gujarat dyestuff industries (pharma unit) e c s

ENVIRONMENTAL IMPACT ASSESSMENT

FOR

EXISTING – BULK DRUGS, PROPOSED EXPANSION –

ETHOXYLATES, METFORMIN & OTHER ORGANIC PRODUCTS

SYNTHETIC ORGANIC CHEMICALS INDUSTRY UNDER SCHEDULE - 5(f)

Gujarat Dyestuff Industries

(Pharma Unit)

PLOT NO. 133/4, 133/5, 133/6, GIDC NANDESARI, NANDESARI, AND DIST: VADODARA-391340

E C S

CONSULTANTS

ECO-CARE SOLUTIONS 306-307 DWARKESH COMPLEX, SUN PHARMA-ATLADARA ROAD.

VADODARA-390020, GUJARAT, INDIA

Gujarat Dyestuff Industries (Pharma Unit) Table of Contents

Rapid Environmental Impact Assessment Report 1

EXECUTIVE SUMMARY ....................................................................................................................................................11

INTRODUCTION: ...................................................................................................................................................................11

PURPOSE OF STUDY & REGULATORY FRAMEWORK ......................................................................................................11

PRODUCT DETAILS ..............................................................................................................................................................11

PROJECT COST ......................................................................................................................................................................13

SITE LOCATION ....................................................................................................................................................................13

POWER REQUIREMENT: .....................................................................................................................................................14

FUEL & EMISSIONS: ............................................................................................................................................................14

PROCESS EMISSIONS: ..........................................................................................................................................................14

WATER & WASTE WATER ENVIRONMENT ....................................................................................................................14

HAZARDOUS WASTE ...........................................................................................................................................................15

ENVIRONMENTAL MANAGEMENT ....................................................................................................................................16

JUSTIFICATION OF SELECTING THE PROPOSED PRODUCT & UNIT SIZE. ......................................................................16

TOR COMPLIANCES ...........................................................................................................................................................17

STANDARD - TOR COMPLIANCES ...............................................................................................................................18

CHAPTER – 1: INTRODUCTION ....................................................................................................................................29

1.1 PURPOSE OF STUDY & REGULATORY FRAMEWORK ...............................................................................................29

1.2 IDENTIFICATION OF THE PROJECT AND PROJECT PROPONENT ............................................................................29

1.3 PROJECT BRIEF: ............................................................................................................................................................30

1.4 NATURE AND SIZE OF THE PROJECT .........................................................................................................................32

1.5 PROJECT COST ..............................................................................................................................................................33

1.6 SITE LOCATION .............................................................................................................................................................33

1.7 INDIAN POLICIES REQUIRING REIA ..........................................................................................................................38

1.8 THE REIA CYCLE & PROCEDURES ............................................................................................................................38

1.9 SCOPE OF THE EIA STUDY ..........................................................................................................................................38

1.10 APPLICABLE ENVIRONMENTAL REGULATIONS & STANDARDS .........................................................................39

1.11 STRUCTURE OF EIA REPORT ...................................................................................................................................39

CHAPTER – 2: PROJECT DESCRIPTION .....................................................................................................................40

2.1 TYPE OF PROJECT & CAPACITY ..................................................................................................................................40

2.2 NEED FOR REIA ...........................................................................................................................................................40

2.3 COST OF THE PROJECT .................................................................................................................................................41

2.4 PROJECT LOCATION & SURROUNDING AREA...........................................................................................................41

2.5 APPROACH TO SITE ......................................................................................................................................................41

2.6 PLANT LAYOUT .............................................................................................................................................................45

2.7 MAGNITUDE OF THE PROJECT ....................................................................................................................................46

2.7.1 Details of Products ....................................................................................................................................................... 46

2.8 RAW MATERIAL STORAGE & HANDLING .................................................................................................................48

2.9 SOLVENT RECOVERY ....................................................................................................................................................66

2.10 METHODOLOGY FOR ZLD ........................................................................................................................................67

2.10.1 Details of UF-RO Plant ............................................................................................................................................. 67

2.10.2 Details of MEE Plant ................................................................................................................................................. 69

2.11 TECHNOLOGY / PROCESS DESCRIPTION ................................................................................................................70

2.11.1 Mass Balance................................................................................................................................................................ 70

2.12 PLANT INFRASTRUCTURE AND BASIC REQUIREMENTS ................................................................................... 122



2.12.1 Land................................................................................................................................................................................ 122

2.12.2 Plant Equipment/Machineries .......................................................................................................................... 122

2.12.3 Details of Utilities ..................................................................................................................................................... 125

2.12.4 Power Requirement ................................................................................................................................................ 126

2.12.5 Fuel ................................................................................................................................................................................. 126

2.12.6 Water ............................................................................................................................................................................. 126

2.12.7 Manpower ................................................................................................................................................................... 127

2.13 SOURCE OF POLLUTION & ITS MANAGEMENT ................................................................................................... 127

2.13.1 Waste Water Generation& its management ............................................................................................... 127

2.13.1.1 Details of wastewater generation with qualitative and quantitative analysis .. 131

2.13.1.2 Treatment Methodology .......................................................................................................... 131

2.13.1.3 Effluent treatment scheme ..................................................................................................... 133

2.13.2 Air Pollution and Control System ..................................................................................................................... 136

2.13.2.1 Details of Scrubber ..................................................................................................................... 137

2.13.3 Hazardous Waste Generations and Disposal System .............................................................................. 138

2.13.4 Noise Level and Control System ........................................................................................................................ 139

2.13.5 Soil................................................................................................................................................................................... 139

2.14 STATUS OF APPLICABLE RULES, ACTS, REGULATION: ..................................................................................... 140

2.15 PROPOSED SCHEDULE FOR APPROVAL AND IMPLEMENTATION .................................................................... 140

CHAPTER – 3: BASELINE ENVIRONMENTAL STATUS .................................................................................... 141

3.1 INTRODUCTION .......................................................................................................................................................... 141

3.2 METHODOLOGY ......................................................................................................................................................... 141

3.2.1 Study Period & Frequency of Sampling ............................................................................................................ 141

3.2.2 Method of Environmental Sampling & Analysis ........................................................................................... 142

3.2.3 Baseline Environmental Status ............................................................................................................................ 143

3.3 MICROMETEOROLOGY .............................................................................................................................................. 143

3.3.1 Temperature Details ................................................................................................................................................. 143

3.3.2 Relative Humidity (RH) ............................................................................................................................................ 143

3.3.3 Rainfall ............................................................................................................................................................................ 144

3.3.4 Wind Speed .................................................................................................................................................................... 144

3.3.5 Temperature, Relative Humidity & Wind Speed .......................................................................................... 145

3.3.6 Wind Rose ....................................................................................................................................................................... 145

3.4 AIR ENVIRONMENT ................................................................................................................................................... 147

3.4.1 Summary ......................................................................................................................................................................... 151

3.5 NOISE ENVIRONMENT .............................................................................................................................................. 151

3.6 WATER ENVIRONMENT............................................................................................................................................ 152

3.6.1 Methodology for Water Quality Monitoring .................................................................................................. 152

3.6.2 Baseline Ground water quality ............................................................................................................................. 156

3.6.3 Baseline Surface Water Quality ........................................................................................................................... 156

3.7 LAND ENVIRONMENT ............................................................................................................................................... 156

3.7.1 Soil Quality ..................................................................................................................................................................... 156

3.7.2 Summary of Soil Quality .......................................................................................................................................... 158

3.8 GEOLOGICAL & HYDROLOGICAL DATA ................................................................................................................ 158

3.8.1 Method of Preparation ............................................................................................................................................. 158



3.8.2 Description of Geological Classification & Area Under Different Formations ............................... 158

3.8.3 Geological Map ............................................................................................................................................................ 158

3.9 LAND USE PATTERN ................................................................................................................................................. 159

3.9.1 Method of Data Preparation ................................................................................................................................. 159

3.10 TOPOSHEET ............................................................................................................................................................. 162

3.11 ECOLOGICAL INFORMATION ................................................................................................................................. 162

3.11.1 Flora ............................................................................................................................................................................... 164

3.11.2 Fauna ............................................................................................................................................................................. 165

3.12 SOCIO - ECONOMIC ENVIRONMENT ..................................................................................................................... 165

3.12.1 Demography ............................................................................................................................................................... 165

3.12.2 Literacy Rate .............................................................................................................................................................. 169

3.12.3 Occupational Structure ......................................................................................................................................... 170

3.12.4 Amenities ..................................................................................................................................................................... 171

CHAPTER – 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ................. 174

4.1 GENERAL..................................................................................................................................................................... 174

4.2 DETAILS OF ANTICIPATED ENVIRONMENTAL IMPACTS DUE TO PROJECT LOCATION, PROJECT DESIGN, PROJECT

CONSTRUCTION, REGULAR OPERATIONS OF A PROJECT. (IMPACT ASSESSMENT MATRIX) ...................... 175

4.3 ASSESSMENT OF SIGNIFICANCE OF IMPACTS (CRITERIA FOR DETERMINING SIGNIFICANCE, ASSIGNING

SIGNIFICANCE) & MITIGATION MEASURES ...................................................................................................... 175

4.4 OVERALL IMPACTS .................................................................................................................................................... 181

4.4.1 Impact on Air Environment ................................................................................................................................... 182

4.4.1.1 Fugitive emission .......................................................................................................................... 182

4.4.2 Ambient Air Quality Modelling ............................................................................................................................. 183

4.4.2.1 Details of Air Dispersion Model ............................................................................................... 183

4.4.2.2 Presentation of Result: ................................................................................................................ 184

4.4.3 Impact on Water Environment ............................................................................................................................ 195

4.4.4 Impact on Land/Soil Environment ..................................................................................................................... 195

4.4.5 Impact on Noise Levels ............................................................................................................................................. 196

4.4.6 Impact on Socio-Economy ...................................................................................................................................... 196

4.5 IRREVERSIBLE & IRRETRIEVABLE COMMITMENTS OF ENVIRONMENTAL COMPONENTS ............................. 197

4.6 INCREMENTAL CONCENTRATION ........................................................................................................................... 197

CHAPTER – 5: ANALYISIS OF ALTERNATIVES.................................................................................................... 199

5.1 ANALYSIS OF ALTERNATIVES .................................................................................................................................. 199

5.2 BEST AVAILABLE TECHNOLOGIES .......................................................................................................................... 200

CHAPTER –6: ENVIRONMENTAL MONITORING PROGRAM ......................................................................... 201

6.1 INTRODUCTION .......................................................................................................................................................... 201

6.2 IMPLEMENTATION ARRANGEMENT ....................................................................................................................... 201

6.3 ENVIRONMENTAL ASPECTS TO BE MONITORED .................................................................................................. 201

6.3.1 During Construction Stage ..................................................................................................................................... 202

6.3.2 During Operation Phase .......................................................................................................................................... 202

6.3.2.1 Ambient Air Monitoring Within Plant Area........................................................................ 202

6.3.2.2 Effluent Monitoring ...................................................................................................................... 202

6.3.2.3 Work Zone Noise Levels ............................................................................................................. 202

6.3.2.4 Ambient Noise ................................................................................................................................ 203

6.3.2.5 Solid / Hazardous Waste Disposal ......................................................................................... 203



6.3.2.6 Green Belt Development ............................................................................................................ 203

6.3.2.7 House Keeping ................................................................................................................................ 203

6.4 ENVIRONMENTAL MONITORING PLAN .................................................................................................................. 204

6.5 DOCUMENTS & RECORDS ......................................................................................................................................... 204

6.6 BUDGETARY PROVISIONS FOR ENVIRONMENTAL PROTECTION MEASURES ................................................... 205

6.7 UPDATING OF EMP ................................................................................................................................................... 205

CHAPTER – 7: RISK ASSESSMENT ............................................................................................................................ 206

7.1 RISK ASSESSMENT..................................................................................................................................................... 206

7.1.1 Introduction .................................................................................................................................................................. 206

7.1.2 Objective ......................................................................................................................................................................... 206

7.1.3 Approach to the Study .............................................................................................................................................. 206

7.2 QUANTITY OF HAZARDOUS CHEMICALS ................................................................................................................ 206

7.3 LIST OF HAZARDOUS CHEMICALS ALONG WITH THEIR TOXICITY LEVEL AS PER MSIHC RULES ................ 208

7.4 MSDS OF ALL THE PRODUCTS & RAW MATERIALS ............................................................................................ 212

7.5 HAZARD IDENTIFICATION & PREVENTIVE MEASURES ....................................................................................... 212

7.5.1 Process hazards and controls ............................................................................................................................... 212

7.5.2 General Hazards & Controls .................................................................................................................................. 213

7.6 FIRE & SAFETY .......................................................................................................................................................... 213

7.6.1 Safety Measures to be provided ........................................................................................................................... 214

7.6.2 Provisions for Human Health Hazards & Work Place ............................................................................... 215

7.7 LEAK DETECTION & REPAIR (LDAR) ................................................................................................................... 215

7.7.1 Following Methodology of LDAR Program will be followed: ................................................................. 215

7.7.2 Following shall be done to Prevent Leaks: ...................................................................................................... 216

7.7.3 Following shall be done in case of Spills: ......................................................................................................... 216

7.8 INFORMATION ON SOLVENT STORAGE AREA AND ASSOCIATED REACTORS .................................................... 217

7.9 ON SITE EMERGENCY PLAN .................................................................................................................................... 217

7.9.1 Purpose: .......................................................................................................................................................................... 217

7.9.2 PESO Permission: ........................................................................................................................................................ 217

7.10 WORST CASE SCENARIO ...................................................................................................................................... 217

7.10.1 Scope: ............................................................................................................................................................................. 217

7.11 CHECKLIST - DO’S & DON’TS FOR HANDLING OF CHEMICALS, WORKING IN CHEMICAL LABORATORY, WORKING ON MACHINES, MAINTAINING GOOD HOUSEKEEPING, WORKING ON HEIGHT, WORK IN

CONFINED SPACE, FIRE PREVENTION, IN CASE OF FIRE ............................................................................... 217

7.12 SOCIAL IMPACT ASSESSMENT R&R ACTION PLANS ......................................................................................... 223

7.13 MITIGATION MEASURES FOR SEEPAGE & SOIL CONTAMINATION ................................................................. 223

7.14 CHEMICAL SPILLAGE CONTROL MEASURES ....................................................................................................... 223

CHAPTER – 8: PROJECT BENEFITS .......................................................................................................................... 224

8.1 INTRODUCTION .......................................................................................................................................................... 224

8.2 ECONOMICAL BENEFITS ........................................................................................................................................... 224

8.3 SOCIO ECONOMIC DEVELOPMENT OF THE REGION ............................................................................................. 224

8.4 UN-SKILLED MANPOWER ........................................................................................................................................ 224

8.5 SOCIO ECONOMIC DEVELOPMENT ASPECTS ......................................................................................................... 225

CHAPTER – 9 ENVIRONMENTAL COST BENEFIT ANALYSIS ........................................................................ 226

CHAPTER – 10 ENVIRONMENTAL MANAGEMENT PLAN .............................................................................. 228

10.1 BACKGROUND .......................................................................................................................................................... 228



10.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN ................................................................................. 228

10.3 COMPONENTS OF EMP .......................................................................................................................................... 228

10.4 ORGANOGRAM OF ENVIRONMENTAL MANAGEMENT CELL ............................................................................. 229

10.4.1 Reporting system on non compliances/violations of Environmental Laws.................................. 230

10.5 ENVIRONMENT MANAGEMENT DURING CONSTRUCTION PHASE .................................................................. 230

10.6 ENVIRONMENT MANAGEMENT DURING OPERATION PHASE. ......................................................................... 231

10.6.1 Air Environment ....................................................................................................................................................... 231

10.6.1.1 Fugitive emission ........................................................................................................................ 232

10.6.1.2 VOC Monitoring Plan ................................................................................................................. 233

10.6.2 Water Environment ................................................................................................................................................ 233

10.6.2.1 Economical and Technical Viability of the Effluent Treatment System ............... 233

10.6.3 Hazardous Waste Management ........................................................................................................................ 234

10.6.3.1 Storage of Hazardous Waste: ................................................................................................. 234

10.6.3.2 Transportation of Hazardous Waste: ................................................................................. 234

10.6.3.3 Disposal of Hazardous Waste: ............................................................................................... 234

10.6.3.4 Methodology of Decontamination of drums/containers ........................................... 235

10.6.4 Noise Environment .................................................................................................................................................. 235

10.6.5 Odour Control Plan ................................................................................................................................................. 236

10.7 OCCUPATIONAL HEALTH & SAFETY .................................................................................................................... 237

10.8 GREEN BELT DEVELOPMENT ............................................................................................................................... 238

10.8.1 Plants / Trees Should be Selected for Green Belt Area ........................................................................... 238

10.9 RAIN WATER HARVESTING .................................................................................................................................. 239

10.10 CLEANER PRODUCTION....................................................................................................................................... 240

10.11 FLORA & FAUNA .................................................................................................................................................. 240

10.12 CAPITAL COST FOR ENVIRONMENTAL MANAGEMENT .................................................................................. 240

10.13 PREVENTION OF STORM WATER CONTAMINATION. ..................................................................................... 241

CHAPTER – 11 SUMMARY & CONCLUSION .......................................................................................................... 242

11.1 INTRODUCTION ....................................................................................................................................................... 242

11.2 LOCATION OF THE PROJECT .................................................................................................................................. 242

11.3 PRODUCT & CAPACITY........................................................................................................................................... 242

11.4 COST OF THE PROJECT ........................................................................................................................................... 244

11.5 BASELINE ENVIRONMENTAL ANALYSIS .............................................................................................................. 244

11.5.1 Ambient Air Quality ................................................................................................................................................ 244

11.5.2 Water Quality ............................................................................................................................................................ 245

11.5.3 Noise level .................................................................................................................................................................... 245

11.5.4 Soil Quality .................................................................................................................................................................. 246

11.6 ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES ........................................................ 246

11.6.1 Water Requirement, Waste Water Generation and Treatment: ....................................................... 246

11.6.2 Air Pollution source and Mitigation measure ............................................................................................ 246

11.6.3 Hazardous Waste Generations and Disposal .............................................................................................. 247

11.6.4 Noise Level and Mitigation Measure ............................................................................................................... 247

11.6.5 Soil & Geology ............................................................................................................................................................ 247

11.6.6 Impacts on Socio Economy & Mitigation measures: ................................................................................ 247

11.7 GREEN BELT: ........................................................................................................................................................... 248



11.8 ENVIRONMENTAL MONITORING PROGRAMME ................................................................................................. 248

11.9 ENVIRONMENTAL MANAGEMENT PLAN ............................................................................................................. 248

11.10 ADDITIONAL STUDIES ......................................................................................................................................... 248

11.11 PROJECT BENEFITS .............................................................................................................................................. 249

11.12 CONCLUSION ......................................................................................................................................................... 249

CHAPTER 12: DISCLOSURE OF CONSULTANTS ENGAGED ........................................................................... 250

12.1 DISCLOSURE OF CONSULTANT .............................................................................................................................. 250

Gujarat Dyestuff Industries (Pharma Unit) List of Tables


LIST OF TABLES

TABLE 1.1 PRODUCT DETAILS .....................................................................................................................................32

TABLE 2.1 BREAK-UP OF PROJECT COST ................................................................................................................41

TABLE 2.2 AREA CALCULATION FOR EXISTING & PROPOSED STRUCTURES .........................................46

TABLE 2.3 PRODUCT PROFILE .....................................................................................................................................46

TABLE 2.4 MEANS OF TRANSPORTATION OF RAW MATERIALS AND PRODUCTS ...............................48

TABLE 2.5 PHYSICAL & CHEMICAL PROPERTIES OF THE RAW MATERIAL & PRODUCTS ...............50

TABLE 2.6 STORAGE DETAILS ......................................................................................................................................65

TABLE 2.7 DETAILS OF PLANT MACHINERIES .................................................................................................. 122

TABLE 2.8 DETAILS OF UTILITIES ........................................................................................................................... 125

TABLE 2.9 FUEL STORAGE DETAILS ....................................................................................................................... 126

TABLE 2.10 FUEL SOURCE & TRANSPORTATION DETAILS ......................................................................... 126

TABLE 2.11 DETAILS OF WATER CONSUMPTION &W/W GENERATION ............................................... 128

TABLE 2.12 CHARACTERISTICS OF WASTEWATER ........................................................................................ 131

TABLE 2.13 ANALYSIS RESULTS AFTER CHEMICAL TREATMENT (LIME + ALUM): ......................... 131

TABLE 2.14 ANALYSIS RESULTS AFTER SECONDARY / BIOLOGICAL TREATMENT ......................... 131

TABLE 2.15 ANALYSIS AFTER TERTIARY TREATMENT ................................................................................ 131

TABLE 2.16 FINAL REDUCTIONS AFTER TREATMENT .................................................................................. 132

TABLE 2.17 FINAL REDUCTIONS AFTER TREATMENT .................................................................................. 132

TABLE 2.18 DETAILS OF ETP (NAME OF UNIT & CAPACITY) ...................................................................... 133

TABLE 2.19 DETAILS OF STACKS ............................................................................................................................. 136

TABLE 2.20 DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL ..................................... 138

TABLE 3.1 FREQUENCY OF ENVIRONMENTAL MONITORING .................................................................... 142

TABLE 3.2 METHOD OF ENVIRONMENTAL SAMPLING & ANALYSIS ....................................................... 142

TABLE 3.3 TEMPERATURE DATA ............................................................................................................................ 143

TABLE 3.4 RELATIVE HUMIDITY DATA ................................................................................................................ 143

TABLE 3.5 RAINFALL DATA ........................................................................................................................................ 144

