium hydrosulfite solution added to decolorize the
pinkish color filtrate. The white to light pink colored filtrate is cooled under Nitrogen
atmosphere and filtered to give pure M1. The cake is washed with methanol and dried in
oven at 45-50o C.
CHEMICAL REACTION:
34
Process flow chart:
MASS BALANCE:
35
[12] 6-Methyl pyridine-3 yl-2,4-Methylsulfonyl phenyl Etanone (Ketosulfone)
PROCESS DESCRIPTION:
Charged 4-Methyl thiophenyl acetonitrile in toluene in Reactor at RT.Charged Sodium
Methoxide powder in above reaction mixture slowly at RT.Charged Methyl 6 methyl
nicotinate in RM and was heated and stirred. Add water in above reaction mass.
The reaction mixture was heated and stirred. Now cool the reaction mass.
The separated solid was filtered.
Charged methanol and above solid in Reactor at RT
Cool the reaction mass and add Sulfuric Acid and Sodium Tangustate
Slowly add hydrogen peroxide under stirring with cooling
Cool the reaction mass and separate the wet cake by filtration. Dry the Product
CHEMICAL REACTION:
36
Process Flow diagram:
MASS BALANCE:
Input Qty in
Kg
Output Qty in
Kg
4 Methyl thiophenyl acetonitrile 160 Finished Product 250
Toluene 240 Toluene (Recd) 215
Sodium Methoxide 80 Distillation+ Drying Loss 105
Methyl 6 methyl nicotinate 148 Residue 3
Water 500 Effluent 873
Methanol 150
Sodium Tangustate 3
Hydrogen Peroxide 160
Conc. Sulfuric Acid 5
Total 1446 Total 1446
37
[13] 4 Bromo methyl 2 Cyano biphenyl (Bromo OTBN)
PROCESS DESCRIPTION:
4 Methyl 2 Cyanobiphenyl is Brominated in Presence of Hydrogen Peroxide to get 4 Bromo
Methyl 2 Cyanobiphenyl.The 4-Bromo Methyl Biphenyl is given Ethyl Acetate washings and
subjected to Drying.4 Bromo Methyl Biphenyl is then packed in 50 Kg PPE Bags.
CHEMICAL REACTION:
MASS BALANCE:
38
Annexure -4
___________________________________________________________________________
Details of Water Consumption and Wastewater generation
Water Consumption and Wastewater generation:
S.No. Usage
Water Consumption
(KL/Day)
Waste Water Generation
(KL/Day)
Proposed Proposed
1. Domestic 1.0 0.8
2. Gardening 1.0 --
3. Industrial
4. Process 8.3 9.0
5. Boiler 3.0 0.2
6. Cooling (Make-up) 3.0 0.3
7. Washing 0.5 0.5
8. Sub-Total: Industrial 14.8 10.0
9. Grand Total 16.8 10.8
39
Water Balance:
All figures are in KL/day
Water – 16.8
Domestic- 1.0 Gardening- 1.0 Industrial – 14.8
0.8 KL/Day
� Septic
tank/soak
pit
Process- 8.3 Washing- 0.5 Boiler-3.0 Cooling- 3.0
Process- 9.0 Washing- 0.5 Boiler- 0.2 Cooling- 0.3
ETP (10.0) CETP for further
treatment
40
Annexure -5:
___________________________________________________________________________
Details of ETP
PROCESS DESCRIPTION: ETP (EFFLUENT TREATMENT PLANT)
M/s. Krishna Chemicals shall have an Effluent treatment plant consisting of primary,
secondary and tertiary treatment units. The effluent confirming to inlet standards of CETP.
The details of ETP are as follows.
First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall be
collected in Collection cum Neutralization tank (CNT-01) where the continuous addition and
stirring of Caustic solution is done to maintain neutral pH of wastewater from Caustic Dosing
Tank (CDT-01) as per requirement by gravity. Mixer is provided at bottom of the CNT-01 to
keep all suspended solids in suspension and for proper mixing.
Then after, neutralized wastewater shall be pumped to Flash Mixer (FM-01). Alum and
Polyelectrolyte shall be dosed from Alum Dosing Tank (ADT-01) and Polyelectrolyte Dosing
Tank (PEDT-01) respectively by gravity into FM-01 to carry out coagulation by using a Flash
Mixer.
Then after, coagulated wastewater shall be settled in Primary Settling Tank (PST-1). Clear
supernatant from PST-01 shall be passed in Aeration Tank (AT-01) Here, biodegradation of
organic matter of the wastewater shall be carried out by bacteria (suspended growth) in the
AT-1 and for that oxygen shall be supplied by 2 nos. of air blowers (B-01) through diffusers.
Air blowers also keep MLSS in suspension. Here, the suspended solids shall be settled and
excess activated sludge shall be sent to Sludge Drying Beds (SDBs-01-A/B). Activated sludge
shall be removed from bottom of SST-1 and pumped to AT-1 to maintain MLSS and
remaining will be sent to SDBs-01-A/B. Nutrients will be added from NDTs to Aeration Tank
for growth of Bacteria. Clear effluent is the collected in of Intermediate Sump (IS) by gravity.