TABLE 3.6 WIND SPEED DATA .................................................................................................................................. 144

TABLE 3.7 SITE SPECIFIC METEOROLOGICAL DATA (PERIOD: OCTOBER 2018 TO DECEMBER, 2018) ............................................................................................................................................................ 145

TABLE 3.8 LOCATIONS OF THE AMBIENT AIR, NOISE, WATER AND SOIL ............................................ 149

TABLE 3.9 AMBIENT AIR QUALITY STATUS (OCTOBER, 2018 TO DECEMBER, 2018) .................... 149

TABLE 3.10 BACKGROUND NOISE LEVELS .......................................................................................................... 152

TABLE 3.11 GROUND & SURFACE WATER QUALITY ....................................................................................... 153

TABLE 3.12 PHYSICO-CHEMICALS CHARACTERISTICS OF SOIL ................................................................ 157

TABLE 3.13 LIST OF FLORA ........................................................................................................................................ 164

TABLE 3.14 LIST OF FAUNA ....................................................................................................................................... 165

TABLE 3.15 DEMOGRAPHIC DATA .......................................................................................................................... 166

TABLE 3.16 POPULATION DENSITY........................................................................................................................ 168

TABLE 3.17 LITERACY RATE ...................................................................................................................................... 169

TABLE 3.18 OCCUPATIONAL STRUCTURE ........................................................................................................... 170

TABLE 3.19 DETAILS OF AMMENITIES AVAILABLE IN STUDY AREA ...................................................... 172

TABLE 4.1 IMPACT IDENTIFICATION MATRIXES ............................................................................................. 175

TABLE 4.2ENVIRONMENTAL IMPACT ASSESSMENTS ................................................................................... 176

Gujarat Dyestuff Industries (Pharma Unit) List of Tables


TABLE 4.3 FLUE GAS STACK EMISSION RATES.................................................................................................. 184

TABLE 4.4. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF PM, (µG/M3) ......................... 186

TABLE 4.5. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF SO2, (µG/M3) .................... 189

TABLE 4.6. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF NO2, (µG/M3) ................... 192

TABLE 4.7 MAXIMUM GLCS FROM THE DISPERSION MODEL ..................................................................... 195

TABLE 6.1: ENVIRONMENTAL MONITORING PROGRAMME (DURING CONSTRUCTION STAGE) 202

TABLE 6.2 PROJECT ENVIRONMENT MONITORING PLAN ........................................................................... 204

TABLE 6.3 COST OF ENVIRONMENTAL PROTECTION MEASURES ........................................................... 205

TABLE 7.1 STORAGE DETAILS OF RAW MATERIALS ...................................................................................... 207

TABLE 7.2 DETAILS OF HAZARDOUS CHARACTERISTICS OF PRODUCT – PROPOSED PRODUCTS ........................................................................................................................................................................ 208

TABLE 7.3 DETAILS OF HAZARDOUS CHARACTERISTICS OF RAW MATERIALS – PROPOSED PRODUCTS ................................................................................................................................................. 209

TABLE 7.4 TOXICITY INDEX AS PER MSIHC RULE 2000 ................................................................................ 211

TABLE 7.5 PROCESS HAZARDS AND CONTROLS ............................................................................................... 212

TABLE 7.6 GENERAL HAZARDS & CONTROLS .................................................................................................... 213

TABLE 7.7 PROPOSED FIRE EXTINGUISHERS AS PER IS 15683: ................................................................ 214

TABLE 8.1 BUDGETARY PROVISIONS FOR SOCIAL UPLIFTMENT/YEAR ............................................... 225

TABLE 9.1 BUDGET ALLOCATION FOR ENVIRONMENT MANAGEMENT ............................................... 226

TABLE 9.2 ECONOMICAL AND TECHNICAL VIABILITY OF THE EFFLUENT TREATMENT SYSTEM ........................................................................................................................................................................ 227

TABLE 10.1 ENVIRONMENT MANAGEMENT CELL .......................................................................................... 230

230

TABLE: 10.2 CONTROL MEASURES FOR CONSTRUCTION PHASE ............................................................. 230

TABLE 10.3 DETAILS OF AIR EMISSION ................................................................................................................ 232

TABLE 10.4 DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL ..................................... 234

TABLE 10.5 SPECIES PROPOSED TO BE GROWN FOR GREENBELT DEVELOPMENT ....................... 239

TABLE 10.6 BUDGET FOR GREENBELT DEVELOPMENT ............................................................................... 239

TABLE 10.7 BUDGET ALLOCATION FOR ENVIRONMENT MANAGEMENT ............................................ 240

Gujarat Dyestuff Industries (Pharma Unit) List of Maps / Figures


LIST OF MAPS & FIGURES

MAP 1.1 PROJECT LOCATION ON INDIA/GUJARAT MAP ..................................................................................35

MAP 1.2 PROJECT LOCATION ON NANDESARI GIDC MAP ...............................................................................36

MAP 1.3 PROJECT LOCATION ON GOOGLE IMAGE ..............................................................................................37

MAP 2.1 PROJECT SITE INDICATING THE BOUNDARY OF THE SITE ..........................................................42

MAP 2.2 STUDY AREA .......................................................................................................................................................43

MAP 2.3 TOPOSHEET MAP OF THE STUDY AREA ................................................................................................44

FIGURE 2.1 LAYOUT PLAN .............................................................................................................................................45

FIGURE 2.2 UF & RO PLANT ...........................................................................................................................................68

FIGURE 2.3 WATER BALANCE DIAGRAM ............................................................................................................. 129

FIGURE 2.4 FLOW DIAGRAM OF ETP - EXISTING .............................................................................................. 135

FIGURE 2.5 APCM ............................................................................................................................................................ 137

FIGURE 3.1A WIND ROSE DIAGRAM ....................................................................................................................... 146

FIGURE 3.1B STABILITY CLASS DISTRIBUTION ................................................................................................ 146

FIGURE 3.2 LOCATIONS OF THE AMBIENT AIR, NOISE, WATER AND SOIL .......................................... 148

FIGURE 3.3 MAJOR GEOLOGICAL FEATURES ...................................................................................................... 159

FIGURE 3.4 LAND USE / LAND COVER ................................................................................................................... 161

FIGURE 3.5 TOPOSHEET .............................................................................................................................................. 162

FIGURE 3.6 POPULATION DENSITY ........................................................................................................................ 168

FIGURE 3.7 LITERACY DATA ...................................................................................................................................... 169

FIGURE 4.1 WIND ROSE DIAGRAM .......................................................................................................................... 185

FIGURE 4.2 (A) ISOPLETHS MAP FOR PM ............................................................................................................. 187

FIGURE 4.2 (B)ISOPLETHS IN GOOGLE MAP FOR PM ..................................................................................... 188

FIGURE 4.3(A) ISOPLETHS MAP FOR SO2 ............................................................................................................. 190

FIGURE 4.3(B) ISOPLETHS IN GOOGLE MAP FOR SO2 ..................................................................................... 191

FIGURE 4.4(A) ISOPLETHS MAP FOR NO2 ............................................................................................................ 193

FIGURE 4.4(B) ISOPLETHS IN GOOGLE MAP FOR NO2 ................................................................................... 194

Gujarat Dyestuff Industries (Pharma Unit) List of Annexures


List of Annexure

ANNEXURE 1 – TOR LETTER ...................................................................................................................................... 251

ANNEXURE 2 – PLOT ALLOTMENT LETTER FROM GIDC .............................................................................. 252

ANNEXURE 3 – RISK ASSESSMENT REPORT ....................................................................................................... 253

ANNEXURE 4 – EMERGENCY MANAGEMENT PLAN ........................................................................................ 254

ANNEXURE 5 – UNDERTAKING ................................................................................................................................. 255

ANNEXURE 6 – SAFETY AUDIT ................................................................................................................................. 256

ANNEXURE 7 – MSDS RAW MATERIALS ............................................................................................................... 257

ANNEXURE 8 – MSDS FINISHED PRODUCTS ....................................................................................................... 258

ANNEXURE 9 – LAYOUT PLAN FACTORY PREMISES ....................................................................................... 259

ANNEXURE 10 – DETAILS OF CETP NANDESARI .............................................................................................. 260

ANNEXURE 11 – WATER SUPPLY LETTER FROM GIDC ................................................................................. 261

ANNEXURE 12 – MEMBERSHIP FOR HAZARDOUS WASTE .......................................................................... 262

ANNEXURE 13 – HON. HIGH COURT STAY ORDER ........................................................................................... 263

ANNEXURE 14 – MOEF CERTIFED COMPLIANCE REPORT ........................................................................... 264

ANNEXURE 15 – SOP INDEX ....................................................................................................................................... 265

ANNEXURE 16 – CETP NANDESARI PERMISSION FOR DISPOSAL OF TREATED EFFLUENT ......... 266

ANNEXURE 17 – PROJECT IMPLEMENTATION SCHEDULE .......................................................................... 267

ANNEXURE 18 – XGN GENERATED REPORTS .................................................................................................... 268

ANNEXURE 19 – ADEQUACY OF EXISTING EMS ................................................................................................ 269

ANNEXURE 20 – COPY OF EXISTING EC ................................................................................................................ 270

ANNEXURE 21 –BASELINE DATA CERTIFICATE ............................................................................................... 271

ANNEXURE 22 –EXISTING PESO LICENSE ............................................................................................................ 272

ANNEXURE 23 –PLI COPY ............................................................................................................................................ 273

ANNEXURE 24 –COPY OF CTE & CTO ..................................................................................................................... 274

ANNEXURE 25 – TRAFFIC SURVEY .......................................................................................................................... 275

Gujarat Dyestuff Industries (Pharma Unit) Executive Summary


EXECUTIVE SUMMARY

Introduction:

M/s. Gujarat Dyestuff Industries (Pharma Unit). located at Plot No. 133/4, 133/5, 133/6, GIDC

Nandesari, Dist: Vadodara-391340., Gujarat.

This is an existing unit into manufacturing of Bulk Drugs such as Cifixime Trihydrate, Cefuroxime

Axetil, Cefpodoxime Proxetil, Ampicilin, Amoxicillin Trydrydate, Clobetasole Propionate,

Betamethasone Dipropionate, Betamethasone Valerate, Betamethasone Sodium Phosphate,

Dexamethasone Sodium Phosphate, Beclomethasone Dipropionate, Mometasone Furoate,

Methylcobalamine, Ofloxacin, Levofloxacin, Quinon Sulphate, Cloxacillin Sodium, Oxacillin Sodium,

Di Cloxacillin Sodium, Flucoxacillin Sodium.

New products Ethoxylates, Metformin Hydrochloride, and additional Methylcobalamine that falls in

Schedule 5(f) are planned to be manufactured and hence the application for EC is being done.

Purpose of Study & Regulatory Framework

Environmental Impact Assessment Report has been prepared for obtaining Environmental Clearance

for M/s. Gujarat Dyestuff Industries (Pharma Unit). Located at Plot No. 133/4, 133/5, 133/6, GIDC

Nandesari, Dist: Vadodara-391340., State: Gujarat, India for Manufacturing of Synthetic Organic

Chemicals Category 5(f) and is included category of the Environmental Impact Assessment

Notification, issued in September-2006 and subsequent amendments. The industry is located within

the notified industrial area/estate GIDC Nandesari and therefore as per NGT Order dated 23.08.2019

in the matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara it will fall in

category “A” of the Environmental Impact Notification requiring Environmental Clearance from

MoEF, New Delhi.

This is a “Existing Unit manufacturing Bulk Drugs”.

Product Details

The proposed products will be.

Product details

The New Product falls under Project activity5(f), Category A NGT Order dated 23.08.2019 in the matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara

Sr. no.

Name of the Products CAS no. / CI no.

Quantity MT/Month*

End-use of the products

Existing (Products)

Proposed (Products)

1 CIFIXIME TRIHYDRATE or 79350-37-1 10 0 Used for manufacturing

of Antibiotic drug

formulation.

2 CEFUROXIME AXETIL or 64544-07-6 3 CEFPODOXIME PROXETIL or 87239-81-4 4 AMPICILIN or 69-53-4 20 0

5 AMOXICILLIN TRYDRYDATE or 61336-70-7 20 0

6 CLOBETASOLE PROPIONATE or

25122-46-7 0.5 0 Used for manufacturing of Steroid drug

formulation. 7 BETAMETHASONE

DIPROPIONATE or 5593-20-4 0.5 0

8 BETAMETHASONE VALERATE or

2152-44-5 0.5 0



9 BETAMETHASONE SODIUM PHOSPHATE or

151-73-5 0.5 0

10 DEXAMETHASONE SODIUM PHOSPHATE or

2392-39-4 0.5 0

11 BECLOMETHASONE DIPROPIONTE

4419-39-0 0.5 0

12 MOMETASONE FUROATE or 105102-22-5 0.5 0 13 METHYLCOBALAMINE or 13422-55-4 0.5 0.5 Used for

manufacturing of vitamin B-12

formulation. 14 OFLOXACIN or 82419-36-1 20 0 Used for

manufacturing of Antibiotic

drug formulation.

15 LEVOFLOXACIN or 100986-85-4 20 0 16 QUINON SULPHATE or 6119-70-6 20 0 17 CLOXACILLIN SODIUM or 7081-44-9 20 0 18 OXACILLIN SODIUM or 1173-88-2 20 0 19 DI CLOXACILLIN SODIUM or 7081-44-9 20 0 20 FLUCOXACILLIN SODIUM or 1847-24-1 20 0 21 ETHOXYLATES A POLYETHYLENE GLYCOL or 25322-68-3 0 1000 Manufacturing

in agro emulsifier,

cosmetics, soap, detergent,

textile

B HYDROGENATED CASTOR OIL or

8001-78-3 0

C CASTOR OIL ETHOXYLATES or 61791-12-6 0 D NONYL PHENOL

ETHOXYLATES or 68412-53-3 0

E OCTYL PHENOL ETHOXYLATES or

68987-90-6 0

F CARD PHENOL ETHOXYLATES or

37330-39-5 0

G STYRUNATED PHENOL ETHOXYLATES or

61788-44-1 0

H LAURYL ALCOHOL ETHOXYLATES or

68439-50-9 0

I TRIDECYL ALCOHOL ETHOXYLATES or

24938-91-8 0

J CESTOSTYRYL ALCOHOL ETHOXYLATES or

68439-49-6 0

K TALLOW ALCOHOL ETHOXYLATES or

37335-03-8 0

L STEARYL AMINE ETHOXYLATES or

26635-92-7 0

M COCO AMINE ETHOXYLATES or 61791-14-8 0 N OLEYL AMINE ETHOXYLATES

or 90367-28-5 0

O POLY SORBATE ETHOXYLATES or

9005-64-5 0

P STEARIC ACID ETHOXYLATES or

9009-90-9 0

22 METFORMIN HYDROCHLORIDE

1115-70-4 0 500 Used for manufacturing of diabetic drug

formulation. Total 20 1500.5



Project Cost

Gujarat Dyestuff Industries (Pharma Unit). shall spend Approximately Rs. 50 Lac for Existing

Products & Rs. 109 Lac for proposed Product as capital expenditure on environmental management.

With a total of 159 lac.

The recurring cost could be Approximately Rs. 15.5 Lac per annum for Existing Products & Rs. 96.5

lac for proposed Product. With a total of 112 lac/annum.

Break-up of Project Cost

Particulars Amount in INR

(crore)

Existing

Amount in INR

(crore)

Proposed

Amount in INR

(crore)

Total

Land 1.0 - 1.0

Factory Building 0.50 0.50 1.0

Plant & Machineries 1.0 2.50 3.50

Other Assets 1.50 1.00 2.50

Total 4.0 4.0 8.0

Site Location

The site is located at Plot No. 133/4, 133/5, 133/6, GIDC Nandesari, Dist: Vadodara-391340.

Vadodara district lies in the Eastern part of the Gujarat.

Other locational details are as follows:

The site is located:

o The site is located Approximately 14.0 km in North West of Vadodara city.

o Approximately 106 km South East of Ahmedabad.

o Nandesari Railway Station 1.8Km towards N

o Vadodara Railway Station – 13 Km towards SE

o Vadodara Airport – 15 Km towards SE approximately.

Geographical Location & Area of the Premises are displayed below

o 22°24'6.96"N, 73° 5'50.04"E

o 22°24'4.98"N, 73° 5'54.30"E

o 22°24'0.30"N, 73° 5'49.80"E

o 22°24'4.32"N, 73° 5'46.50"E

Elevation above Mean Sea Level: Approximately 35.5 meters.

Seismic Zone: 3

o The total area of the site Plot No. 133/4, 133/5, 133/6, GIDC Nandesari, is 3691.10

m2 (0.36911 Ha).

Sr No. Description of Area Area (Sq. m.) 1 Building Area (Production plant, Utilities & storage area, ETP) 1965

2 Road & Parking Area 250

4 Green Belt 1476 5 Open Area 0

Total Plot Area 3691



Power Requirement:

Power requirement for the project will be 1600KVA, for proposed product 1000KVA, for existing

Products 600 KVA which is supplied by DGVCL. DG Set of 385 KVA to be installed for backup.

Fuel & Emissions:

Sr. no.

Source of emission

With Capacity

Stack Height

(meter)

Type of Fuel

Quantity of Fuel

MT/Day

Type of emissions

i.e. Air Pollutants

Air Pollution Control

Measures (APCM)

Existing Flue Gas emissions

1 Thermic Fluid Heater

(20 Lac Kcal)

30 F.O / LDO 40 Lit/Hr. PM, SO2, NO2 Caustic Scrubber

Proposed Flue Gas emissions 1 Thermic Fluid

Heater (40 Lac Kcal)

30 Natural Gas 555Nm3/Hr. PM, SO2, NO2 Adequate Stack Height

2 DG Set (385 KVA)

5 HSD 90 Lit/Hr. PM, SO2, NO2 Adequate Stack Height

Process Emissions:

Existing – No Process Emissions

Proposed – No Process Emissions

Water & Wastewater Environment

Water Existing KLD

Proposed (Additional)

KLD

Total after Expansion

KLD

Remarks

(A) Domestic 5 5 10 - (B) Gardening 5 0 5 - (C) Industrial

Process 17 0 17 - Washing 1 3 4 -

Boiler 0 0 0 -- Cooling 10 240 250 -

Others (Scrubber) 0 1 1 -- Industrial Total 28 244 272

Grand Total (A+B+C) 38 249 287 - Recycled 39.6

Fresh Water Required 247.4



Wastewater Existing KLD


KLD


KLD

Remarks

(A) Domestic 4 4 8 Septic Tank & Soak Pit

(B) Industrial Process 18.4 1 19.4 - Washing 1.0 3 4 -

Boiler 0 0 0 -- Cooling 0.6 15 15.6 --

Others (Scrubber) 0 1 1 -- Total Industrial

wastewater 20 20 40 To RO Plant for

Recovery ETP RO Plant Product 20 Reused for Cooling

Tower Makeup ETP RO Plant Reject

Effluent 20 To MEE for

Evaporation. 19.6 KLD Condensate recovered reuse.

Existing Products - 38 KLD, Proposed Products 249 KLD, 40 KLD Treated Effluent from ETP to be

recycled after RO & MEE Plant hence 247.4 KLD fresh water will be used, which will be met through

GIDC Nandesari Industrial Estate water supply (attached as Annexure 11). Out of which, process (17

KLD), cooling tower (250 KLD), boiler (0 KLD), Scrubber (1 KLD), Washing (4 KLD) & Domestic (10

KLD). Total water requirement will be 287 KLD in which 20 KLD Treated Effluent from ETP to be

recycled after RO Plant & 19.6 KLD Condensate from MEE Plant. Hence freshwater requirement will

be 247.4 KLD.

Hazardous Waste

Sr. no

.

Type/Name of

Hazardous waste

Specific Source of generatio

n (Name of

the Activity, Product

etc.)

Category and

Schedule as per

HW Rules.

Quantity (MT/Annum)

Management of HW

Existing Products

Proposed Products

Total After

Expansion

1 ETP Sludge ETP Sch-I/ 35.3

12 MT/Annu

m

0 12 MT/Annu

m

Collection, storage,

treatment, transportation, and disposal at

Nandesari Environment Control Ltd

(NECL) TSDF 2 Discarded

Bags & Containers

Production plant

Sch-I/ 33.1

108 MT/ Annum

0 108 MT/ Annum

Collection storage &

Decontamination within

factory premises.



3 Used Oil From Machinery

and TFH

Sch-I/ 5.1

0.6 KL/Annu

m

0 0.6 KL/Annu

m


transportation, Disposal by

selling to registered re-

refiners 4 Distillation

residues From

Solvent Recovery

Sch-I/ 20.3

36 MT/Annu

m

30 MT/Annu

m

66 MT/Annu

m

CHWIF incinerator

facility of M/s. Nandesari

Environment Control Ltd.

(NECL) / Coprocessing

5 Spent Solvent for

recovery Process

Sch-I/ 20.2

252 MT/Annu

m

4116 MT/Annu

m

4368 MT/Annu

m

Captive In-house

Recovery.

6 MEE Salt

From Evaporatio

n of RO Reject

Sch-I/ 37.3

0 MT/Annu

m

144 MT/Annu

m

144 MT/Annu

m


(NECL) TSDF

Environmental Management

Sr. No.

Description Capital cost (Rs.)

(Lac) Recurring cost (Rs.)

(Lac. /annum) Existing Proposed Total Existing Proposed Total

1 Air pollution

control 6.5 2.5 9 5 1.5 6.5

2 Water pollution

control 33 100 133 4.5 90.5 95

3 Hazardous

waste management 3 2.5 5.5 2.5 1.5 4

4 Environment monitoring & Management 5 3 8 2 1.5 3.5

5 Occupational

health 1 0.5 1.5 0.5 0.5 1

6 Greenbelt

development 1.5 0.5 2 1 1 2 Total 50 109 159 15.5 96.5 112

Justification of selecting the proposed product & unit size.

Existing products are Bulk drugs for manufacturing of Antibiotic Drugs, Steroid formulations, B-12,

& the proposed products i.e. ethoxylates are used for manufacturing of Agro emulsifier, Cosmetics,

Soap, Detergent, Textile, Also the proposed bulk drug Metformin is used for diabetic drug

formulation. These products have a good market demand. Due to the increasing demand we have

selected the products.

Process Effluent Generation during the manufacturing of Ethoxylates and Metformin Hydrochloride

is negligible. Major effluent contribution is Cooling Tower Blowdown & Washing. Existing 20 KLD &

Additional 20 KLD i.e. total of 40 KLD / 60 MTD of product manufactured.

Gujarat Dyestuff Industries (Pharma Unit) ToR Compliances


TOR Compliances

Sr. No. ToR point Compliance status 1. Compliance to MoEFCC’s OM Dated 01/05/2018

regarding “Corporate Environment Responsibility” (CER), Fund allocation for Corporate Environment Responsibility (CER) shall be made as per MoEFCC’s O.M. No 22-65/2017-IA.III dated 01/05/2018 for various activities therein. The details of fund allocation and activities for CER shall be incorporated in the EIA/EMP report.

Chapter 8, Point 8.5, Page 225.

2. Explore the use of renewable energy to the maximum extent possible. Details of provisions to make the project energy efficient through of energy efficient devices and adoption of methods of alternative eco-friendly sources of energy like solar water heater, solar lighting etc. Measures proposed for energy conservation.

Use of Common area Solar Lighting will be done for the proposed expansion. We are evaluating feasibility for use of solar energy.

3. PP Shall address spent solvent with details of storage, handling & re-use under the Hazardous & other waste (Management & Transboundary movement) Rules 2016.

Kindly refer Point 2.9, Chapter-2, Page No 66, Point No 2.13, Page No. 127 - 130.

4. PP Shall furnish status of all the applicable rules, acts, regulation, clearances in a tabular form.

Kindly refer Chapter 2, Point 2.14, Page 140.

5. Leak detection and Repairing Programme (LDAR) for all the volatile organic solvent proposed for use in-house with detailed chemical properties including vapor pressure. LDAR shall endeavor prevention of losses of solvents to the best minimum extent.

Chapter 7, Point 7.7, Page 215-217. Chapter 2, Table 2.5 Page 50.

6. Safety precautions including flame proof electrical electric fittings to be taken to avoid fire hazard during unloading, storage, transportation, handling, and processing of solvents.

Chapter 7, Point 7.5, Page 212-213, Point 7.6 Page 213-215.



Standard - TOR Compliances

Sr. No.

ToR point Compliance status

1. A tabular chart with index for point-wise compliance of below mentioned TORs.

Complied

2. Executive summary of the project – giving a prima facie idea of the objectives of the proposal, use of resources, justification, etc. In addition, it should provide a compilation of EIA report, including EMP and the post project monitoring plan in brief.

Executive Summary Page 11-16. Chapter 6.0, Point 6.4, Page 204.

3. Justification for selecting the proposed product and unit size.

Executive Summary Page 16

4. Land requirement for the project including its breakup for various purposes, its availability and optimization.

Executive Summary Page 13, Chapter 2, Table 2.2 Page 46. No additional land to be procured.

5. Land Possession documents. Copy of NA order showing permission to use the project land for industrial purpose. If located in GIDC, copy of plot holding certificate to be obtained from GIDC Authority.

Copy of plot holding certificate obtained from Nandesari GIDC is given as Annexure-2.

6. Location of the project site and nearest habitats with distances from the project site to be demarcated on a toposheet (1:50000)

Kindly refer pages 159, 161 & 162

7. Topography details of the project area. Chapter 3, Page 160, 161 8. Geological features and geo-hydrological status of the

study area. Chapter 3, Point 3.8, Page 158, 159

9. In case of project located outside notified area: Legal undertaking stating that unit is complying the three conditions, [i.e. water consumption less than 25m3/day, Fuel consumption less than 25 TPD, and not covered in the category of MAH units as per the management, storage, Import of Hazardous Chemicals Rules (MSIHC Rules), 1989] as per the amendment to EIA Notification 2006 vide SO 1599(E) dated 25/06/2014.

Unit is located in the Notified area of Nandesari GIDC.

10. Present land use pattern of the study area shall be given based on satellite imagery.

Refer Chapter No 3, Point 3.9 Page 159- 161.

11. Layout plan of the factory premises clearly demarcating various units within the plant. Provision of separate entry & exit and adequate margin all-round the periphery for unobstructed easy movement of the emergency vehicle / fire tenders without reversing back. Mark the same in the plant layout.

Plant layout is given as figure no. 2.1, Page 45 in chapter 2, Page No 46. Also kindly refer Annexure 9.

12. Technical details of the plant/s along with details on best available technologies (BAT), proposed technology and reasons for selecting the same.

Point no. 5.2 of chapter 5 page no 200. Point 2.12 page 122 – 127.

13. Product spectrum (Proposed products along with production capacity) and processes.

2.7 of chapter 2 page no 46-48.

14. Chemical name of each proposed product to be manufactured. Details on end use of each product. (Provide CAS number of all the products and raw materials. In case of dyes CI number)

Pls. refer Chapter 2, Point No 2.7, table no. 2.3, Page 46-48. Table 2.5, Page 50-64.



Sr. No.


15. Details on raw materials, source and storage within premises.

Refer Table 2.5 & 2.6 Page 50 to 65.

16. Details of manufacturing process / operations of each product along with chemical reactions, process flow diagram describing each unit process and unit operations along with mass balance, consumption of raw materials etc.

Kindly refer chapter 2. Point No 2.11, Page No 70 to 121.

17. Details on strategy for the implementation of cleaner production activities.

Pls. refer section 10.10 of chapter 10 for cleaner production. Page 240.

18. Assessment of source of the water supply with adequacy of the same to meet with the requirements for the project. Permission letter obtained from the concerned authority for supply of raw water.

Source of the water supply is Nandesari GIDC water supply. Water balance diagram is given as figure 2.3 page 129-130 & Table 2.11, Page 126 to 128 of chapter 2. letter from GIDC Nandesari for supply of water is given as Annexure-11.

19. Undertaking stating that no bore well shall be dug within the premises. (If project is located within the industrial estate).

Undertaking stating that no borewell shall be dug within the premises is given as Annexure 5.

20 Details on water balance including quality of effluent generated, recycled and reused. Details of methods to be adopted for water conservation.

Water balance diagram is given as figure 2.3 of chapter 2. Table 2.11, Page 126 to 128. Details of Qualitative and quantitative analysis of the waste stream from the processes is given in section 2.13.1.1-chapter 2 Page 131-135.

21. Efforts to minimize effluent discharge and to maintain quality of receiving water body.

For the proposed products there shall be optimum use of fresh water with evaluation of possibilities wherever to reduce the freshwater consumption. We shall maximize reuse, recover and recycle of the water. The Effluent Treatment Plant will treat the total effluent. Treated Effluent to be passed through RO Plant to recover 50% treated wastewater. 50% of ETP RO Reject to be taken to MEE. MEE Condensate to be recovered.

22. Explore the possibilities for Zero Liquid Discharge (ZLD) option for the proposed project.

40 KLD Treated Effluent to be passed through RO Plant to recover 50% treated wastewater. 50% of ETP RO Reject to be taken to MEE. MEE Condensate to be recovered Hence ZLD will be incorporated.

23. Segregation of waste streams, characterization and quality with specific treatment and disposal of each stream including action plan for maximum recycle of treated wastewater and minimum discharge for effluent.

Pls. refer Chapter 2, section 2.13.1, Page 127, 2.13.1.3 Page 133 to 135 for effluent treatment scheme For Qualitative analysis refer Chapter 2, Point No 2.13.1.1, Page 131-132.

24. Capacity of ETP in KL/Day. Details of ETP including dimensions of each unit along with schematic flow

Pls. refer Chapter 2, section 2.13.1.3, Page 133 to 135 for effluent treatment scheme



Sr. No.


diagram. Inlet, transitional and treated effluent qualities with specific efficiency of each treatment unit in reduction in respect of all concerned/regulated environmental parameters. Inlet effluent quality should be based on worst case scenario considering production of most polluting products that can be manufactured in the plant concurrently.

For Qualitative analysis refer Chapter 2, Point No 2.13.1.1, Page 131-132. For Effluent Treatment Plant tank details refer Chapter 2, Table No 2.18. Point No 2.13.1.3, Page 133-134. Specific efficiency of treatment can be seen from qualitative analysis.

25. In case of discharge into GIDC Drainage / Pipeline 1. Copy of permission letter with quantity

(KL/Day) from the concern authority of drainage network pipeline with conformation for spare capacity available to take additional effluent.

2. Characteristics of the contained effluent and treated water to be sent to common pipeline with reference to the MoEFCC/CPCB/GPCB discharge norms.

3. Provision of continuous monitoring system for wastewater discharge.

Present existing permission from CETP is available for 20KLD. However, we have decided to incorporate ZLD Scheme.

26. In Case of wastewater sent to Common Facilities (CF) like CETP, MEE, Spray Dryer etc.

a. Details of Common facilities including (1) Total Capacity of the CF. (2) Copy of CC&A of the CF. (3) Actual load at present (Qualitative and Quantitative – KL per day). (4) Booked quantity & Spare capacity of CF. (5) Copies of XGN generated Inspection reports with analysis reports of the GPCB in last 2 year and point wise compliance thereof. (6) Copies of Show-Cause notices, closure notices etc. served by the GPCB and its compliance. (6) Recommendations and suggestions of the last two Environment Audit reports of CETP and its compliance report. (7) Common Facility Upgradation scheme if any.

b. Status of compliance to the 18(1) (b) direction issued by the CPCB with respect to CETP compliance & CEPI area action plan along with relevant supportive document.

c. Give status of compliance of Environmental norms of existing Common Infrastructure i.e. CETP, MEE & Spray Dryer (Whichever is applicable) in which you are a member.

d. Submit adequacy of Common Infrastructure i.e. CETP, MEE & Spray Dryer for additional load (Whichever is applicable) along with written conformation/membership certificate mentioning the same (Total consented

Present existing permission from CETP is available for 20KLD. However, we have decided to incorporate ZLD Scheme. For Points 1, 2, 3, 5 - Kindly refer Annexure – 10. For Point 4 - Kindly refer Annexure 16.



Sr. No.


quantity, total quantity booked so far, quantity booked for the unit, spare quantity available).

27. In case of Zero Liquid Discharge (ZLD): I. Action plan for ‘Zero’ Discharge of effluent

shall be included, Notarized undertaking for assuring that underground drainage connection will not be taken in the unit and there shall be no effluent discharge outside the plan premises.

II. Economical and technical viability of the effluent treatment plant system to achieve Zero Liquid Discharge (ZLD).

III. Certification of adequacy of proposed ZLD scheme through credible institutes of National repute.

IV. To estimate & monitor ground water quality & its contamination status, piezometer wells, one on up gradient of the groundwater flow and other three on the down gradient side of the ground water flow of the proposed project at different depth based on available ground water depth shall be established and all the parameters mentioned in IS 10500 for potable water standard shall be mentioned.

Present existing permission from CETP is available for 20KLD. However, we have decided to incorporate ZLD Scheme.

1. For Action Plan of ZLD refer Table 2.11 Page 128 & water balance diagram Fig 2.3 Page 129. Point 2.10 Page 67-68 for details of UF & RO Plant, Point 2.10.2 Page 69 for details of MEE Plant.

2. For viability refer Point 10.6.2 Page No 233.

28. In case of In-house MEE/Spray dryer for wastewater treatment. Capacity of the MEE / Spray Dryer in KL/Hr. Technical details of MEE including evaporation capacity, steam required for evaporation, adequacy of the proposed boiler to supply steam for evaporation in addition to the steam required for the process etc. Techno-economic viability of the evaporation system. Control measures proposed for the evaporation system in order to avoid / reduce gaseous emission / VOC from evaporation of industrial effluent containing solvents & other chemicals.

Spray Dryer not to be installed. For MEE refer point 2.10.2 Page 69. Thermic Fluid to be used for MEE Operation. For viability refer Point 10.6.2 Page No 233. Solvent Recovery plant installed for solvent recovery and avoid evaporation in industrial effluent. For solvent recovery refer point 2.9 Page 66.

29. Technical Details of ATFD/Crystallizer/Spray Dryer, RO/NF system etc. (If any)

ATFD, Crystallizer, Spray Dryer not to be installed. RO Plant to recover 50% of the Treated Effluent will be Installed. 50% Reject will go to MEE Plant. Concentrate of the MEE will go to the ATFD. Refer Point 2.10 Page 67-68 for UF-RO Details.

30. Details of the treatability and feasibility of wastewater to be disposed off by means of spray dryer and its impact on environment & human health.

Treated Wastewater will not be disposed by spray dryer. RO & MEE to be installed. For Qualitative analysis refer Chapter 2, Point No 2.13.1.1, Page 131-132. For



Sr. No.


Effluent Treatment Plant tank details refer Chapter 2, Table No 2.18, Page 133-134.

31. Undertaking stating that a separate electric meter will be provided for the wastewater treatment system viz. ETP, RO, MEE, Spray Dryer etc. (Whichever is applicable)

Undertaking stating that a separate energy meter will be provided for the ETP, RO, MEE is given as Annexure 5.

32. Economical & technical viability of the effluent treatment plant

Pls. refer point 10.6.2.1 of chapter 10, page no 233. Kindly also refer Chapter 9.

33. Plans for management, collection and disposal of waste streams to be generated from spillage, leakages, vessel washing, used container washing etc. Measures proposed for preventing effluent discharge during unforeseen circumstances.

Please refer 7.7.2 & 7.7.3, Page 216-217 of Chapter 7. Kindly refer Chapter 10, Point 10.13 page 241 for prevention of storm water contamination.

34. Action plan for reuse of liquid waste streams like spent acids, Poly Aluminum Chloride etc. within the premises to convert into valuable products instead of sending outside to actual end-users.

There will be no generation of Spent Acids or Byproducts.

35. Adequacy of the proposed EMS with respect to the pollution load envisaged in terms of Air, Water & Hazardous waste.

Kindly refer Point 2.13.1.3, Page 133-134, Point 2.13.2 page 136-137, Point 2.13.3 Page 138-139, Annexure-11 for water supply, Annexure-12 for Membership of Hazardous waste, Annexure-16 for CETP Membership.

36. One season Site-specific micro-meteorological data using temperature, relative humidity, hourly wind speed and direction and rainfall should be incorporated.

Details are covered in section 3.3 of chapter 3. Kindly refer windrose fig 3.1A, Page 146.

37. Anticipated environmental impacts due to the proposed project/production may be evaluated for significance and based on corresponding likely impacts VECs (Valued Environmental Components) may be identified. Baseline studies may be conducted within the study area of 10 km for all the concerned/identified VECs and likely impacts will have to be assessed for their magnitude in order to identify mitigation measures.

Anticipated environment impacts & mitigation measure due to the proposed projects are covered in chapter 4. Pls. refer chapter 3 for baseline monitoring data. Kindly refer chapter 10 Environmental Management.

38. One complete season baseline ambient air quality data (except monsoon) to be given along with the dates of monitoring. The parameters to be covered shall be in accordance with revised national ambient air quality standards as well as project specific parameters like NH3, HCL, Cl2, HBr, VOC etc. Locations of the monitoring stations should be so decided as to take into considerations the pre-dominant downwind direction, population zone & sensitive receptors. There should be at least one monitoring station in the upwind direction. There should be at least one monitoring station in the predominant downwind direction at a location where maximum ground level concentration is likely to occur.

One complete season base line ambient air quality data is covered in section 3.4 of chapter 3, page 147 to 151. Baseline data has been procured from Aqua-Air Environmental Engineers Pvt. Ltd. Surat, for the Period October 2018 to December 2018.



Sr. No.


39. Modeling indicating the likely impact on ambient air quality due to proposed activities. The details of model used, and input parameters used for modeling should be provided. The air quality contours may be shown on location map clearly indicating the location of sensitive receptors, if any, and the habitation. The wind rose showing pre-dominant wind direction should also be indicated on the map. Impact due to vehicular movement shall also be included into the prediction using suitable model. Results of Air dispersion modeling should be superimposed on google map / geographical area map.

Details of Modeling indicating the likely impact on ambient air quality due to proposed activities covered in chapter 4 Air quality contour superimposed on google map/geographical area map is given in figure 4.2(a) & 4.2(b) Page 187-188, Figure 4.3(a) & 4.3(b) Page 190-191, Figure 4.4(a) & 4.4(b) Page 193-194 of chapter 4.

40. Base line status of the noise environment, impact of noise on present environment due to the project and proposed measures for noise reduction including engineering controls.

Pls. refer Section 3.5, Page 151-152 & table no. 3.10 of Page 152 for Baseline noise level status of chapter 3.

41. Specific details of (a) Process gas emission of each unit process with its quantification (b) Air pollution control measures (APCM) for process gas emission. Adequacy of the Air pollution control measures for process gas emission, measures to achieve the GPCB norms. (c) Details of the utility required. (d) Type & quantity (MT/hr. & MT/Day) of fuel to be used for each utility. (e) Flue gas emission rate from each utility. (f) Air pollution control measures proposed to each of the utility along with its adequacy. (g) List the sources of fugitive emission along with its quantification & proposed measures to control it. (h) Details on tail gas treatment. (if any)

Kindly refer Point 2.13.2, Page 136-137. Utilities Point 2.12.3, Page 125-126. Fugitive emission Point 4.4.1.1 page 182, Table 4.3, Page 184.

42. Provision of CEMS (Continuous Emission Monitoring System).

Natural Gas to be used as fuel for the proposed TFH. Hence, we have not considered provision of CEMS. We have considered getting the stack monitoring done by recognized agency at regular intervals.

43. Action plan for odour control to be submitted. Please refer Point 10.6.5, Page 236 of Chapter 10.

44. Management plan for hazardous/solid wastes including storage, handling, utilization and safe disposal as per the Hazardous and Other Wastes (Management & Transboundary Movement) Rules 2016. CPCB guidelines in respect to specific treatment, such as solar evaporation, incineration, etc. Need to be followed.

Pls. refer Point no 2.13.3, Page No 138-139 of chapter 2. Refer point 10.6.3.3, Page 234-235, Point 10.6.3, page 234 to 237.

45. How the manual handling of the hazardous wastes will be minimized? Methodology of de-contamination and disposal of discarded containers and its record keeping.

Point 7.3 Page 212, Methodology of de-contamination and disposal of discarded containers is given in section 10.6.3.4, Page 235 of chapter 10.

46. Management plan for by-products which fall under the perview of the Hazardous and Other Wastes (Management & Transboundary Movement) Rules

No By-products will be generated.



Sr. No.


2016. as per the said rules and necessary permissions from the concerned authority.

47. Membership of Common Environmental Infrastructure including the TSDF / Common Incineration Facility (CHWIF), MEE, Spray Dryer etc.

Kindly refer Annexure 11 for document covering water supply & Annexure 16 for effluent disposal.

48. Name and quantity of each type of solvents to be used for proposed production. Details of in-house solvent recovery system including mass balance, solvent loss, recovery efficiency (% recovery), feasibility of reusing the recovered solvents etc. for each type of solvent.

Kindly refer Table 2.5, Page 50 of Chapter 2. Kindly see Point 2.9 Page 66.

49. Appropriate monitoring network has to be designed and proposed, to access the possible residual impact on VECs.

Anticipated environment impacts & mitigation measure due to the proposed projects are covered in chapter 4.

50. A detailed EMP including the protection and mitigation measures for impact on human health and environment as well as detailed monitoring plan and environmental management cell proposed for implementation and monitoring of EMP. The EMP should also include the concept of waste minimization, recycle/reuse/recover techniques, energy conservation, and natural resource conservation. Total capital cost and recurring cost/annum earmarked for environment pollution control measures.

Detailed EMP is given in separate chapter 10. Environmental Monitoring details are given Point 6.3 & 6.4, Page 201-204 in chapter 6. Total capital cost and recurring cost/annum earmarked for environment pollution control measures is given in table 6.3 page 205 of chapter 6.

51. Details of In-House monitoring capabilities and the recognized agencies if proposed for conducting monitoring.

Monitoring will be got done from Recognized agencies.

52. Permission from (PESO), Nagpur for storage of solvents, other toxic chemicals if any.

Permission attached vide Annexure 22. Layout plan attached vide Annexure 9.

53. Occupational health impacts on the workers and mitigation measures proposed to avoid the human hazards along with the personal protective equipment to be provided. Provision of industrial hygienist and monitoring of the occupational injury to workers as well as impacts to the worker. Plan for periodic medical checkup for the worker exposed. Details of workplace Ambient Air Quality monitoring plan as per Gujarat Factories rules.

Pls. refer point 10.7 page 237, Point 7.5.2 page 213.

54. Details on volatile organic compounds (VOCs) from the plant operations and occupational safety and health protection measures. Proposal for Leak Detection and Repair (LDAR) program as per the CPCB guidelines.

Pls. refer Point 10.6, 10.6.1.2, Page 233 of chapter 10 LDAR vide Point 7.7, Page 215-217,

55. Risk assessment including prediction of the worst-case scenario and maximum credible accident scenario should be carried out. The worst-case scenario should take in to account the maximum inventory of storage at site at any point of time. The risk contour should be plotted on the plant lay out map clearly showing which of the facility would be affected in case of any accident taking place. Based on the same, proposed safeguard measures including on site/off site plans should be provided.