Thereafter, the wastewater shall be passed through Dual Media Filter (DMF-01) to remove
left out TSS. After tertiary treatment, effluent shall be collected in Treated Effluent Sump
(TES) before sent to CETP of M/s. PETL for further treatment.
Sludge settled in PST-01 and excess sludge from SST-01 shall be collected in Sludge Drying
Beds (SDBs-01-A/B) where, dewatering shall be carried out before storage in HWSA and
ultimate disposal to TSDF.
41
CHARACTERISTICS OF WASTEWATER BEFORE & AFTER TREATEMENT.
Sr. No. Parameter Characteristics (mg/L) CETP Intel Norms
(mg/L) Untreated Treated
1 pH 5-6 6.5-8.5 5.0-9.0
2 COD (mg/L) < 8000 < 2500 3200
3 BOD3 (mg/L) < 3500 < 700 1000
4 NH3-N (mg/L) < 50 < 50 50
Effluent Treatment Plant (Dimension):
SIZE OF TANKS
S.N. Name of unit Size (m x m x m) No. MOC/
Remark
Stream Flow 10 KLD
1
Collection cum
Neutralization Tank
(CNT-01)
2.5 m x2.5 m x
(2.0 m+0.5 FB) 1
MOC= RCC
M25+A/A Bk.
Lining
2 Flash Mixer (FM-01) 1.0 m x 0.8 m x
(1.5 m +0.5 FB) 1
MOC= RCC
M25
3 Primary Settling Tank
(PST-01)
1.5 m x 1.0 m x
(1.5 m + 0.5 HB+0.5 FB) 1
MOC= RCC
M25
4 Aeration Tank (AT-1) 4.0 m x 2.0 m x
(4.0 m+0.5 m) 1
MOC= RCC
M25
5 Secondary Settling
Tank(SST-01)
1.5 m x 1.0 m x
(1.5 m + 0.5 HB+0.5 FB) 1
MOC= RCC
M25
6 Intermediate Sump (IS) 1.5 m x 1.0 m x
(2.0 m+0.5) 1
MOC= RCC
M25
7 Dual Media Filter (DMF) 1.0 m3/ hr 1 MOC = FRP
9 Treated Effluent Sump
(TES)
5.0 m x2.5 m x
(2.0 m+0.5 FB) 1
MOC= RCC
M25
10 Sludge Drying Beds 3.0m x 2.0 m 2 MOC= Bk.
42
(SDBs-01-A/B) Maso + PCC
Bedding
RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)
PCC = PLAIN CEMENT CONCRETE
PP = POLYPROPELENE
MSEP = MILD STEEL EPOXY PAINTED
SS = STAINLESS STEEL
43
Flow Diagram:
44
Annexure -6
___________________________________________________________________________
Details of hazardous waste generation, storage & disposal
Type of waste Category Proposed
(MT/Month)
Disposal Method
Discarded
Containers/Bags/
Liners
33.1 200 Nos Collection, Storage, Transportation, reuse/
sale to authorize vendor
Used oil 5.1 10
lit/month
Collection, Storage, Transportation, reuse/
sale to authorize vendor
ETP Sludge 35.1 5
MT/Month
Collection, Storage, transportation and
disposal common TSDF site
Distillation
Residue
20.3 10
MT/Month
Collection, Storage, Transportation and sent
for co-processing in cement industries or
Disposal at common incineration site.
Process Waste -- 5
MT/Month
Collection, Storage, Transportation &
Disposal at TSDF of BEIL, Ankleshwar or
PSWMCL, Panoli.
Spent Carbon 28.3 1.3 Collection, Storage, Transportation &
Disposal at Incinerator Site (BEIL, Ankleshwar)
or sell to cement industry for co-processing.
Inorganic Salt -- 17
MT/Month
Collection, Storage, transportation and
disposal common TSDF site
KCl -- 62
MT/Month
Collection, storage, transportation and sell to
end user.
45
Annexure -7
___________________________________________________________________________
Details of flue gas & proposed pollution control equipment
1. Details of Flue Gas Stack; Stack Attached To Boiler,
2. Details of Process Vent
Sr.
No.
Stack attached
to
Stack
Height
Air Pollution
Control System
Parameter Permissible
Limit
1 Process Vent - 1 11 m Scrubber SO2 40 mg/Nm3
2 Process Vent – 2 11 m Scrubber HCl 20 mg/Nm3
Particulars Fuel Fuel
Quantity
Stack
height
Emission
Norms
APCM
Proposed
Steam Boiler
(Capacity-1.5
MT/Hr)
Agro waste 4 MT/Day 30 m
Particulate matter
<150mg/NM3
SO2 < 100 ppm
NOX < 50 ppm
Multicyclone
Separator, bag
filter
Thermic
Fluid Heater
(Capacity-2
Lakh
Kcal/Hr)
Agro waste 2 MT/Day 30 m Particulate matter
<150mg/NM3
SO2 < 100 ppm
NOX < 50 ppm
Multicyclone
Separator, bag
filter
D.G. Set HSD 5 lit/hr 11 m Particulate matter
<150mg/NM3
SO2 < 100 ppm
NOX < 50 ppm
--
46
Annexure -8
Storage Details of Hazardous Chemicals
Sr.