Kindly refer Annexure 3 for Risk Assessment Report.



Sr. No.


56. MSDS of all the products & raw materials Kindly refer Annexure 7 for MSDS of Raw Materials. Kindly refer Annexure 8 for MSDS of Products.

57. Details of hazardous characteristics & toxicity of raw materials & products to be handled & the control measures proposed to ensure safety & avoid the human health impacts. this shall include the details of antidotes also

Kindly refer Annexure 3, Risk Assessment Report, Table 2.5, Page 50-64. Antidotes have been given in MSDS of Raw material & products.

58. Details of quantity of each hazardous chemicals (including solvents) to be stored, material of construction (MOC) of major hazardous chemical storage tanks, dyke details, threshold storage quantity as per schedules of the manufacture, storage & import of hazardous chemicals rules of major hazardous chemicals, size of the biggest storage tanks to be provided for each raw material & product etc. How the manual handling of the hazardous chemicals will be minimized?

Kindly refer Table 2.5, Page 50. Kindly refer Annexure 3, Risk Assessment report. Chapter 7, Point 7.3 Page 208-211. Page 214 for dyke.

59. Details of the separate isolated storage area for flammable chemicals. Details of flame proof electrical fittings, DCP extinguisher & other safety measures proposed. Detailed fire control plan for flammable substances & processes showing hydrant pipeline network, provision of DG Sets, fire pumps, jockey pumps, toxic gas detectors etc.

Point No 7.6, Page 213-215, BAT vide Pls. refer section 7.8 of chapter 7. Point No 7.6, Page 213, Point No 7.6.1, Page 214, Point No 7.7, Page 215-217

60. Submit checklist in the form of Do’s & Don’ts of preventive maintenance, strengthening of HSE, manufacturing utility staff for safety related measures.

Kindly refer Point 7.11 vide Page No 217 to 223.

61. Specify safety precautions to be taken for chemical storage, process, handling and transportation hazard.

Kindly refer Point 7.6 vide Page No 213-215.

62. Details of workers training before engaging work, periodical, in-house, outside etc.

Kindly refer Annexure 15

63. Details of various SOP to be prepared. SOP Index has been attached vide Annexure 15.

64. Details of safety audit to be carried out and their compliance status.

Kindly refer Annexure 6

65. Specific safety measures to be taken for general Public living in the vicinity.

Kindly refer Chapter 7, Point 7.6 page 213-215. Copy of PLI attached vide Annexure 23.

66. Details on hazard identification i.e. HAZOP, HAZEN, Fault Tree analysis, Event tree analysis, Checklist, Audit etc. to be adopted for the safety operation of the plant.

Hazop will be conducted after the design of the plant. Kindly find attached Annexure 4 Emergency

67. Detection and monitoring of VOC’s / gases. Please refer Chapter 6, point 6.4 page 204, Chapter 7, Point 7.6.2, page 215, Chapter 10, Point 10.6.1.2 Page 233.

68. Detailed five-year greenbelt development program including annual budget, planning schedule, species, width of plantation, number of trees to be planted, area under green belt development [with map], budgetary outlay etc. ; along with commitment of the

Please refer Point 10.8 vide Chapter 10. Page 238-239. Kindly refer Annexure 5 for commitment of management for green belt development.



Sr. No.


management to carry out the tree plantation activities outside the premises at appropriate places in the nearby areas and elsewhere.

69. Action plan for greenbelt development – species, width of plantations, planning schedule, etc. in accordance with CPCB published guidelines.

Please refer Point 10.8 vide Chapter 10. Page 238-239. Kindly refer Annexure 5 for commitment of management for green belt development.

70. Detailed socio-economic development measures including community welfare program most useful in the project area for the overall improvement of the environment. Submit a detailed plan for social corporate responsibilities, with appropriate budgetary provisions for the next five years and activities proposed to be carried out; specific to the current demographic status of the area.

Pls. refer point 8.5, page 225 of chapter 8.

71. (a) Does the company have a well laid down Environment Policy approved by its Board of Directors? If so, it may be detailed in the EIA report. (b). Does the Environment Policy prescribe for standard operating process / procedures to bring into focus any infringement / deviation / violation of the environmental or forest norms / conditions? If so, it may be detailed in the EIA.

Kindly refer Chapter 10, Page 230.

72. What is the hierarchical system or administrative order of the company to deal with the environmental issues and for ensuring compliance with the EC conditions? Details of this system may be given.

Pls. refer section 10.4, Page 229-230 of chapter 10.

73. Does the company have a system of reporting of non-compliances / violations of environmental norms to the Board of Directors of the company and / or shareholders or stakeholders at large? This reporting mechanism should be detailed in the EIA Report.

Pls. refer section 10.4.1, page 230 of chapter 10

74. Phase wise project implementation schedule with bar chart and time frame, in terms of development, infrastructure provision, EMS implementation etc.

Kindly find Annexure 17

75. Certificate of accreditation issued by the NABET, QCI to the environmental consultant should be incorporated in the EIA report.

Please refer Annexure 13 for stay order from Hon. High Court

76. An undertaking by the Project Proponent on the ownership of the EIA report as per the MoEF&CC OM dated 5/10/2011 and an undertaking by the consultant regarding the prescribed TORs have been complied with and the data submitted is factually correct as per the MoEF&CC OM dated 04/08/2009.

Please refer Annexure 5 for Undertaking.

77. All Documents to be properly referenced with index and continuous page numbering.

This has been done.

78. Where data are presented in the report especially in Tables, the period in which the data were collected, and the sources should be indicated.

Indicated

79. Project Proponent shall enclose all the analysis / testing reports of water, air, soil, noise etc. using the MoEF&CC/NABL accredited laboratories. All the

Baseline data has been procured from Aqua-Air Environmental Engineers Pvt.



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original analysis/testing reports should be available during appraisal of the project.

Ltd. Surat, for the Period October 2018 to December 2018. Annexure 21.

80. In case of expansion of the project. a. Need for the proposed expansion should be

justified in detail. b. Adequacy of existing EMS (Environmental

management System) c. Explore the Possibility to achieve Zero Liquid

Discharge (ZLD) for existing as well as proposed activity.

d. Records of any legal breach of Environmental laws i.e. details of show-cause notices, closure notices, etc. served by the GPCB to the existing unit in last five years and actions taken then after for prevention of pollution.

e. Copies of Environmental Clearances obtained for the existing plant, its point wise compliance report.

f. Environmental Audit reports for last 3 years and compliance of its recommendations/suggestions. (include latest audit report and its compliance)

g. Copy of Consent to operate (CC&A) obtained along with point wise compliance status of all the conditions stipulated therein.

h. Compliance of MoEFCC circulars vide No: J-11011/618/2010-IAII (I) dated 30/05/2012 and J-11013/41/2006-IA-II(I) dated 20/10/2009.

i. Copies of XGN generated inspection reports with analysis reports of the water/Air/Hazardous samples collected by GPCB (Last 2 year). Copies of instructions issued by GPCB in last 2 year and point wise compliance thereof.

a. Kindly refer Executive Summary

Page 16.

b. Kindly refer Annexure 19.

c. Permission for disposal of 20 KLD Existing + 20 KLD Proposed Treated wastewater to CETP Nandesari available. However, ZLD has been planned.

d. No Notices, Closures etc. received by the unit in last five years.

e. Copy of Environmental Clearance attached vide Annexure 20.

f. Environmental Audit not applicable.

g. CTE & CTO has been attached vide Annexure 24.

h. Copy of compliance attached vide Annexure 14.

i. XGN Generated reports attached vide annexure 18.

81. In case of project is located in Ankleshwar-Panoli, Vatva-Narol & Vapi GIDC.

A. Compliance of MoEFCC’s OM No J-11013/5/2010-IA. II (I) dated 25/11/2016 regarding lifting of moratorium on the consideration of projects for environmental clearance.

B. Compliance of direction under section 18 (1) (b) of the water (Prevention and Control of Pollution) act, 1974 issued by CPCB dated 31/03/2016 regarding compliance of CETP. a. Action initiated by GPCB, if any, against

proposed unit regarding non-compliance of prescribed standards under the various environmental laws.

b. Performance of CETP with respect to current hydraulic load and prescribed

Unit is located at GIDC Nandesari.



Sr. No.


standards with No-Objection Certificate of CETP regarding incorporation of the proposed unit for acceptance of wastewater.

c. Performance of TSDF site with respect to current load & prescribed standards with No Objection Certificate of TSDF site regarding incorporation of the proposed unit for acceptance of hazardous waste to the common infrastructure.

d. Copies of quarterly action report taken for the above points submitted to the CPCB.

e. Report of GPCB which have conducted monitoring as per the said direction by CPCB dated 31/03/2016.

Validity of ToR: • The ToRs prescribed for the project will be

valid for three years for submission of EIA & EMP report.

• The period of validity could be extended for a maximum period of one year provided an application is made by the applicant to the Regulatory Authority, at least three months before the expiry of validity period together with an updated Form-1, based on proper justification and also recommendation of the SEAC.

Noted

Gujarat Dyestuff Industries (Pharma Unit) Chapter 1 Introduction


CHAPTER – 1: INTRODUCTION

1.1 Purpose of Study & Regulatory Framework

Environmental Impact Assessment Report has been prepared for obtaining Environmental

Clearance for M/s. Gujarat Dyestuff Industries (Pharma Unit). located at Plot No. 133/4, 133/5,

133/6, GIDC Nandesari, Dist: Vadodara-391340, State: Gujarat, India for Expansion in the existing

Bulk Drug Manufacturing unit for Manufacturing of Ethoxylates & Metformin Hydrochloride i.e.

under Category 5(f) and is included category of the Environmental Impact Assessment Notification,

issued in September-2006 and subsequent amendments. The industry is located within the notified

industrial area/estate GIDC Nandesari and therefore as per NGT Order dated 23.08.2019 in the

matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara it will fall in category

“A” of the Environmental Impact Notification requiring Environmental Clearance from MoEF, New

Delhi.

This is a “Existing Unit”. This is an existing unit into manufacturing of Bulk Drugs such as Cifixime

Trihydrate, Cefuroxime Axetil, Cefpodoxime Proxetil, Ampicilin, Amoxicillin Trydrydate,

Clobetasole Propionate, Betamethasone Dipropionate, Betamethasone Valerate, Betamethasone

Sodium Phosphate, Dexamethasone Sodium Phosphate, Beclomethasone Dipropionate,

Mometasone Furoate, Methylcobalamine, Ofloxacin, Levofloxacin, Quinon Sulphate, Cloxacillin

Sodium, Oxacillin Sodium, Di Cloxacillin Sodium, Flucoxacillin Sodium.

New products Ethoxylates, Metformin Hydrochloride, and additional Methylcobalamine that falls

in Schedule 5(f) are planned to be manufactured and hence the application for EC is being done.

1.2 Identification of the Project and Project Proponent


Nandesari, Dist: Vadodara-391340.









• Project is located in GIDC Nandesari, which is an industrial area, so requirement of

industrial land is fulfilled. All other infrastructure facilities such as water, fuel, power, Storm



water drainage, effluent disposal facilities, proper road network for transportation of raw

materials & products, skilled & unskilled manpower etc. are also easily available.

• Rehabilitation and resettlement will not be required, as project is in Industrial area.

• No national park or wildlife sanctuary within 10 radius of the project site.

• Vadodara is the nearest city, which is properly connected to all other cities by road & rail

networks.

Details of the Project Proponent / Directors is given below.

SH. D.C. SHARMA

Pattharwala Bungalows, Nr. Sri

Ram Society, Gotri Road,

Vadodara 390007

MO .NO: 9376210937

TEL NO: 0265-2397901

SH. OM PRAKASH C-22, Mahendra Enclave, Azadpur

Model Town, Delhi- 110033 TEL NO: 011-26515127

SHRIMATI SHAMMI

GARG

807, D.B. Gupta Road, Nr. Sheila

Cinema, New Delhi. TEL NO.: 0265-2326676

Detail of the Key Personnel is given below.

Name & Designation

Age (years)

Qualification Total No. of Years of

experience

Description of Experience

Atul Jayprakash Pathak Sr. Manage-

Production

36 MSC 12 Experience in production and facility improvement

in various pharma products

L.C Bhosle Manager-QA

44 BSc 18

Experience in Quality Assurance

Kaniyalal Manger-

Engineering

45 Diploma in Electrical

15 Rich Experience in Electrical and engineering

S.N Shukla Manager-

Commercial

55 MA 32 Experience in Excise and commercial

Sanjeev Kumar In charge-QC

30 M-Pharma 6 Experience in quality control lab

1.3 Project Brief:

M/s. Gujarat Dyestuff Industries (Pharma Unit) is located at Plot No. 133/4, 133/5, 133/6, GIDC

Nandesari, Dist: Vadodara-391340.











RLG Group began its journey in 1974, when the company was established and formed by Sh. Ram

Lal Goyal as a Plasticizer manufacturing company. Today, the company has grown into a large &

dynamic business house, which currently occupies a leading position in the field of Chemical

Manufacturing, Pharmaceutical’s Manufacturing, Power Plant, Marketing & Exports in the Domestic

as well as the International Market. The corporation also includes hard work & dedication by Mr.

Raman Goyal, and Mr. Rahul Goyal.

As a global manufacturer of pharmaceuticals, chemicals & power the vision and leadership of those

at the helm is critical to success. The team of approx. 800 people (as counted in the year 2015),

comprises of skilled and experienced professionals, who are technically sound and enterprising.

Foreseeing the standards that would be expected for manufacturing of world class quality, they

implement the same ahead of time. It is because of this focused dedication and hard work that RLG

had accounted total revenue of 60 Million Dollars in the year 2014-15.

The team in the organization has been carefully handpicked to provide right mix of diverse skills

that complement each other. Under the guidance of RLG’ management, the technical team and

support personnel have achieved exceptional levels of productivity and success in product

development, quality control, quality assurance and all aspects of business and operations.

The Corporate Headquarters at New Delhi, India, houses capable staff that is thoroughly dedicated

in understanding the requirements of RLG’s partners and provides realistic customer solutions.

With this balanced mix of young dynamism and experienced perspective, the company has unfurled

its flag across the globe and is doggedly stepping into new territories, widening the customer across

the globe.

Over a period of years, RLG has grown as a company and achieved greater heights. Today, the

business has 9 state-of-the-art manufacturing facilities which includes chemical manufacturing

units for production of Acetic Anhydride, Monochloro Acetic Acid, Acetanilide Flakes, Power

Alcohol, Aniline Oil, and Nitro Benzene.

The group has around 50% market share of total production of Acetic Anhydride in India and is one

of the top 10 manufacturers of Acetanilide Flakes in the world.

The group has a combined Cycle Power Plant of 225 MW at Kashipur is the 1st Gas Based power

Plant of Uttrakhand is one of the leading power suppliers to Uttrakhand government, the power

plant cost about Rs. 850.00 cr.



1.4 Nature and Size of the Project

The Products fall under Project activity 5(f), Category A as per NGT Order dated 23.08.2019 in

the matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara. The details

of proposed products are given in Table – 1.1.

TABLE 1.1 PRODUCT DETAILS

Sr. no.

Name of the Products CAS no. /

CI no.

Quantity MT/Month* End-use of the

products Existing (Products)

Proposed (Products)

1 CIFIXIME TRIHYDRATE or 79350-37-1 10 0 Used for


drug formulation.

2 CEFUROXIME AXETIL or 64544-07-6 3 CEFPODOXIME PROXETIL or 87239-81-4

4 AMPICILIN or 69-53-4 20 0

5 AMOXICILLIN TRYDRYDATE or

61336-70-7 20 0

6 CLOBETASOLE PROPIONATE or

25122-46-7 0.5 0

Used for manufacturing of Steroid drug

formulation.

7 BETAMETHASONE DIPROPIONATE or

5593-20-4 0.5 0

8 BETAMETHASONE VALERATE or

2152-44-5 0.5 0

9 BETAMETHASONE SODIUM PHOSPHATE or

151-73-5 0.5 0

10 DEXAMETHASONE SODIUM PHOSPHATE or

2392-39-4 0.5 0

11 BECLOMETHASONE DIPROPIONTE

4419-39-0 0.5 0

12 MOMETASONE FUROATE or 105102-22-

5 0.5 0

13 METHYLCOBALAMINE or 13422-55-4 0.5 0.5

Used for manufacturing of vitamin B-12

formulation. 14 OFLOXACIN or 82419-36-1 20 0

Used for manufacturing

of Antibiotic drug

formulation.

15 LEVOFLOXACIN or 100986-85-

4 20 0

16 QUINON SULPHATE or 6119-70-6 20 0 17 CLOXACILLIN SODIUM or 7081-44-9 20 0 18 OXACILLIN SODIUM or 1173-88-2 20 0 19 DI CLOXACILLIN SODIUM or 7081-44-9 20 0 20 FLUCOXACILLIN SODIUM or 1847-24-1 20 0 21 ETHOXYLATES A POLYETHYLENE GLYCOL or 25322-68-3 0

1000

Manufacturing in agro

emulsifier, cosmetics,

soap, detergent,

textile

B HYDROGENATED CASTOR OIL or

8001-78-3 0

C CASTOR OIL ETHOXYLATES or

61791-12-6 0

D NONYL PHENOL ETHOXYLATES or

68412-53-3 0

E OCTYL PHENOL ETHOXYLATES or

68987-90-6 0



F CARD PHENOL ETHOXYLATES or

37330-39-5 0

G STYRUNATED PHENOL ETHOXYLATES or

61788-44-1 0


68439-50-9 0

I TRIDECYL ALCOHOL ETHOXYLATES or

24938-91-8 0

J CESTOSTYRYL ALCOHOL ETHOXYLATES or

68439-49-6 0


37335-03-8 0


26635-92-7 0

M COCO AMINE ETHOXYLATES or

61791-14-8 0

N OLEYL AMINE ETHOXYLATES or

90367-28-5 0

O POLY SORBATE ETHOXYLATES or

9005-64-5 0

P STEARIC ACID ETHOXYLATES or

9009-90-9 0

22 METFORMIN HYDROCHLORIDE

1115-70-4 0 500


of diabetic drug


1.5 Project Cost

The Existing: Rs.4.0 Crore, Proposed: Rs.4.0 Crore, Total: Rs. 8.0 Crore. Gujarat Dyestuff Industries

(Pharma Unit). shall spend Approximately Rs. 50 Lac for Existing Products & Rs. 109 Lac for

proposed Product as capital expenditure on environmental management. With a total of 159 lac.



1.6 Site Location

M/s. Gujarat Dyestuff Industries (Pharma Unit) located at Plot No. 133/4, 133/5, 133/6, GIDC

Nandesari, Dist: Vadodara-391340. State: Gujarat, India. Vadodara district lies in the Eastern part

of the Gujarat.

Other locational details are as follows:

The site is located:

• The site is located Approximately 14.0 km in North West of Vadodara city.

• The site is located Approximately 14.0 km in North West of Vadodara city.

• Approximately 106 km South East of Ahmedabad.

• Nandesari Railway Station 1.8 Km towards N.



• Vadodara Railway Station – 13 Km towards SE.

• Vadodara Airport – 15 Km towards SE approximately.


• 22°24'6.96"N, 73° 5'50.04"E

• 22°24'4.98"N, 73° 5'54.30"E

• 22°24'0.30"N, 73° 5'49.80"E

• 22°24'4.32"N, 73° 5'46.50"E


Map 1.1 shows location of project site on India, Gujarat State map

Map 1.2 shows location of the unit in GIDC Map.

Map 1.3 shows location of the unit in satellite imagery.



MAP 1.1 PROJECT LOCATION ON INDIA/GUJARAT MAP



MAP 1.2 PROJECT LOCATION ON NANDESARI GIDC MAP



MAP 1.3 PROJECT LOCATION ON GOOGLE IMAGE



1.7 Indian Policies Requiring REIA

Environmental Impact Assessment Report has been prepared for obtaining Environmental

Clearance for M/s. Gujarat Dyestuff Industries (Pharma Unit). This is a “Existing Unit”. This is an

existing unit into manufacturing of Bulk Drugs such as Cifixime Trihydrate, Cefuroxime Axetil,

Cefpodoxime Proxetil, Ampicilin, Amoxicillin Trydrydate, Clobetasole Propionate, Betamethasone

Dipropionate, Betamethasone Valerate, Betamethasone Sodium Phosphate, Dexamethasone Sodium

Phosphate, Beclomethasone Dipropionate, Mometasone Furoate, Methylcobalamine, Ofloxacin,

Levofloxacin, Quinon Sulphate, Cloxacillin Sodium, Oxacillin Sodium, Di Cloxacillin Sodium,

Flucoxacillin Sodium.



The site is located at Plot No. 133/4, 133/5, 133/6, GIDC Nandesari, Dist: Vadodara-391340., State:

Gujarat, India. The products fall under EIA Notification issued in September – 2006.

1.8 The REIA Cycle & Procedures

The general steps of the REIA process comprises of the following phases:

• Screening

• Scoping and consideration of alternatives (ToR)

• Baseline data collection

• Impact prediction

• Assessment of alternatives, delineation of mitigation measures and environmental impact

statement

• Environment Management Plan

• Decision making

• Monitoring the clearance conditions

1.9 Scope of the EIA Study

The project proponent has made an application in Form-I to the State Environmental Appraisal

Committee – Gandhinagar for seeking comprehensive Terms of Reference for addressing relevant

environmental concerns for the preparation of an Environmental Impact Assessment (EIA) Report

and Environmental Management Plan (EMP) in respect of the proposed expansion for Manufacture

of bulk drug Metformin Hydrochloride & Ethoxylates. Subsequently, our proposal was duly

considered by the Expert Committee in its 155th Meeting dated 28th December 2018. Sr. No 4 and

based on the discussion and details submitted, the committee has worked out the TORs for proposed

project. The project proponent has received the terms of reference vide letter vide the letter No:



SEIAA/GUJ/TOR/5(f)/81/2019 Dated: 10th January 2019. TOR Letter is given as Annexure-1. TOR

with its compliance is given above on page no. 17-27.

1.10 Applicable Environmental Regulations & Standards

With respect to prevention and control of environmental pollution, the following Acts and Rules of

MoEFCC govern the proposed project:

• EIA Notification No. 1533(E) dtd. 14th September 2007 and its amendments.

• Water (Prevention and Control of Pollution) Act, 1974 as amended in 1978 and 1988:

• Air (Prevention and Control of Pollution) Act, 1981 as amended in 1987:

• Environment (Protection) Act, 1986 amended 1991 and Environment (Protection) rules,

1986 and amendments thereafter

• Hazardous & Other Waste (Management & Trans boundary Movement) Rules’2016

• The Noise Pollution (Regulation and Control) Rules, 2000 and as amended in 22.11.2000.

1.11 Structure of EIA Report

The structure of the EIA report has been made as per the requirements of Environmental Impact

Assessment (EIA) Notification 2006 (S. O. 1533).

The report consists of the following Chapters.

Executive Summary

• Chapter 1 Introduction

• Chapter 2 Project Description

• Chapter 3 Description of the Environment

• Chapter 4 Anticipated Environmental Impacts and Mitigation Measures

• Chapter 5 Analysis of Alternatives (Technology/site)

• Chapter 6 Environmental Monitoring Programme

• Chapter 7 Risk Assessment On/Off Site Emergency Plan and occupational health & safety

• Chapter 8 Project Benefits

• Chapter 9 Environmental Cost Benefit Analysis

• Chapter 10 Environmental Management Plan (EMP)

• Chapter 11 Summary and Conclusion

• Chapter 12 Disclosure of Consultant

Gujarat Dyestuff Industries (Pharma Unit) Chapter 2 Project Description


CHAPTER – 2: PROJECT DESCRIPTION

2.1 Type of Project & Capacity











2.2 Need for REIA

Every anthropogenic activity has some impact on the environment. More often it is harmful to the

environment than benign. However, mankind as it is developed today cannot live without taking up

these activities for his food, security and other needs. Consequently, there is a need to harmonize

developmental activities with the environmental concerns. Environmental impact assessment

(REIA) is one of the tools available with the planners to achieve the above-mentioned goal.

It is desirable to ensure that the development options under consideration are sustainable. In doing

so, environmental consequences must be characterized early in the project cycle and accounted for

in the project design.

The objective of REIA 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. The REIA

process should then allow for the communication of this information to:

• The project proponent.

• The regulatory agencies; and,

• All stakeholders and interested groups.

REIA integrates the environmental concerns in the developmental activities right at the time of

initiating for preparing the feasibility report. In doing so it can facilitate the integration of

environmental concerns and mitigation measures in project development. REIA can often prevent

future liabilities or expensive alterations in project design.



2.3 Cost of the Project

TABLE 2.1 BREAK-UP OF PROJECT COST

Particulars Amount in INR (crore) Existing

Amount in INR (crore)

Proposed


Total Land 1.0 - 1.0

Factory Building 0.50 0.50 1.0 Plant & Machineries 1.0 2.50 3.50

Other Assets 1.50 1.00 2.50 Total 4.0 4.0 8.0

2.4 Project Location & Surrounding Area

The topography of the land is flat. The site falls within the industrial area of GIDC Nandesari. The

main activities in this area are Industrial. The site lies in GIDC Nandesari, Vadodara. The location of

the project has been shown in Map 1.1 & 1.2.

The site is located Approximately 14.0 km in North West of Vadodara city.


o 22°24'6.96"N, 73° 5'50.04"E

o 22°24'4.98"N, 73° 5'54.30"E

o 22°24'0.30"N, 73° 5'49.80"E

o 22°24'4.32"N, 73° 5'46.50"E


The total area of the site Plot No. 133/4, 133/5, 133/6 is 3691.10 m2 (0.36911 Ha).

2.5 Approach to Site

• The site is well connected with NH8. The site comes under Ta. Vadodara.

• Road: Site is 4km aerial distance away from NH-8. Via NH-8 site is well connected to

Bharuch, Surat, Mumbai, Vadodara, Ahmedabad.

• RAIL: The nearest railway station is Vadodara Junction, Nandesari Railway Station 1.8Km

towards N, Vadodara Railway Station – 13 Km towards SE. . Western Railway Connects from

Mumbai-Surat-Bharuch-Vadodara-Godhra-Ratlam-Kota-Delhi.

• AIRPORT: The nearest airport is Vadodara which is in approximately 15 Km (Aerial

Distance). Regular flights from Delhi and Mumbai are available.



MAP 2.1 PROJECT SITE INDICATING THE BOUNDARY OF THE SITE



MAP 2.2 STUDY AREA



MAP 2.3 TOPOSHEET MAP OF THE STUDY AREA



2.6 Plant Layout

The key plan and plant layout are shown in Figure 2.1.

FIGURE 2.1 LAYOUT PLAN



TABLE 2.2 AREA CALCULATION FOR EXISTING & PROPOSED STRUCTURES

Sr. No. Structure Ground Floor

Area Coverage Proposed Proposed

1 Processing Area 388 470 858

2 QC Lab 87 0 87

3 Admin Building 250 0 250

4 Utility 200 50 250

5 Raw Material Storage 105 25 130

6 Tank Farm & Storage 150 0 150

8 Finished Goods Processing

Area 84 0 84

9 Finished Goods Storage 56 0 56

10 ETP Area 300 50 350

11 Green Belt Area 791 685 1476 Total Ground Floor Coverage 2411 1280 3691

Sr. No. Description of Area Existing Area Proposed Area (Sq.

m.)

Total Area

(Sq. m.) (Sq. m.)

1 Plant Facilities 720 495 1215

2 Utilities & Storage area 350 50 400

3 Other Building Area (Road &

Parking) 250 0 250

4 ETP Area 300 50 350

5 Green Belt 791 685 1476 Total 2411 1280 3691

2.7 Magnitude of the Project

2.7.1 Details of Products

The proposed products to be manufactured are listed in Table 2.3 with their respective capacities.

TABLE 2.3 PRODUCT PROFILE

The New Product falls under Project activity5(f), Category A as per NGT Order dtd 23.08.2019 in the matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara

Sr. no.


CI no.



Proposed (Products)



drug formulation.



5 AMOXICILLIN TRYDRYDATE

or 61336-70-7 20 0

6 CLOBETASOLE PROPIONATE

or 25122-46-7 0.5 0


formulation. 7

BETAMETHASONE DIPROPIONATE or

5593-20-4 0.5 0



Sr. no.


CI no.



Proposed (Products)

8 BETAMETHASONE

VALERATE or 2152-44-5 0.5 0

9 BETAMETHASONE SODIUM

PHOSPHATE or 151-73-5 0.5 0

10 DEXAMETHASONE SODIUM

PHOSPHATE or 2392-39-4 0.5 0

11 BECLOMETHASONE

DIPROPIONTE 4419-39-0 0.5 0


5 0.5 0





of Antibiotic drug

formulation.


4 20 0


1000



soap, detergent,

textile

B HYDROGENATED CASTOR

OIL or 8001-78-3 0

C CASTOR OIL ETHOXYLATES

or 61791-12-6 0

D NONYL PHENOL


E OCTYL PHENOL


F CARD PHENOL


G STYRUNATED PHENOL



68439-50-9 0

I TRIDECYL ALCOHOL


J CESTOSTYRYL ALCOHOL



37335-03-8 0


26635-92-7 0

M COCO AMINE ETHOXYLATES

or 61791-14-8 0

N OLEYL AMINE ETHOXYLATES

or 90367-28-5 0



Sr. no.


CI no.



Proposed (Products)

O POLY SORBATE


P STEARIC ACID


22 METFORMIN

HYDROCHLORIDE 1115-70-4 0 500

Used for manufacturing of diabetic drug


2.8 Raw Material Storage & Handling

• Means of Transportation of raw materials and products at Gujarat Dyestuff Industries

(Pharma Unit). – Nandesari is tabulated in Table 2.4

• Physical & Chemical properties of Raw materials have been shown in table 2.5.

• A storage detail of raw materials to be used for the manufacturing and the products has been

shown in Table 2.6.

TABLE 2.4 MEANS OF TRANSPORTATION OF RAW MATERIALS AND PRODUCTS

Sr Raw

Materials

Physical & chemical

composition Source of Supply

Means of Transportation

Distance of the

supplier from

project site, km

Maximum Quantity

Transported Chemical Formula

State

Proposed

1 N-Butanol C4H10O Liquid J.K. Enterprise,

Nandesari road, Vadodara

Road transport 20 5 Ton

2 Di Ethelene

Glycol C4H10O3 Liquid

Bhagvati Petro, J.K. Enterprise,


Road transport

30 20 Ton

3 Castor Oil C57H104O9 Liquid Hindprakash,

Laxmicastoroil Road transport

87 20 Ton

4 Lauryl Alcohol C12H26O Liquid Embry oleo,

Soofi Enterprise Road transport

456 20 Ton

5 Tridecyl Alcohol

C13H28O Liquid Ankit Polymers

Industries, Ahmedabad


6 Ethylene

Oxide C2H4O Liquid

To be procured from GDI VS Plant that is within 100m in the common premises by pipeline linkage.

Existing

1 Butyle Acetate C6H12O2 Liquid J.K. Enterprise,





Sr Raw

Materials

Physical & chemical

composition Source of Supply

Means of Transportation

Distance of the

supplier from

project site, km

Maximum Quantity

Transported Chemical Formula

State

2 Sulphuric

Acid H2SO4 Liquid

Panoli Intermediate Ind. Pvt. Ltd.,

Vadodara, Shreenathji Chemicals, Vadodara

Road transport 0.3 20 Ton

3 Acetone C3H6O Liquid Dayaram Chemical,

Anklehwar


4 Tri ethyle

amine C6H15N Liquid

Tirupati Enterprise, Waghodia, Vadodara

Road transport 25 0.1 Ton

5 MDC CH2Cl2 Liquid Panshul

Enterprise, Vadodara


6 Methanol CH3OH Liquid Gayatri

Industries, Vadodara


7 Ethyle Acetate C4H8O2 Liquid GNFC, Baroda Road transport 21 2 Ton

8 Hydrochloric

acid HCL Liquid

Shreenathji Chemicals,

Gotri, Vadodara


9 Formaldehyde CH2O Gas

Apurva acid & Chemicals, Padmala, Vadodara


10 Di Methyle Formamide C3H7NO Liquid

J.K. Enterprise, Nandesari road,

Vadodara




TABLE 2.5 PHYSICAL & CHEMICAL PROPERTIES OF THE RAW MATERIAL & PRODUCTS

For Proposed Products

S. No. Raw Materials Physical & chemical composition

B. P F. P LEL UEL

TLV ppm or

mg/Nm3

LD50, mg/Kg LC50

mg/l

Sp. Gr. (water = 1) at

V.D. at

(air = 1)

Odour Threshold

ppm or mg/m3

No. of container

& size

Chemical Formula

State 0 C 0 C % 200 C 200 C

2 3 4 5 6 7 8 9 10 11 12

1. Ethoxylates

Di Ethelene Glycol VP-0.01 mm of Hg (@ 20°C)

C4H10O3 Liquid 245 138 2%-12.3%

-- LD50 – 2565 mg/kg

1.12 3.66 -- 25 MT

Hydrogenated Castor Oil VP-NA

-- Liquid >100 -- -- -- LD50 – 15000 g/kg

1 -- -- 25 MT

Castor Oil VP-NA

-- Liquid 313 230 -- -- -- 0.962 -- -- 25 MT

Nonyl Phenol VP-NA

-- Liquid -- 279 -- -- LD50 – 1410 mg/kg

1.055 1 -- 77.3 MT

Octyl Phenol VP-NA

(C8H17) C6H4OH Solid 175 -- -- -- LD50 – 4600 mg/kg

-- -- -- 74 MT

Card Phenol VP-NA

-- Liquid -- -- -- -- -- -- -- -- 84 MT

Styrunated Phenol VP-NA

C30H30O Liquid 250 182 -- -- -- 1.02 -- -- 72 MT

Lauryl Alcohol VP-0.1 hPa at 20 °C

C12H26O Solid 260 121 0.6%-4%

-- LD50 – 2.0 mg/kg

-- -- -- 25 MT

Tridecyl Alcohol VP-20.9KPa at 200 °C

C13H28O Liquid 254 130 -- -- LD50 – 4.75 mg/kg

0.846 6.9 -- 25 MT

Cetostyryl Alcohol VP-NA

-- Solid -- -- -- -- LD50 – 3200 mg/kg

0.82 9.5 -- 53 MT

Tallow Amine VP-NA

-- Liquid >200 >100 -- -- LD50 – 1950 mg/kg

0.812 >1 -- 69 MT

Stearyl Amine VP-NA

C18H39N Solid 346.8 148 -- -- LD50 – 2395 mg/kg

0.791-0.861

-- -- 88 MT

Coco Amine VP-NA

-- Liquid 180 150 -- -- LD50 – 2000 mg/kg

0.805 -- -- 112 MT



Oleyl Amine VP-NA

C18H37N Liquid 300 154 -- -- LD50 – 1689 mg/kg

0.810 -- -- 38 MT

Sorbitian Mono Laurate VP-NA

C18H34O6 Liquid -- -- -- -- LD50 - 33600 mg/kg

-- -- -- 66 MT

Sorbitian Mono Stearate VP-NA

C24H46O6 Solid -- -- -- -- LD50 – 31000 mg/kg

1 -- -- 66 MT

Sorbitian Mono Oleate VP-NA

C24H44O6 Liquid >100 148.89 -- -- -- 1 -- -- 66 MT

Sorbitian Tri Oleate VP-NA

C60H108O8 Liquid -- -- -- -- -- 0.95 -- -- 66 MT

Stearic Acid VP-NA

C18H36O2 Solid 350 196.11 -- -- LD50 – 4640 mg/kg

0.9408 9.8 20 ppm 116 MT

CAUSTIC POTASH FLAKES KOH solid 1384 - -- LD50-273 mg/kg

2.044 -- -- 7 MT

Ethylene Oxide VP 1.4 mmHg @ 25 °C

2(CH2) O Liquid 10.7 <-18 3.% - 100%

- 72(LD) 0.87 1.49 900-1260 mg/m3

Pipeline from VS

Plant 2. Metformin

N-BUTANOL

VP-6.7 mbar @ 20 °C

CH3(CH2)2CH2OH Liquid 117.7 28.9 1.4%, 11.2%

-- 790 mg/kg 0.81 2.55 1.2 ppm 20 MT

DMA.HCL VP-NA

C2-H7-N.ClH Solid -- -- -- -- 1070 mg/kg -- -- -- 58 MT

DCDA VP-NA

C2H4N4 Solid -- -- -- 10 mg/m3

-- 1.40 -- -- 59 MT

N.A. Not Applicable, NA Not Available, VP-Vapor Pressure.



For Existing Products

S. No.

Raw Materials Physical & chemical composition

B. P F. P LEL UEL TLV ppm or

mg/Nm3

LD50, mg/Kg LC50 mg/l


V.D. at

(air = 1)

Odour Threshold

ppm or mg/m3

No. of container

& size

Chemical Formula

State 0 C 0 C % 200 C 200 C MT / CUM

2 3 4 5 6 7 8 9 10 11 12 1. CEFIXIME

TRIHYDRATE

GCLE VP-NA

C24H23CIN2O5S Not specific

-- -- -- -- -- -- -- -- 3.4 MT

PHENOL VP-NA

C6H5OH Liquid 181.7 81 1.3%-9.5% 5 ppm -- 1.072 3.24 0.048 ppm 5.2 MT

BUTYL ACETATE

CH3COO(CH2)CH3 Liquid 126.5 37 1.7%, 7.6% -- LD50 – 17601 mg/kg

0.9 4.01 0.31 ppm 50 MT

SODIUM BI CARBONATE VP-NA

NaHCO3 Solid -- -- -- -- LD50-3360 mg/kg

2.159 -- -- 400 Kg

CARBON VP-NA

C Solid -- -- -- -- -- 1.8 -- odourless 70 Kg

EDTA VP-NA

C10H12N2Na4O8 .2H2O

Solid -- 93.3 -- LD50-2000 mg/kg

0.77 -- -- 34 Kg

SULPHURIC ACID VP-NA

H2SO4 Liquid 290 -- -- 1 ppm LC50-510 mg/m3/2H

1.84 3.4 -- 10 MT

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 1400 Kg

MDC

VP-350 mbar @ 20°C

CH2Cl2 Liquid 39.8 -4 13%-22% 50 ppm -- 1.322 2.9 207-305ppm

8 MT

DMF

VP-0.3 kPa (@ 20°C)

HCON(CH3)2 Liquid 153 57 2.2%-15.2%

-- LD50-2800 mg/kg rat

0.949 2.51 100 ppm 2 MT

MICA ESTER VP-NA

C15H12N4O4S3 solid -- -- -- 3 LD50-15 g/kg -- -- -- 1.4 MT

ETHYL ACETATE VP-12.4 kPa (@ 20°C)

C4H802 Liquid 77 -4 2.1%-11.5%

400 ppm -- 0.902 3.04 0.006-0.686 mg/l

700 Kg

HCL VP-16 kPa (@ 20°C)

HCl Liquid 48.5 -- -- 5 ppm LC50-900 mg/kg

1.19 1.3 5 ppm 20 MT

SODIUM HYDROXIDE NaOH Solid 139 -- -- 2 -- 1.3 -- -- 260 Kg



VP-NA METHANOL

VP- 12.3 kPa (@ 20°C) CH3OH Liquid 64.5 -- 6%, 36.5% -- LD50- 5628

mg/kg 0.7915 1.11 100 ppm 20MT x 3

Nos TRI ETHYL AMINE

VP-54 mm of Hg (@ 20°C)

(CH3CH2)3N Liquid 89.7 37.8 1.2%-8% -- LD50 – 460 mg/kg

0.73 3.48 -- 20 MT

SODIUM BROMIDE VP-NA

NaBr solid 1390 -- -- -- LD50-3500 mg/kg

3.21 -- -- 350 Kg

TRI PHENYL PHOSPHINE VP-NA

(C6H5)3P Solid -- -- -- -- -- -- -- -- 1 MT

FORMALDEHYDE VP- 2.4 kPa (@ 20°C)

HCHO Liquid 98 -- 6%, 36.5% -- LD50 – 42 mg/kg

1.08 1.03 100 ppm 20 MT

2. CEFUROXIME AXETIL 7ACA

VP-NA C10H12N2O5S Solid -- -- -- -- -- -- -- -- 1.9 MT

SIDE CHAIN -- -- -- -- -- -- -- -- -- -- -- METHANOL

VP- 12.3 kPa (@ 20°C) CH3OH liquid 64.5 16 -- -- LD50- 5628

mg/kg 0.7915 1.11 100 20MT x 3

Nos HCL

VP-16 kPa (@ 20°C) HCL Liquid 108.58 -- -- -- LD50 – 900

mg/kg 1.1 1.267 0.25 to 10 20 MT

CAUSTIC VP-NA

NaOH Liquid 1388 - -- -- -- 2.13 -- -- 300 Kg

ACETIC ACID

VP- 2.09 kPa at 25°C

C2H4O2 Liquid 56.5 -20 2.5%12.8% 500 ppm LC50-50,100mg/m3

0.79 2.0 7.7 ppm 90 Kg

ACETONE

VP-247 hPa (20 °C)

C3H6O Liquid 56.2 -9 2.6%, 12.8%

750 ppm LD50 – 5800 mg/kg

0.79 2 62 20 MT

CSIC ClSO2NCO Liquid 107 -- -- -- -- 1.624 4.88 -- 600 Kg DI METHYL

ACETAMIDE VP- 0.2 kPa (@ 20°C)

C4H9NO Liquid 163 66 1.8%-11.5%

-- 275 ppm 1H on Rat

0.942 3 21.4 ppm 2.9 MT

SODIUM CARBONATE Na2CO3 solid -- -- -- -- LD50-4090 mg/kg

2.532 -- -- 230 Kg

ACETOXY SIDE CHAIN C16H19NO5 ETHYL ACETATE

VP-12.4 kPa (@ 20°C) C4H802 Liquid 77 -4 2.1%-

11.5% 400 ppm -- 0.902 3.04 0.006-

0.686 mg/l 10 MT

SODIUM BI CARBONATE

NaHCO3 Solid -- -- -- -- LD50-3360 mg/kg

2.159 -- -- 500 Kg



CARBON C solid -- -- -- -- -- 3.51 -- -- 50 Kg 3. CEFPODOXIME

PROXETIL

7ACA C10H12N2O5S Solid -- -- -- -- -- -- -- -- 2.3 MT SULFONALE C4H8O2S Solid 104 177 -- -- LD50 – 1.9

mg/kg -- -- -- 14 MT

SODIUM HYDROXIDE NaOH Solid 139 -- -- 2 -- 1.3 -- -- 300 Kg SODIUM CHLORIDE NaCl Solid 1413 -- -- -- LD50 – 3000

mg/kg 2.165 -- -- 1.7 MT

METHANOL VP- 12.3 kPa (@ 20°C)

CH3OH Liquid 64.5 -- 6%, 36.5% -- LD50- 5628 mg/kg

0.7915 1.11 100 ppm 20MT x 3 Nos

METHYLENE CHLORIDE

46.5 kPa (@ 20°C)