No.
Raw Materials Storage
Capacity
(MT)
Type of
Storage &
MOC
No. of
Vessel
Vessel
Capacity
(MT)
Type of Hazard
1. Sulfuric acid -98% 6 MS Tank 1
6 Corrosive
2. Hydrobromic acid
(48%)
10 MS Tank 1 10 Corrosive
3. Hydrochloric acid
25 HDPE
Tank
1 25 Corrosive
4. Formic Acid
10 HDPE
Tank
1 10 Toxic/Flammable
5 Acetic Acid 5 Drums
(HDPE)
25 200 lit Corrosive
6 Toluene 2 Drums 10 200 lit Toxic
7 Isopropyl alcohol 2 Drums 10 200 lit Toxic/Flammable
8 Methanol 2 Drums 10 200 lit Toxic
9 Tert Butyl Alcohol 2 Drums 10 200 lit Flammable
10 Xylene 2 Drums 10 200 lit Toxic/Flammable
11 Dimethyl
Formamide
2 Drums 10 200 lit Toxic/Flammable
12 Acetone 2 Drums 10 200 lit Toxic/Flammable
13 Ethyl Acetate 2 Drums 10 200 lit Toxic/Flammable
14 Benzyl Chloride 2 Drums 10 200 lit Toxic/Flammable
15 Thionyl Chloride 2 Drums 10 200 lit Toxic
16 MDC 2 Tank 10 200 lit Toxic
17 Bromine 300 kg Bottle 100 3 kg Toxic
47
Annexure – 9
Socio - Economic Impacts
1) Employment Opportunities
The manpower requirement for the proposed expansion project is being expected to
generate some permanent jobs and secondary jobs for the operation and maintenance of
plant. This will increase direct / indirect employment opportunities and ancillary business
development to some extent for the local population.
This phase is expected to create a beneficial impact on the local socio-economic
environment.
2) Industries
Required raw materials and skilled and unskilled laborers will be utilized maximum from the
local area. The increasing industrial activity will boost the commercial and economical status
of the locality, to some extent.
3) Public Health
The company regularly examines, inspects and tests its emission from sources to make sure
that the emission is below the permissible limit. Hence, there will not be any significant
change in the status of sanitation and the community health of the area, as sufficient
measures have been taken and proposed under the EMP.
4) Transportation and Communication
Since the existing factory is having proper linkage for the transport and communication, the
development of this project will not cause any additional impact.
In brief, as a result of the proposed there will be no adverse impact on sanitation,
communication and community health, as sufficient measures have been proposed to be
taken under the EMP. The proposed scenario is not expected to make any significant change
in the existing status of the socio - economic environment of this region.
48
Annexure-10
__________________________________________________________________________
Proposed Terms of Reference for EIA Studies
1. Project Description
• Justification of project.
• Promoters and their back ground
• Project site location along with site map of 5 km area and site details providing various
industries, surface water bodies, forests etc.
• Project cost
• Project location and Plant layout.
• Existing infrastructure facilities
• Water source and utilization including proposed water balance.
• List of Products & their capacity
• Details of manufacturing process of proposed products
• List of hazardous chemicals
• Mass balance of each product
• Storage and Transportation of raw materials and products.
2. Description of the Environment and Baseline Data Collection
• Micrometeorological data for wind speed, direction, temperature, humidity and rainfall
in 10 km area.
• Existing environmental status Vis a Vis air, water, noise, soil in 10 km area from the
project site.
• Ground water quality at 8 locations within 10 km.
• Complete water balance
3. Socio Economic Data
• Existing socio-economic status, land use pattern and infrastructure facilities available in
the study area were surveyed.
4. Impacts Identification And Mitigatory Measures
• Identification of impacting activities from the proposed project during construction and
operational phase.
• Impact on air and mitigation measures including green belt
• Impact on water environment and mitigation measures
• Soil pollution source and mitigation measures
• Noise generation and control.
• Solid waste quantification and disposal.
• Control of fugitive emissions
5. Environmental Management Plan
• Details of pollution control measures
• Environment management team
• Proposed schedule for environmental monitoring including post project
49
6. Risk Assessment
• Objectives, Philosophy and methodology of risk assessment
• Details on storage facilities
• Process safety, transportation, fire fighting systems, safety features and emergency
capabilities to be adopted.
• Identification of hazards
• Consequence analysis
• Recommendations on the basis of risk assessment done
• Disaster Management Plan.
7. Information for Control of Fugitive Emissions
8. Information on Rain Water Harvesting
9. Green Belt Development plan
50
Annexure-11
__________________________________________________________________________
GIDC Plot Allotment Letter
51
52
Annexure-12
__________________________________________________________________________
GIDC Water Supply Letter
53
Annexure-13
__________________________________________________________________________
CETP Membership Letter
54
Annexure-14
__________________________________________________________________________
BEIL's Common TSDF & CHWIF membership Certificate
55
Annexure-15
__________________________________________________________________________
Toposheet