CH2Cl2 Liquid 39.7 -- 12%-19% 50 ppm LD50-1600 mg/kg Rat

1.326 2.93 214 ppm 20 MT

TRI ETHYL AMINE 54 mm of Hg (@ 20°C)

(CH3CH2)3N Liquid 89.7 37.8 1.2%-8% -- LD50 – 460 mg/kg

0.73 3.48 -- 20 MT

MAEM -- -- -- -- -- -- LD50 – 300 mg/kg

-- -- -- 1.7 MT

DI METHYL ACETAMIDE VP- 0.2

kPa (@ 20°C)

C4H9NO liquid 163 37.8 1.8% - 11.5 %

-- LD50 – 4300 mg/kg

0.9429 3 21.4 3.1 MT



1.84 3.4 -- 10 MT

IODO ETHYL ISO PROPYL CARBONATE

C6H11ClO3 -- 164.31 -- -- -- -- -- -- -- 1.4 MT

SODIUM THIOSULPHATE

Na2S2O3 Solid -- -- -- -- -- 1.73 -- -- 50 Kg

DBU C9H16N2 Liquid 80-83 116 1.1%-6.5% -- LD50 – 681 mg/kg

-- -- -- 550 Kg

CARBON C solid -- -- -- -- -- 3.51 -- -- 50 Kg AMMONIA SOLUTION

VP-48 kPa-20 °C -- Liquid -- -- -- -- LD50 – 350

mg/kg 0.898 -- 5-50 ppm 2.1 MT

ETHYL ACETATE VP-12.4 kPa (@ 20°C)

C4H802 Liquid 77 -4 2.1%-11.5%

400 ppm -- 0.902 3.04 0.006-0.686 mg/l

10 MT

4. AMPICILLIN FERMENTATION

PROCESS



SODIUM CHLORIDE (LR GRADE)

NaCl Solid 1413 -- -- -- LD50 – 3000 mg/kg

2.165 -- -- 500 gr plastic bottle

COBALT CHLORIDE (LR GRADE)

-- Solid 100 -- -- -- LD50 – 766 mg/kg

1.01 0.62 -- 500 gr plastic bottle

FERROUS SULPHATE (LR GRADE)

FeSO4.xH2O Solid -- -- -- -- -- -- -- -- 500 gr glass bottle

CALCIUM CHLORIDE (LR GRADE)

CaCl2 Solid 1670 -- -- -- LD50 – 1000 mg/kg


MANGANAOUS SULPHATE (LR GRADE)

MnSO4.H2O Solid 850 -- -- -- -- 2.95 -- -- 500 gr plastic bottle

BACTERIOLOGICAL PEPTONE (LR GRADE HI

MEDIA)

-- Solid -- -- -- -- -- -- -- -- 500 gr plastic bottle

SUCROSE (SUGAR) (PHARMA GRADE)

C12H22O11 Solid -- -- -- -- LD50 – 29700 mg/kg

1.587 -- -- 50 kg bag

POTASSIUM DI HYDROGEN PHOSPHATE

(COMMERCIAL)

KH2PO4 Solid -- -- -- -- LD50 – 4640 mg/kg

2.34 -- -- 25 kg bag

AMMONIUM SULPHATE (COMMERCIAL)

(NH4)2SO4 solid -- 93.5 -- -- LD50 – 640 mg/kg

1.77 -- -- 25 kg bag

MAGNESIUM SULPHATE (COMMERCIAL)

MgSO4 Solid -- -- -- -- -- -- -- -- 25 kg bag

CALCIUM CARBONATE (COMMERCIAL)

CaCO3 solid -- -- -- -- LD50 – 6450 mg/kg

2.8 -- -- 25 kg bag

YEAST EXTRACT (COMMERCIAL)

-- Solid -- -- -- -- -- -- -- -- 25 kg bag

PPG 2000 (COMMERCIAL)

C3H8O2 Liquid 287.6 229.4 -- -- LD50 – 2.0 mg/kg

-- -- -- 50 ltr carboy



1.08 1.03 100 ppm 20 MT

SODIUM HYDROXIDE (COMMERCIAL)

NaOH Solid 139 -- -- 2 -- 1.3 -- -- 50 kg bag



ACETIC ACID



0.79 2.0 7.7 ppm 50 ltr carboy

POLYMIN -SK 25 (COMMERCIAL)

-- Liquid -- 100 -- -- LD50- 13400 mg/kg

1.06 -- -- 50 ltr carboy

GLUTARLDEHYDE 25% (COMMERCIAL)

-- Liquid 101 -- -- -- LD50 – 2500 mg/kg

1.062 1.05 0.04 ppm 220 ltr

AMMONIA SOLUTION VP-48 kPa-20 °C

-- Liquid -- -- -- -- LD50 – 350 mg/kg

0.898 -- 5-50 ppm 220 ltr drum

ACETIC ACID



0.79 2.0 7.7 ppm 220 ltr drum

BEADS PREPARATION PROCESS

CHITOSAN -- solid -- -- -- -- -- 1.4 -- -- 50 ltr carboy

GELATIN -- solid 100 -- -- -- -- 1.2 -- --

BUTYL ACETATE

VP-Value: 15 kPa-

20°C

CH3COO(CH2)CH3 Liquid 126.5 37 1.7%, 7.6% -- LD50 – 17601 mg/kg

0.9 4.01 0.31 ppm 25 MT + 25 MT

VICAPOL 80 -- Liquid >100 >149.9 -- -- LD50 – 25000 mg/kg

1.06 -- -- 25 kg bag


1.06 -- -- 20 kl tanker

GLUTARLDEHYDE 25%

OHC(CH2)3CHO Liquid 101 -- -- -- LD50 – 2500 mg/kg

1.062 1.05 0.04 ppm 50 ltr carboy

ESTER PREPARATION PROCESS

50 ltr carboy



0.7915 1.11 100 ppm 20MT x 3 Nos

PHENYL GLYCIN BASE C8H9NO2 Solid -- -- -- -- -- -- -- -- 50 Kg



1.84 3.4 -- 10 MT

CAUSTIC LYE 47.5% NaOH Liquid 1388 - -- -- -- 2.13 -- -- 25 kg bag

Final AMPICILLIN PROCESS

20 KL tanker

6 APA C8H12N2O3S -- -- -- -- -- LD50 – 2000 mg/kg

-- -- -- 20 KL tanker



HYFLO SUPER-CEL SiO2 Solid -- -- -- -- -- 2.3 -- -- 50 Kg

HCL 35% 16 kPa (@ 20°C)

HCL Liquid 108.58 -- -- -- LD50 – 900 mg/kg

1.1 1.267 0.25 to 10 20 MT

CAUSTIC LYE 47.5% NaOH Liquid 1388 - -- -- -- 2.13 -- -- 25 kg bag

EDTA C10H12N2Na4O8 .2H2O

Solid -- 93.3 -- LD50-2000 mg/kg

0.77 -- -- 20 kl tanker

5. AMOXICILLIN TRYDRYDATE

FERMENTATION PROCESS

SODIUM CHLORIDE (LR GRADE)

NaCl Solid 1413 -- -- -- LD50 – 3000 mg/kg


COBALT CHLORIDE (LR GRADE)

-- Solid 100 -- -- -- LD50 – 766 mg/kg

1.01 0.62 -- 500 gr plastic bottle

FERROUS SULPHATE (LR GRADE)

FeSO4.xH2O Solid -- -- -- -- -- -- -- -- 1 & 500 gr glass bottle

CALCIUM CHLORIDE (LR GRADE)

CaCl2 Solid 1670 -- -- -- LD50 – 1000 mg/kg

2.15 -- -- 5 & 500 gr plastic bottle

MANGANAOUS SULPHATE (LR

GRADE)

MnSO4.H2O Solid 850 -- -- -- -- 2.95 -- -- 4 & 500 gr plastic bottle

BACTERIOLOGICAL PEPTONE (LR GRADE

HI MEDIA)

-- Solid -- -- -- -- -- -- -- -- 0.5 & 500 gr plastic

bottle SUCROSE (SUGAR)

(PHARMA GRADE) C12H22O11 Solid -- -- -- -- LD50 – 29700

mg/kg 1.587 -- -- 96 & 50 kg

bag POTASSIUM DI

HYDROGEN PHOSPHATE

(COMMERCIAL)

KH2PO4 Solid -- -- -- -- LD50 – 4640 mg/kg

2.34 -- -- 30 & 25 kg bag

AMMONIUM SULPHATE

(COMMERCIAL)

(NH4)2SO4 solid -- 93.5 -- -- LD50 – 640 mg/kg

1.77 -- -- 13.8 & 25 kg bag



MAGNESIUM SULPHATE

(COMMERCIAL)

MgSO4 Solid -- -- -- -- -- -- -- -- 5 & 25 kg bag

CALCIUM CARBONATE (COMMERCIAL)

CaCO3 solid -- -- -- -- LD50 – 6450 mg/kg

2.8 -- -- 1 & 25 kg bag

YEAST EXTRACT (COMMERCIAL)

-- Solid -- -- -- -- -- -- -- -- 1.5 & 25 kg bag

PPG 2000 (COMMERCIAL)

C3H8O2 Liquid 287.6 229.4 -- -- LD50 – 2.0 mg/kg

-- -- -- 1 & 50 ltr carboy



1.08 1.03 100 ppm 20 MT

SODIUM HYDROXIDE (COMMERCIAL)

NaOH Solid 139 -- -- 2 -- 1.3 -- -- 9.5 & 50 kg bag

ACETIC ACID



0.79 2.0 7.7 ppm 2 & 50 ltr carboy

POLYMIN -SK 25 (COMMERCIAL)

-- Liquid -- 100 -- -- LD50- 13400 mg/kg

1.06 -- -- 2 & 50 ltr carboy

GLUTARLDEHYDE 25% (COMMERCIAL)

-- Liquid 101 -- -- -- LD50 – 2500 mg/kg

1.062 1.05 0.04 ppm 0.4 & 220 ltr drum

AMMONIA SOLUTION VP-48 kPa-20 °C

-- Liquid -- -- -- -- LD50 – 350 mg/kg

0.898 -- 5-50 ppm 0.05 & 20 kl tanker

ACETIC ACID



0.79 2.0 7.7 ppm 12 & 50 ltr carboy

BEADS PREPARATION PROCESS

CHITOSAN -- solid -- -- -- -- -- 1.4 -- -- 0.48 & 25 kg bag

GELATIN -- solid 100 -- -- -- -- 1.2 -- -- 2.4 & 25 kg bag

BUTYL ACETATE CH3COO(CH2)CH3 Liquid 126.5 37 1.7%, 7.6% -- LD50 – 17601 mg/kg

0.9 4.01 0.31 ppm 25 MT + 25 MT


1.06 -- -- 0.12 & 50 ltr carboy


1.06 -- -- 0.024 & 50 ltr carboy

GULTARLDEHYDE 25% OHC(CH2)3CHO Liquid 101 -- -- -- LD50 – 2500 mg/kg

1.062 1.05 0.04 ppm 4.32 & 200 ltr drum



ESTER PREPARATION PROCESS



0.7915 1.11 100 ppm 20MT x 3 Nos

PHPG-PARAHYDROXY

PHENYLGLYCINE BASE

C8H9NO3 -- -- -- -- -- -- -- -- -- 3.0 MT



1.84 3.4 -- 10 MT

CAUSTIC LYE 47.5% NaOH Liquid 1388 - -- -- -- 2.13 -- -- 20 kl tanker

FINAL AMOXYCILLIN PROCESS

6 APA C8H12N2O3S Solid -- -- -- -- LD50 – 2.0 mg/kg

-- -- -- 2.8 MT

HI FLOW SUPER CELL SiO2 Solid -- -- -- -- -- 2.3 -- -- 50 Kg



1.1 1.267 0.25 to 10 20 MT

CAUSTIC LYE 47.5% NaOH Liquid 1388 - -- -- -- 2.13 -- -- 20 kl tanker

EDTA C10H12N2Na4O8 .2H2O

Solid -- 93.3 -- LD50-2000 mg/kg

0.77 -- -- 50 Kg

6. CLOBETASOLE PROPIONATE

BETAMETHASONE BASE

C22H29FO5 Solid -- -- -- -- -- -- -- -- 800 & 25 kg bag

MDC

VP-350 mbar @ 20°C


25 MT + 25 MT

TRIETHYL ORTHO PROPONATE (T.E.O.P.)

C7H8 Liquid -- -- -- -- -- -- -- -- 100 Kg

PARA TOLUENE SULPHONIC ACID

(PTSA)

-- Liquid 56.2 37.8 2.6%, 12.8%

-- LD50- 2840 mg/kg

0.82 2 62 ppm 50 Kg

ETHYL ACETATE 12.4 kPa (@ 20°C)

C4H802 Liquid 77 -4 2.1%-11.5%

400 ppm -- 0.902 3.04 0.006-0.686 mg/l

10 MT



ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT

ORTHO PHOSPHORIC ACID (O.P.A.)

-- Liquid 158 -- -- -- -- -- -- -- 50 Kg

PYRIDINE VP-13,3 hPa at 13,2 °C

26,7 hPa at 25,0 °C

C5H5N Liquid 115 17 1.8%, 12.4%

-- 891 mg/kg -- -- -- 500 Kg

METHANSULPHONYL CHLORIDE (M.S.C.)

CH3ClO2S Liquid 161 110 -- -- LD50 – 50 mg/kg

1.4805 3 -- 100 Kg

LITHIUM CHLORIDE LiCl Solid 1360 -- -- -- LD50 – 526 mg/kg

2.07 -- -- 200 Kg



0.7915 1.11 100 ppm 20MT x 3 Nos

ACTIVATED CARBON C solid -- -- -- -- -- 3.51 -- -- 100 Kg

HYFLOW SUPER CELL SiO2 Solid -- -- -- -- -- 2.3 -- -- 50 Kg

DMF

VP-0.3 kPa (@ 20°C)

HCON(CH3)2 Liquid 153 -- 2.2%, 15.2%

-- LD50 – 4720 mg/kg

0.949 2.51 100 ppm 20 MT

DRY ICE CO2 Solid -109.3 F

-- -- -- -- 1.56 0.115 -- -

7. BETAMETHASONE DIPROPIONATE

BETAMETHASONE C22H29FO5 Solid -- -- -- -- -- -- -- -- 200 Kg

MDC

VP-350 mbar @ 20°C

CH2Cl2 Liquid 40 -- 13% - 23% -- LD50 – 873 mg/kg

1.33 2.93 -- 25 MT + 25 MT

TRIETHYL ORTHO PROPONATE (TEOP)

C9H20O3 Liquid 155 60 -- -- -- -- -- -- 100 Kg


(PTSA)

-- Liquid 56.2 37.8 2.6%, 12.8%

-- LD50- 2840 mg/kg

0.82 2 62 ppm 100 Kg

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT



0.7915 1.11 100 ppm 20MT x 3 Nos


26,7 hPa at 25,0 °C

C5H5N Liquid 115 17 1.8%, 12.4%

-- 891 mg/kg -- -- -- 1.5 MT



PROPIONIC ANHYDRIDE VP-NA

C6H10O3 Liquid 169 37.8 1.3%, 9.5% -- LD50-2360 mg/kg

-- 4.5 -- 200 Kg



8. BETAMETHASONE VALERATE


TRIMETHYL ORTHO VALERATE

C8H18O3 Liquid 165 41 -- -- -- -- -- -- 200 Kg

MDC

VP-350 mbar @ 20°C

CH2Cl2 Liquid 40 -- 13% - 23% -- LD50 – 873 mg/kg

1.33 2.93 -- 25 MT + 25 MT


-- Liquid 56.2 -20 -- -- LD50 – 2570 mg/kg

0.82 2 62 ppm 100 Kg

ORTHO PHOSPHORIC ACID (O.P.A.)

-- Liquid 158 -- -- -- -- -- -- -- 50 Kg

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT



9. DEXAMETHASONE SODIUM PHOSPHATE

DEXAMETHASONE C22H29FO5 Solid -- -- -- -- LD50 – 3.0 mg/kg

-- -- -- 200 Kg

TETRAHYDRO FURON C4H8O Liquid 65 -14.5 2% - 11.8%

-- LD50 – 1650 mg/kg

0.8892 2.5 20 – 50 ppm

1 MT

PYROPHOSPHORYL CHLORIDE

Cl4O3P2 Liquid 90 -- -- -- -- -- -- -- 100 Kg

CHLOROFORM VP-21.1 kPa (@ 20°C)

CHCl3 Liquid 61 -- -- -- LD50-36 mg/kg

1.484 4.36 85 ppm 50 Kg



0.7915 1.11 100 ppm 20MT x 3 Nos

ISOPROPYL ALCOHOL 4.4 kPa (@ 20°C)

C3H8O Liquid 82.5 37.8 2%, 12.7% -- LD50- 3600 mg/kg

0.785 2.07 22 ppm 15 & 20 kl tanker

CAUSTIC SODA FLAKES NaOH Solid 1388 - -- -- -- 2.13 -- -- 50 Kg





10. BETAMETHASONE SODIUM PHOSPHATE


TETRAHYDRO FURAN 19.3 kPa (@ 20°C)

C4H8O Liquid 65 -14.5 2% - 11.8%

-- LD50 – 1650 mg/kg

0.8892 2.5 20 – 50 ppm

1 MT

PYROPHOSPHORYL CHLORIDE

Cl4O3P2 Liquid 90 -- -- -- -- -- -- -- 100 Kg



1.484 4.36 85 ppm 50 Kg



0.7915 1.11 100 ppm 20MT x 3 Nos



0.785 2.07 22 ppm 15 & 20 kl tanker

CAUSTIC SODA FLAKES NaOH Solid 1388 - -- -- -- 2.13 -- -- 50 Kg



11. BECLOMETHASONE DIPROPIONTE

DB – XI C22H28O5 -- -- -- -- -- -- -- -- -- 200 Kg



1.1 1.267 0.25 to 10 20 MT

KOH KOH solid 1384 - -- LD50-273

mg/kg

2.044 -- -- 200 Kg



1.484 4.36 85 ppm 200 Kg

MDC (METHYLENE DICHLORIDE)


1.5 MT

TEOP (TRIETHYL ORTHOPROPIONATE)

C9H20O3 Liquid 155 60 -- -- -- -- -- -- 100 Kg


(PTSA)

-- Liquid 56.2 37.8 2.6%, 12.8%

-- LD50- 2840 mg/kg

0.82 2 62 ppm 50 Kg



O P A (ORTHO PHOSPHORIC ACID)

-- Liquid 158 -- -- -- -- -- -- -- 50 Kg

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT


26,7 hPa at 25,0 °C

C5H5N Liquid 115 17 1.8%, 12.4%

-- 891 mg/kg -- -- -- 500 Kg

PROPIONIC ANHYDRIDE VP-NA

C6H10O3 Liquid 169 37.8 1.3%, 9.5% -- LD50-2360 mg/kg

-- 4.5 -- 200 Kg



12. MOMETASONE FUROATE

8 D M -- Solid -- -- -- -- -- -- -- -- 200 Kg

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT

Tri ethyl amine 0.0002

mmHg @ 21 °C

C6H15N Liquid 88.8 -14.9 8%, 12% -- LD50- 730 mg/kg

-- -- -- 20 MT

MSC CH3ClO2S Liquid 161 110 -- -- LD50 – 50 mg/kg

1.4805 3 -- 100 Kg

2-FUROYL CHLORIDE C5H3ClO2 Liquid 173 85 -- -- -- -- -- -- 50 kg

SODIUM BICARBONATE NaHCO3 Solid -- -- -- -- LD50-3360 mg/kg

2.159 -- -- 200 Kg

TETRAHYDRO FURAN 19.3 kPa (@ 20°C)

C4H8O Liquid 65 -- 2%, 11.8% -- LD50 – 1650 mg/kg

0.8892 2.5 20- 50 ppm

1 MT



0.785 2.07 22 ppm 8 & 20 kl tanker



1.1 1.267 0.25 to 10 20 MT



13. METHYLCOBALAMINE

CYANOCOBAL AMINE (B12)

C63H88CoN14O14P Solid -- -- -- -- -- -- -- -- 500 Kg



METHYL IODIDE

VP-544 hPa at 20 °C

CH3-I Liquid 42.5 -- -- -- LD50-76 mg/kg

2.28 4.89 -- 500 Kg

SODIUM BOROHYDRIDE

NaBH4 Solid -- -- -- -- LD50 – 160 mg/kg

1.074 1.3 -- 500 Kg

PHENOL VP-NA

C6H5OH Liquid 181.7 81 1.3%-9.5% 5 ppm -- 1.072 3.24 0.048 ppm 1.2 MT



1.484 4.36 85 ppm 4.4 MT

ACETONE

VP-247 hPa (20 °C)

C3H60 Liquid 56.5 -20 2.5%-12.8%

500 ppm LC50-50, 100 mg/m3

0.79 2.0 -- 20 MT



0.7915 1.11 100 ppm 20MT x 3 Nos



TABLE 2.6 STORAGE DETAILS

Raw Material for Proposed Products

Sr. No. Raw Material CAS No Storage Quantity,

CUM/MT MOC

No. of Vessel / DRUMS

1 n-butanol 71-36-3 20 SS 304 1

2 Di Ethelene Glycol 111-46-6 25 SS 1

3 Castor Oil 8001-79-4 25 SS 1

4 Lauryl Alcohol 112-53-8 25 SS 1

5 Tridecyl Alcohol 112-70-9 25 SS 1

6 Ethylene Oxide 75-21-8 This will come by

Pipeline from our GDI VS plant

SS Pipeline -

Raw Material for Existing Products

Sr. No. Raw Material CAS No Storage Quantity, in

KL MOC

No. of Vessel / DRUMS

1 Butyl Acetate 123-86-4 25 MS 2 2 Sulphuric Acid 7664-93-9 10 MS 1 3 Acetone 67-64-1 20 MS 1 4 Tri ethyl amine 121-44-8 20 MS 1 5 MDC 75-09-2 25 MS 2 6 Methanol 67-56-1 20 MS 3 7 Ethyl Acetate 141-78-6 10 MS 1 8 HCL 7647-01-0 20 HDPE 1 9 Formaldehyde 50-00-0 20 SS 1

10 Di Methyl Formamide 68-12-2 20 MS 1



2.9 Solvent Recovery

Spent solvent generated from the process - Captive In-house Recovery.

Existing Solvents: Methanol, Acetone, Chloroform etc.

Proposed Solvents: n-butanol,

Solvent recovery plant existing at site and % recovery is minimum 95%.

Name of Solvents

Total Solvent Input

Quantity of Solvent Recovered

Quantity of Solvent Loss

Solvent Recovery

Solvent Loss

Kg/Month Kg/Month Kg/Month % % Methanol 10843 10512 331 96.94 3.06 Acetone 200 191 9 95.5 4.5

Chloroform 9800 9486 314 96.79 3.20

*Note: Per Kg/Month Basis

Proposed Solvent Recovery:

Name of Solvents

Total Solvent Input

Quantity of Solvent Recovered

Quantity of Solvent Loss

Solvent Recovery

Solvent Loss

Kg/Month Kg/Month Kg/Month % % n-Butanol 350000 332000 18000 95 5

*Note: Per Kg/Month Basis

A highly efficient and full fledge solvent recovery system is installed to recover maximum possible

solvent and will be reused back in process. Detailed process is as described below:

For the efficient solvent recovery system, chilled water circulation jacketed, chilled water traps will

be installed on the vent for arresting any escape of vapors from the reaction and distillation unit.

The reactors will be connected to water condenser system. The receiver will also be jacketed with

circulation of water. The recovered solvents will then be stored and reused. Proper planning and

maintenance will enable to have an efficient solvent recovery from the system. The recovery

efficiency of every solvent used is approximately 95%.

Spent Solvent storage tanks are as follows

Name of Solvents Tank Volume No of Tanks MOC Methanol 5 MT 01 MS Acetone 5 MT 01 MS

Chloroform 5 MT 01 MS Mix Solvent 5 MT 01 MS

n-Butanol (Proposed) 10 MT 01 MS



2.10 Methodology for ZLD

2.10.1 Details of UF-RO Plant

Ultra-Filtration followed by RO Plant to be provided for recovery of the Treated Effluent for reuse. RO Plant is designed for recovery of 70% however considering ETP RO and ageing of the membranes, and worst-case scenario recovery is displayed as 50%.

Details of UF Plant

Sr.No. Description of equipment Specs. Qty. 1 Raw water feed pump 5 m3/hr., 30 MWC 2 (1w +1s) 2 Pressure Sand Filter 5m3/hr. 01 3 Activated Carbon Filter 5m3/hr. 01 4 Bag filter housing 10 micron, 5 m3/hr. 01 5 UF skid 1,00,000 – 1,50,000 MWCO 03 6 Control panel & Control valve

with auto controls 1 set with PLC 01 set

7 Interconnection piping PVC Lot 01 set 8 Back wash pump 5 m3/hr., 30 MWC 01 9 Chemical dosing pump 0-4 LPH. 3.5 kg/cm2 03

10 Water Rota meter As per requirement 03 11 Online conductivity / TDS

Meter, As per Requirement 01

12 UF skid. MS base frame As per requirement epoxy painted 01 13 Scour Blower Twin Lobe, 2.0 HP 01

Details of RO Plant

Sr.No. Description of equipment Specs. Qty. 1 Raw water feed pump 3 m3/hr., 30 MWC 2 (1w +1s) 2 Micron filter housing 5 micron, 3 m3/hr. 01 3 Chemical dosing pump 0-4 LPH. 3.5 kg/cm2 02 4 High Pressure Pump 3 m3/hr., 150 MWC 01 5 RO Membranes AG4040C, Brine Water 2x4 + 1x4=12 6 RO Membrane Housing 600 PSI, FRP 2+1=3 7 Control panel & Control valve

with auto controls 1 set with PLC 01 set

8 Interconnection piping PVC Lot 01 set RO Cleaning pump & Tank 3 m3/hr., 30 MWC 01

9 Water Rota meter As per requirement 03 10 Online conductivity / TDS

Meter, As per Requirement 01

11 RO skid. MS base frame As per requirement epoxy painted

01



FIGURE 2.2 UF & RO PLANT



2.10.2 Details of MEE Plant

MEE Plant to be installed to evaporate 20KLD of RO Reject. Concentrate of the MEE Plant to be passed through Filter Press / Nutch Filter to filter the salts. Concentrate liquid will be taken back to feed for evaporation in the MEE Plant. MEE Condensate to be collected for reuse.

Details of MEE Plant

Sr. Particulars Unit Values

1 Water Evaporation Capacity Kgs/hr. 963

2 Feed Rate Kgs/hr. 1000

3 Concentrate Outlet Rate Kgs/hr. 38 4 Total Solids in Product Feed TDS % 1.50% 5 Total Solids in Concentrate Outlet TDS % 40% 6 Concentrate Outlet Temp. °C Approx. 65 to 60 7 Cooling water in let/outlet Temp. °C Approx. 32 to 40 8 Cooling Water Quantity m3 / hr. 33

9 Thermic Oil Flow

Thermic Oil Heat Require in Lacs Thermic Oil In/Out Temperature

M3/Hr. Kcal/Hr.

°C Approx.

05 1.00

175 to 165 10 Plant Power Requirement HP 40

11 Cooling Tower Power with fan HP 7.5

12 Vacuum Pump Power HP 7.5 13 Filter Press HP 2 14 Operating hours Hrs. / Day 20 15 Total Power Required HP/KWH 57 / 43

Sr. No. Particulars M.O.C. Three Stage

1 CALANDRIA: Tubes x 25.4 OD x 6.0 Mtr Long x 1.21 mm THK Tube Sheet Shell Dome

SS316Ti

SS316 SS304 SS316

03 NO

2 Vapor Separator SS316L 03 NO

3 Preheaters: Tubes Tube Sheet Shell

SS316Ti

SS316 SS304

03 NO

4 Surface Condenser: Tubes Tube Sheet Shell

SS304 SS304

CS

01 NO

5 PUMPS with Motors: Feed Pump Re circulation Pumps Transfer Pumps Condensate water Pump

SS316 SS316 SS316 SS316

01 NO 03 NO 01 NO 01 NO

6 Vacuum pumps with motor PSS316 01 NO

7 Pipes & Fittings: Process Piping Vapor Ducting Condensate Piping Non-Condensate Piping Seal Water Line Vacuum Line

SS316

CS SS304 SS304

CS CS

01 LOT

8 Thermo compressor SS304 NA 9 Balance Tank SS304 01 NO



2.11 Technology / Process Description

The capacity along with the product manufacturing pattern has been shown in Table 2.3. The

detailed Manufacturing process has been described in this chapter along with the mass balance

diagram.

2.11.1 Mass Balance

Manufacturing Process

Manufacturing Process - Existing Products

1. CEFIXIME TRIHYDRATE

Step – I GVNE Formation

DMF is charged in the reactor, followed by HCL, GCLE, Sodium Bromide and Tri phenyl Phosphine and stirred at 35°C - 38°C for 1 hour. The Mass is cooled up to 15°C and Dichloro Methane is charged to the mass followed by formaldehyde and caustic solution and stirred for 15 minutes at 25°C - 30°C. HCL is charged to the reaction mass followed by Methanol and stirred for 1 hour at 25°C - 30°C. Dichloromethane and Methanol mixture is distilled under vacuum at 40°C. Cool the mass to 15°C and stirred for 60 minutes and material is filtered, filtered material obtained is GVNE. GVNE is dried and send for next step.

Step – II 7AVCA Formation

Phenol is charged in the Reactor followed by GVNE and stirred for 12 hrs. at 48°C. Butyl Acetate and Sodium Bi Carbonate solution is charged to the mass and stirred for 30 minutes at 35°C. Aqueous Layer is separated and Butyl Acetate layer & Phenol mixture is sent for distillation. Aqueous layer is reacted with Enzyme and transferred for carbon treatment. Solution is filtered and pH is adjusted with Sulphuric Acid to precipitate the material, after the material is precipitated, stir for 1 hour at 20°C. The material is filtered, and material obtained is 7AVCA, which is dried and send for next STEP.

Step – III – Methyl Ester Formation

Methanol is charged in the reactor followed by 7AVCA, Methyl Ester and Triethyl Amine and stirred for 2 hours at 10°C. DMW is charged to the reaction mass and pH is adjusted with HCL to precipitate the Material and stirred for 1 hour. Now the material is filtered, and material obtained is Methyl Ester, which is sent wet for next STEP.

Step – IV – Methyl Ester to Cefixime Trihydrate

DMW is charged to the reactor followed by Methyl Ester and caustic solution at 10°C and stirred for 10 minutes. pH is adjusted with HCL to precipitate the final product Cefixime Trihydrate and stirred for 60 minutes at 20°C. The material is filtered and dried.



Step -4: PREPARATION OF CEFIXIME FROM ACMV

S

N

NH2

NO

COOMe

NH

O

N

S

COOH

CH2

O

S

N

NH2

NO

COOH

NH

O

N

S

COOH

CH2

O

SODIUM HYDROXIDE

PURIFIED WATER .3H2O

Step -3: 7-AVCA to Cefixime

(6R,7R)-7-amino-3-ethenyl-8-oxo-5-thia-1-azabicyclo[4.2.0]oct-2-ene-carboxylic acid (7-

AVCA) is condensation with 2-Mercaptobenzothiazolyl-(Z)-2-(2-aminothiazol-4-yl)-2-

(methoxycarbonyl)methoxyiminoacetate (MICA ESTER) in presence of Triethyl amine in

Tetrahydrofuran and water medium at low temperature to obtain ACMV . The ACMV

compound further hydrolysis with dilute sodium hydroxide solution in water medium at

pH 12.5-13.0 at low temperature for 5-6 min and followed by acidification up to pH 5.5

with dilute hydrochloric solution and filtered . The filtered mass and further acidification up

to pH 2.10-2.30 with dilute hydrochloric acid solution to obtain Cefixime trihydrate.

B.A.

TEA,THF

S

N

NH 2

NO

COOMe

N H

O

N

S

COOH

C H 2

O

NH 2

N

S

C H 2

O O H

O

S

N

NH 2

NO

COOMe

S

O

S

N+

Step -I

+ NaBr + HCHO + PPh3 + NaOH → + NaBr + NaCl + PPh3O + H2O

GCLE Sodium Bromide Formaldehyde TPP GVNE

486.97 102.89 30 262.29 40 464.53 102.89 58.5 278.28 18

Step -2

+ + 3H2O → + H2O + + +

GVNE Phenol AVCA Phenol Phenylacetic p-methoxy benzyl

acid alcohol

464.53 94.11 18 226.25 18 94.11 136.15 138.16

N

S

O

N

Cl

O O

O

CH3

H

O

N

S

O

N

CH2

O O

O

CH3

H

O

N

S

O

N

CH2

O O

O

CH3

H

O OH

N

S

O

NH2

CH2

O OH

OH O H

O

O

CH3 OH



2. CEFUROXIME AXETIL:

Step – I 7ACA to Hydroxy Cefuroxime

DMW and Methanol mixture is charged in the reactor, followed by 7ACA & Caustic Solution at + 10°C and stirred for 2 hours and Acetic Acid solution is added. Prepared side chain is added to the reaction mass maintaining pH to 6.5 to 6.8 by Caustic solution. The reaction mass is stirred for 1 hour at 10°C and DMW is added to the mass and temperature is maintained to 25°C . The pH of reaction mass is adjusted to 2.8 by HCL solution and the mass is stirred for one hour and filtered. The filtered material obtained is Hydroxy Cefuroxime, which is dried and send for next step.

Step – II Hydroxy Cefuroxime to Cefuroxime Acid

Acetone is charged in the reactor, followed by Hydroxy Cefuroxime and cooled to 10°C. CSIC is added to the Reaction mass in 45 minutes at 10°C and stirred for 15 minutes. DMW is added to the reaction mass at + 5°C and stirred for 45 minutes. Intermediate is precipitated and filtered. This material is charged in the reactor containing Acetone. Caustic is added to adjust pH to 2.6 and stirred for 1 hour at 40°C. If the solution is clear than filter it and add DMW to the solution to precipitate the material. As soon as the material is precipitated, stir the mass for 1 hour at 10°C and filter. The filtered material obtained is Cefuroxime Acid which is dried and send for next step.

Step – III Cefuroxime Acid to Cefuroxime Axetil

DMAC is charged to the reactor, followed by Cefuroxime Acid, Sodium Bi Carbonate, Acetoxy side chain and the material is stirred for 4 hours at 10°C. Mixture of Ethyl Acetate and Sodium Carbonate solution is added to the reaction mass and stirred for 30 minutes at 25°C. Water layer is separated and send to E.T.P. Carbon is added to Ethyl Acetate layer and stirred for 30 minutes at 25°C. Carbon is filtered and Ethyl Acetate layer is charged to the next reactor. Ethyl Acetate is distilled under vacuum until precipitation is observed at 30°C. Methanol is charged to the reaction mass and stirred for 1 hour at 10°C. Material is filtered and obtained material is Cefuroxime Axetil, which is dried.

3. CEFPODOXIME PROXETIL:

Step – I 7AMCA to Formation

Sulfolane is charged in the reactor followed by Methanol at 25°C. The reaction mass is cooled to 15°C and BF3 gas is purged for 20 minutes. 7ACA is charged to the reaction mass at 45°C stirred for 1 hour. Chilled DMW is added to the reaction mass followed by Sodium Chloride and stirred for 40 minutes. Methylene Chloride is charged to the reaction mass and stirred for 10 minutes at 35°C. Settle the reaction mass send MDC layer for distillation. Add Tri Ethyl Amine to adjust pH to 1.0 at 15°C and stir the mass for 30 minutes. Again, adjust pH to 3.1 with Tri Ethyl Amine at 15°C and stir the mass for 40 minutes to precipitate the material. Filter the material and filtered material obtained is 7AMCA, which is sent wet for next step.

Step – II Cefpodoxime Acid Formation

DMAC is charged in the reactor followed by MDC and cooled to 15°C. MAEM is charged to the reaction mass at 15°C and pH is adjusted to 7.0 – 7.3 by Triethyl Amine and stirred for 2 hours. DMW is

Chemical Reaction:

----------->

Na2CO3

DMAc Ethyl acetate Cyclohexane

DM water Cefuroxime Axetil (M.W : 510.0) Methanol

Cefuroxime Acid (M.W : 424.4)



added to the reaction mass and stirred for 25 minutes. The mass is settled, and organic layer is separated. The pH is adjusted to 6.0 to 6.5 of aqueous layer by Sulphuric Acid at 25°C. Adjust the pH of aqueous solution to 2.8 with Sulphuric Acid at 25°C and cool the mass to 5°C and stir for 90 minutes. Filter the material and filtered material obtained is CEFPODOXIME ACID, which is dried for next step.

Step – III Cefpodoxime Proxetil Formation

Dimethyl Acetamide is charged to the reactor at 18°C followed by Cefpodoxime Acid and the reaction mass is cooled up to -5°C. DBU is charged to the reaction mass at -5°C and stir for 30 minutes. Ethyl ISO Propyl carbonate is charged to the mixture and stirred for 50 minutes. DMW and Ethyl Acetate mixture is charged to the reaction mass and stir for 50 minutes. Charge Sodium Thiosulphate Solution to the reactor mass at 20°C and stir for 30 minutes. Give settling and separate aqueous layer to ETP. Charge carbon to the Ethyl Acetate layer and stir for 30 minutes. Filter the carbon and Ethyl Acetate is distilled under vacuum at 30°C to get precipitation. Methanol is added to the reaction mass and stirred for 30 minutes and distilled under vacuum. Add DMW to the reaction mass for clarity and filter the reaction mass. Add Ammonia solution to adjust pH to 3.0 to 4.0 for precipitation at 30°C. Cool the mass to 10°C stir for 60 minutes. Filter the material and filtered material obtained is CEFPODOXIME PROXETIL, which is dried.



REACTION SCHEME FOR CEFPODOXIME PROXETIL

CH3OH

Methanol

1. DBU 2. DMAC 3. Cyclohexane 4. DMW 5. Eno carbon 6. Methanol

1. THF 2. DMW

3. Ethyl acetate 4. Triethylamine 5. H2SO4

CH2OCOCH3

+ BF3 Gas

AMCA

7-ACA

+

Sulfolane

CH2OCH3

CH2OCH3

AMCA

1. DMW 2. Triehtylamine 3. Sulphuric acid 4. Carbon

+

MAEM

Cefpodoxime Acid Pure

CH2OCH3

Cefpodoxime Acid

+ CH3

CH3CH -CO3 CH

I CH3

COOH

H

CH2OCH3

Cefpodoxime Acid Crude

CH2OCH3

Cefpodoxime Acid Crude

H

CH2OCH3

CH3

CH3CH -CO3 CH

COO CH3

Cefpodoxime Proxetil

+



4. AMPICILIN:

5. AMOXICILLIN:

Process description

There are four steps to manufacture AMOXYCILLIN, i.e. Fermentation, Beads formation (Coagulation of Enzyme Sludge), Formation of Ester, Formation of AM (End Product)

Process description

Ampicillin

Phenyl Glycine Base

Sulphuric Acid

Methanol

Phenyl Glycine Ester

+

6-Amino Penicillinic Acid

Pen G Acylase (Enzyme)

HCl

NaOH



6. CLOBETASOLE PROPIONATE

Process description

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF MDC AT RT, CHARGING OF BETAMETHASONE AT RT HEAT UPTO REFLUX, ADDITION OF TEOP AT 40˚C, STIRRING, DISTILLATION OF MDC COMPLETELY. ADDITION OF ACETONE, COOLING. ADDITION OF OPA. QUINCHING IN D M WATER. CENTRIFUGING. DRYING M/C NMT 0.5%. CHARING OF PYRIDINE AT RT. ADDITION OF CLOBETA STAGE I AT RT. COOLING. ADDITION OF MSC. QUINCHING. CENTRIFUGING. DRYING. CHARGING OF DMF AT RT. CHARGING OF CLOBETA STAGE II AT RT. HEAT UPTO 60˚C. ADDITION OF LITHIUM CHLORIDE. STIRRING. QUINCHING IN DM WATER. CENTRIFUGING. DRYING. CHARGING OF MEHANOL AT RT. CHARGING OF CLOBETA CRUDE AT RT. HEAT UPTO CLEARITY. ADDITION OF ACTIVATED CARBON. FILTRATION OVER NUFLOW BED. COLLECT FILTRAE IN GLASS FLASK. CONCENTRATED UPTO THICK MASS. UNLOADING & COOLING. FILRATION. DRYING. MICRONIZATION. QUALITY CONTROL SAMPLE AS PER REQUIREMENT OF IP/BP/USP

Amoxicillin

Para Hydroxy Phenyl Glycine Base

Sulphuric Acid

Methanol

Para Hydroxy Phenyl Glycine Ester

+

6-Amino Penicillinic Acid

Pen G Acylase (Enzyme)

HCl

NaOH



Stage: 1st

Stage: 2nd

Stage: 3rd



Stage: 4th

7. BETAMETHASONE DIPROPIONATE

Process description

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF MDC AT RT, CHARGING OF BETAMETHASONE AT RT, HEAT UPTO REFLUX, ADDITION OF TEOP AT 40˚C, ADDITION OF PTSA, STIRRING & CHECK TLC, DISTILLED OUT MDC, ADDITION OF ACETONE, COOLING, ADDITION OF OPA, STIRRING & CENTRIFUGING, DRYING M/C NMT 0.5%, CHARING OF PYRIDINE AT RT, CHARING OF STAGE I, COOLING, ADDITION PROPIONIC ANHYDRIDE, STIRRING & QUINCHING IN DM WATER, CENTRIFUGING, DRYING, CHARGING OF METHANOL, CHARGING OF STAGE II, HEAT UPTO CLEARITY, ADDITION OF ACTIVATED CARBON, FILTRATION OVER HYFLOW BED, COLLECT FILTRATE & ADDITION OF D M WATER, STIRRING & CENTRIFUGING, DRYING & MICRONIZATION

Stage: 1st



Stage: 2nd

Stage: 3rd

8. BETAMETHASONE VALERATE

Process description

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF MDC AT RT, CHARGING OF BETAMETHASONE AT RT, HEAT UPTO REFLUX, ADDITION OF TMOV, ADDITION OF PTSA, STIRRING FOR 30 MIUTES, CHECK TLC IF COMPLETED, DISTILLED OUT MDC COMPLETELY. ADDITION OF ACETONE , COOLING, ADDITION OF OPA, STIRRING, QUINCHNG IN D M WATER, STIRRING & CENTRIFUGING, DRYING M/C NMT 0.5%, CHARING OF ACETONE, CHARGING OF BETAMETHASONE VALERATE CRUDE, STIRRING, CHECK CLEARITY, ADDITION OF ACTIVATED CARBON, FILTRATION OVER HYFLOW BED, COLLECT FILTRATE & ADDITION OF D M WATER, STIRRING & CENTRIFUGING, DRYING M/C NMT 0.5%, QUALITY CONTROL SAMPLE AS PER REQUIREMENT.



BETAMETHASONE SODIUM PHOSPHATE Process description

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF THF, CHARGING OF BETAMETHASONE. COOLING, ADDITION OF PYROPHOSPHORYL CHLORIDE, STIRRING, QUINCHNG IN D M WATER, CHARGE ABOVE R/MASS IN GLASS FLASK, DISTILLATION OF THF, ADDITION OF CHLOROFORM, COOLING AND CENTRIFUGING, DRYING, CHARGING OF METHANOL AT RT, CHARING OF DEXA HYDROGEN PHOSPHATE RT, STIRRING & CHECK CLEARITY, ADDITION OF ACTIVATED CARBON, FILTRATION OVER HYFLOW BED, COLLECT FILTRATE IN GLASS FLASK, ADDITION OF CAUSTIC SODA SOLUTION, FILTRATION, DRYING M/C NMT 8.0%

Stage: 1st

Stage: 2nd



9. DEXAMETHASONE SODIUM PHOSPHATE

PROCESS DESCRIPTION

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF THF, CHARGING OF DEXAMETHASONE.

COOLING, ADDITION OF PYROPHOSPHORYL CHLORIDE, STIRRING, QUINCHNG IN D M WATER,

CHARGE ABOVE R/MASS IN GLASS FLASK, DISTILLATION OF THF, ADDITION OF CHLOROFORM,

COOLING AND CENTRIFUGING, DRYING, CHARGING OF METHANOL AT RT, CHARING OF DEXA

HYDROGEN PHOSPHATE RT, STIRRING & CHECK CLEARITY, ADDITION OF ACTIVATED CARBON,

FILTRATION OVER HYFLOW BED, COLLECT FILTRATE IN GLASS FLASK, ADDITION OF CAUSTIC

SODA SOLUTION, FILTRATION, DRYING M/C NMT 8.0%

Stage: 1st

Stage: 2nd



10. BECLOMETHASONE DIPROPIONTE

Process description

CLEANING & CHECKING OF GLASS FLASK, CHARGING OF HCL, CHARGING OF DB-XI. STIRRING, QUINCHING DM WATER, FILTRATION, DRYING, CHARGING OF MDC AT RT, CHARGING OF BECLO STAGE – I. HEATING UPTO 40˚C, ADDITIO OF TEOP, ADDITION OF PTSA, STIRRING, DISTILALTION OF MDC, ADDITION OF ACETONE, COOLING & ADDITION OF OPA. FILTRATION, DRYING, CHARGING OF PYRIDINE CHARGING OF BECLO STAGE – II, COOLING, ADDITION OF PROPIONIC ANHYDRIDE, STIRRING & QUINCHING IN D M WATER, CENTRIFUGING, DRYING, CHARGING OF ACETONE, CHARGING OF BECLO CRUDE, HEATING & CHECK CLEARITY, ADDITION OF ACTIVATED CARBON, FILTRATION OVER HYFLOW CELL, COLLECT FILTRATE IN GLASS FLASK, CONCENTRATION UPTO THICK MASS, UNLOADING & COOLING, FILTRATION, DRYING, MICRONIZATION, QUALITY CONTROL SAMPLE

Stage: 1st

Stage: 2nd



Stage: 3rd

Stage: 4th



11. MOMETASONE FUROATE

Process description

CLEANING & CHECKING OF GLASS FLASK. CHARGING OF ACETONE AT RT, CHARGING OF TEA AT RT, COOLING, ADDITION OF MSC & STIRRING, HEATING, ADDITION OF LITHIUM CHLORIDE, STIRRING, QUINCHING D M WATER, STIRRING & FILTRATION, DRYING, CHARGING OF MDC, CHARGING MOMETASONE STAGE – I. CHARGING OF TEA, COOLING ADDITION OF 2-FUROYL CHLORIDE, STIRRING, ADDITION OF SODIUM BICARBONATE SOLUTION, LAYER SEPARATION, COLLECT LAYER GLASS FLASK, DISTILLATION OF MDC, ADDITION OF THF, CHARGING OF HCL (LR), COOLING, ADDITION OF THF PRODUCT, STIRRING, QUINCHING D M WATER, FILTRATION, DRYING, CHARGING OF ACETONE, CHARGING O MOMETASONE FUROATE CRUDE, HEATING, CHECK CLEARITY, ADDITION OF ACTIVATED CARBON, FILTRATION OVER HYFLOW CELL, COLLECT FILTRATE IN G. F. DISTILLATION OF ACETONE, ADDITION OF IPA, COOLING, DRYING, MICRONIZATION, QUALITY CONTROL SAMPLE AS PER IP/BP/USP

12. METHYLCOBALAMIN

Process description

Cyanocobalamin is charged in GLR with process water and allow to stir. Add cobalt chloride and isobutanol and cool. Add Sodiumboro hydrate for reduction of Cyanocobalamin. After reduction add trimethyl sulfoxonium Iodide for methylation of reduction mass. Give Phenol and Chloroform washing and finally distill out water from mass and get Methylcobalamin production in acetone. Filter the acetone and dry.

Process Flow Chart:



Chemical Reaction:

13. OFLOXACIN

Process description

Cleaning and Checking of SSR, Charging of NMP in reactor, Charging of DMSO in same reactor, Charging of Q. Acid in same reactor, Charging of Methanol in same reactor, Heating up to 80-85 Centigrade, Check TLC, Addition of Methanol, Stirring and Cooling, Centrifuge- ML will go to Solvent Recovery/Sold to Buyer. Drying in FBD, milling of material, Packing in suitable container.

14. LEVOFLOXACIN

Process description

Cleaning and Checking of SSR, Charging of NMP in reactor, Charging of DMSO in same reactor, Charging of Levo Acid in same reactor, Charging of Methanol in same reactor, Heating up to 80-85 Centigrade, Check TLC

Addition of Methanol, Stirring and Cooling, Centrifuge- ML will go to Solvent Recovery/Sold to Buyer. Drying in FBD, milling of material, Packing in suitable container.



15. QUINON SULPHATE

Process description

Cleaning and Checking of SSR, Charging of DM water in reactor, Charging of Quinon Sulphate Crude in same reactor, Charging of Sulphuric Acid in same reactor, Check Clarity, Addition of Activated Carbon. Filtration over Hiflow Bed. Collect filtrate in SSR, Addition of NaOH solution, Stirring and cooling for crystallization, Drying in FBD, milling of material, Packing in suitable container.

16. CLOXACILLIN SODIUM

Process description

6-APA is reacted with a solution of CMIC in Ethyl acetate and water medium to get a condensation solution. Separate the aqueous layer and wash the organic layer with Sodium bi carbonate and sodium chloride solutions for remove the impurities.

Condensate organic layer reacted with Sodium Hexonate in Ethyl acetate media to get a crystalline CLOXACILLIN in ethyl acetate media. Filter the Cloxacillin solid by centrifugation, following which the material is dried and put through a series of powder processing steps prior to final packing.

Chemical reaction:

+

Ethyl Acetate

Soda Ash Ammonia

Sodium Hexonate



17. OXACILLIN SODIUM

Process description

6-APA is reacted with a solution of PMIC in Ethyl acetate and water medium to get a condensation solution. Separate the aqueous layer and wash the organic layer with Sodium bi carbonate and sodium chloride solutions for remove the impurities.

Condensate organic layer reacted with Sodium Hexonate in Ethyl acetate media to get a crystalline OXACILLIN in ethyl acetate media. Filter the Cloxacillin solid by centrifugation, following which the material is dried and put through a series of powder processing steps prior to final packing.

Process Flow Chart:



Chemical Reaction:

18. DI CLOXACILLIN SODIUM

Process description

6-APA is reacted with a solution of DI CMIC in Ethyl acetate and water medium to get a condensation solution. Separate the aqueous layer and wash the organic layer with Sodium bi carbonate and sodium chloride solutions for remove the impurities.

Condensate organic layer reacted with Sodium Hexonate in Ethyl acetate media to get a crystalline DI CLOXACILLIN in ethyl acetate media. Filter the Di Cloxacillin solid by centrifugation, following which the material is dried and put through a series of powder processing steps prior to final packing.



Chemical reaction:

+

Ethyl Acetate

Soda Ash Ammonia

Sodium Hexonate



19. FLUCOXACILLIN SODIUM

6-APA is reacted with a solution of FLU CMIC in Ethyl acetate and water medium to get a condensation solution. Separate the aqueous layer and wash the organic layer with Sodium bi carbonate and sodium chloride solutions for remove the impurities.

Condensate organic layer reacted with Sodium Hexonate in Ethyl acetate media to get a crystalline FLU CLOXACILLIN in ethyl acetate media. Filter the Flu Cloxacillin solid by centrifugation, following which the material is dried and put through a series of powder processing steps prior to final packing.

CHEMICAL REACTION:

+

Ethyl Acetate

Soda Ash Ammonia

Sodium Hexonate



Manufacturing Process - Proposed Products

1. POLYETHYLENE GLYCOL

Charge Di Ethelene Glycol in reactor. Add caustic potash flakes as a catalyst and start heating for

125 degree C achieve. Simultaneously in vacuum condition purge nitrogen. After that add Ethylene

Oxide in reactor as per mole calculation. And leave reactor for stirring for one hour. For

temperature reduction up to 50 degree C apply cooling water.

Chemical Reaction:

HOCH2OH + n(CH2CH2O) HO(CH2CH2O)n+1H

Where n: Average no of Oxyethylene group

2. HYDROGENATED CASTOR OIL ETHOXYLATE

Charge Hydrogenated Castor Oil in reactor. Add caustic potash flakes as a catalyst and start heating

for 125 degree C achieve. Simultaneously in vacuum condition purge nitrogen. After that add

Ethylene Oxide in reactor as per mole calculation. And leave reactor for stirring for one hour. For


Chemical Reaction:

C57H110O9 + n(CH2CH2O) C57H110O9(CH2CH2O)nH

Where n: No of moles of ethylene oxide

3. CASTOR OIL ETHOXYLATE

Charge Castor Oil in reactor. Add caustic potash flakes as a catalyst and start heating for 125 degree

C achieve. Simultaneously in vacuum condition purge nitrogen. After that add Ethylene Oxide in

reactor as per mole calculation. And leave reactor for stirring for one hour. For temperature

reduction up to 50 degree C apply cooling water.

Chemical Reaction:

C57H104O9 + n(CH2CH2O) C57H103O9(CH2CH2O)nH


4. NONYL PHENOL ETHOXYLATES

Charge Nonyl Phenol in reactor. Add caustic potash flakes as a catalyst and start heating for 125

degree C achieve. Simultaneously in vacuum condition purge nitrogen. After that add Ethylene



Chemical Reaction:

C15H24O + nC2H4O C9H19C6H4(OCH2)nOH




5. OCTYL PHENOL ETHOXYLATES

Charge Octyl Phenol in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction:

C12H22O + nC2H4O C9H19C5H2(OCH2CH2)n OH


6. CARD PHENOL ETHOXYLATES

Charge Card Phenol in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction:

C21H30O + n(CH2CH2O) C9H19C12H10(CH2CH2O)nOH

Where n: No of moles of ethylene oxide.

7. STYRUNATED PHENOL ETHOXYLATES

Charge Styrunated Phenol in reactor. Add caustic potash flakes as a catalyst and start heating for




Chemical Reaction:

C30H30O + n(CH2CH2O) C9H19C21H10(CH2CH2O)nOH


8. LAURYL ALCOHOL ETHOXYLATES

Charge Lauryl Alcohol in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction:

C12H26O + n(CH2CH2O) C12H25(OCH2CH2)NOH


9. TRIDECYL ALCOHOL ETHOXYLATES



Charge Tridecyl Alcohol in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction:

C13H28O + n(CH2CH2O) C13H27(CH2CH2O)nOH


10. CESTOSTYRYL ALCOHOL ETHOXYLATES

Charge Cetostyryl Alcohol in reactor. Add caustic potash flakes as a catalyst and start heating for




Chemical Reaction:

C18H38O + n(CH2CH2O) C18H37(CH2CH2O)nOH


11. TALLOW AMINE ETHOXYLATES

Charge Tallow Amine in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction

C18H32N + n(CH2CH2O) C18H30(C2H4O)nNH2


12. STEARYL AMINE ETHOXYLATES

Charge Stearyl Amine in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction

C18H39N + n(CH2CH2O) C18H37(CH2CH2O)nNH2


13. COCO AMINE ETHOXYLATES

Charge Coco Amine in reactor. Add caustic potash flakes as a catalyst and start heating for 125






Chemical Reaction

R-NH2 + n(C2H4O) R(C2H4O)nNH2


R: alkyl mainly C12-18

14. OLEYL AMINE ETHOXYLATES

Charge Oleyl Amine in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction

C18H37N + n(CH2CH2O) C18H35(CH2CH2O)nNH2


15. POLY SORBATE ETHOXYLATES

Charge Sorbitian Mono Laurate in reactor. Add caustic potash flakes as a catalyst and start heating

for 125 degree C achieve. Simultaneously in vacuum condition purge nitrogen. After that add

Ethylene Oxide in reactor as per mole calculation. And leave reactor for stirring for one hour. For


Chemical Reaction

C18H34O6 + n(C2H4O) C18H34O6(C2H4O)n


16. STREARIC ACID ETHOXYLATES

Charge Stearic Acid in reactor. Add caustic potash flakes as a catalyst and start heating for 125




Chemical Reaction

R-COOH + n(C2H4O) RCOO(C2H4O)nH


R: alkyl Fatty chain

17. METFORMIN HYDROCHLORIDE:

Take pipe for charging n-butanol 300ml in clean and dry vessel under nitrogen atmosphere at 25-

35°C for 10 minutes. After charging of n-Butanol, Charge the Dicyandiamide (DCDA) 0.5075 MT in

reaction vessel then charge Di methyl amine Hydrochloride (DMA.HCL) 0.4974 MT and start



stirring for 10 min continuously. Raise the temperature up to 80°C to 100°C and maintain that

temperature for 60 min and check for clear solution physically. Transfer the mass through

membrane filter to crystallizer up to 60 min then raise the temperature up to 100° C to 118°C for

30 min. Maintain the reaction mass & collect water azeotrpically after 120 min. Check moisture

content till it become <0.5 % after 240 min. Maintain the reaction under pressure (approx. 2 kg) &

slowly raise the temperature up to 132°C to136° C for 1200 min. Slowly cool the temperature of

reaction mass for 120 min. Further cool the temperature up to 20° C -25° C of reaction mass up to

90 min. Maintain the reaction mass with same temperature for 60 min. Centrifuge the wet cake &

slurry wash with n-butanol 200 ml up to 30 min. Spin the cake for 30 min. Again, slurry wash the

wet cake with n-butanol 200 ml up to 30 min. Unload the wet cake and Spin the cake. Dry the solid

in oven till LOD became NMT 0.5 % in 70° C - 80° C for 360 min. Unload the solid & submit the

sample for complete analysis.

Chemical Reaction

18. METHYLCOBALAMIN

Process description

Cyanocobalamin is charged in GLR with process water and allow to stir. Add cobalt chloride and

isobutanol and cool. Add Sodiumboro hydrate for reduction of Cyanocobalamin. After reduction

add trimethyl sulfoxonium Iodide for methylation of reduction mass. Give Phenol and Chloroform

washing and finally distill out water from mass and get Methylcobalamin production in acetone.

Filter the acetone and dry.

C2H4N4 + C2H8NCl C4H12N5Cl

Dicyandiamide Dimethyl amine Hydrochloride

Metformin Hydrochloride



Process Flow Chart:



Chemical Reaction:



Mass Balance – Existing Products

365 KG. HCL

1000 KG. METHANOL

740 KGS. WATER LAYER TO ETP

780 KG. GVNE

1500 KG. PHENOL

14600 KG. BUTYL ACETATE

10 KG. CARBON

2350 LTR. WATER

120 KG 3% SODIUM BI CARBONATE

25 KG. SULPHURIC ACID

400 KG. ACETONE

2835 KG. ML TO E.T.P. 10 KG. E.D.T.A.

200 KG. ETHYL ACETATE

125 KG. HCL

950 KG. Wet Methyl Ester

2450 KG. WATER

FLOW DIAGRAM AND MATERIAL BALANCING OF CEFIXIME TRIHYDRATE

STEP - I GVNE

STEP - II GVNE TO 7 AVCA

1000 WET GVNE

450 KG. ACETONE M.L. RECOVERY

16100 KG. BUTYL ACETATE + PHENOL

MIXTURE SEND FOR DISTILLATION

50 KG. SODIUM HYDROXIE

410 KG WET 7AVCA FOR DRYING

500 KGS MEOH ML FOR DISTILLATION

1000 KG. GCLE

600 KG. DMF

670 KG. DRY CEFIXIMETOTAL OUT : 34400 KG TOTAL IN : 34400 KG

400 KG. MICA ESTER

335 KG. 7AVCA

60 KG. HCL

950 KG. WET METHYL ESTER

100 KG. MDC LOSS

2745 KG. WATER LAYER TO ETP

1025 KG. WET CEFIXIME TRIHYDRATE

2535 KG. ML TO ETP

STEP - IV 7 METHYL ESTER TO CEFIXIME

25 KG. SODIUM HYDROXIDE

10 KG. CARBON

2800 KG. DMW

STEP - III 7 AVCA TO METHYL ESTER

1000 KG. M.D.C.

100 KG. TRI ETHYL AMINE

900 KG. MDC + 200 KG. ETHYL ACETATE

FOR RECOVERY

3610 KG MEOH + MDC + DMF FOR

RECOVERY

300 KG. MDC + MEOH DISTILLATION

LOSS

735 kg. DMW

100 KG. SOD. BROMIDE

300 KG. TPP

1333 KG. MDC

667 KG. FORMALDEHYDE



70 KG. 10% HCL SOLUTION

1000 KG. WATER

500 KG. METHANOL

670 KG. DRY CEFUROXIME

AXETIL

FLOW DIAGRAM AND MATERIAL BALANCING OF CEFUROXIME AXETIL

STEP - I

550 KG. 7ACA

HYDROXY CEFUROXIME

600 KG.SIDE CHAIN

25.2 ACETIC ACID

TOTAL OUT : 10741 KG TOTAL IN : 10741 KG

12.5 KG. CARBON

825 KG. METHANOL

STEP - III

CEFUROXIME ACID TO AXETIL

1870 KG. ML TO E.T.P.

333 KG. ACETOXY SIDE CHAIN

145.8 KG. SODIUM BI CARBONATE

800 KG. DMW

3.O.H. CEFUROXIME ACID

880 KG. WET CEFUROXIME ACID

1200 KG. ML TO ETP

1166 KG. ETHYL ACETATE

200 KG ETHYL ACETATE VAPOUR LOSS

1792 KG. ETHYL ACETATE + DMAC FOR

RECOVERY

1333 KG. ACETONE

580 KG. CEFUROXIME ACID

900 KG. WET CEFUROXIME AXETIL833 KG. DMAC

66.7 KG. SODIUM CARBONATE

900 KG. WET 3.O.H. COMPOUND

650 KG. 3.O.H. COMPOUND

1000 KG. DMW

167.7 KG. CSIC

83.1 KG. CAUSTIC LYE

STEP - II

720 KG.METHANOL FOR DISTILLATION

1100 KG ML TO ETP

1179 KG ACETONE + WATER DISTILLED

AND SEND TO SOLVENT RECOVERY

FLOW DIAGRAM AND MATERIAL BALANCING OF CEFPODOXIME PROXETIL

STEP - I

950 KG. WET 7AMCA

7AMCA FORMATION

655 KG. 7ACA

1000 KG DMW

4000 KG.SULFOLANE

85 KG. SODIUM HYDROXIDE

200 KG. SODIUM CHLORIDE

6000 KG. MDC

9490 KG. MDC + SUFOLANE FOR

RECOVERY

300 KG. MDC VAPOUR LOSS

1200 KG ML TO ETP

730 KG. CEFPODOXIME PROXETIL WET

12575 KG.Ethyl Acetate + Methanol +

DMAC Layer for Distilaltion

300 KG. ETHYL ACETATE VAPOUR LOSS


1500 KG. Dimethyl Acetamide

600 KG. Ammonie Solution2800 KG. ML TO ETP

8000 KG. Ethyl Acetate

3000 KG. METHANOL

Propyl Carbonate

13 KG. Sodium Thiosulphate

150 KG. DBU

2200 KG. DMW

660 KG. DRY

CEFPODOXIME PROXETIL

CEFPODOXIME PROXETIL

STEP - II

15 KG. CARBON

STEP - III

527 KG. Cefpodoxime Acid

400 KG. Iodo Ethyl ISO

850 KG. WET 7 AMCA

2983 KG MEOH + TRI ETHYL AMINE +

DMAC MIXTURE FOR DISTILLATION

500 KG. MAEM

900 KG. DIMETHYL ACETAMIDE CEFPODOXIME ACID FORMATION

630 KG. WET CEFPODOXIME ACID

280 KG. TRIETHYL AMINE

83 KG. SULPHURIC ACID1200 KG. ML TO ETP

1200 MEOH

1000 KG. DMW



166 KG CAUSTIC LYE 47 %

184 KG PHENYL GLYCIN ESTER

200 KG 6 APA

360 LTR DMW

70 KG DMW

FLOW DIAGRAM AND MATERIAL BALANCING OF AMPICILIN

STEP - I

217 KG PHENYL GLYCIN BASE

PHENYL GLYCINE ESTER FORMATION180 KG METHANOL

156 KG SULPHURIC ACID100 KG TO ETP

280 KGS MEOH ML FOR DISTILLATION

40 KG. DMW

744 KG REACTION MASS

379 Kg Wet PHENYL GLYCINE ESTER


0.3 KG EDTA

175 KG CAUSTIC LYE

STEP - III


160 KG HCl

30 KG DMW

STEP - II

ENZYMATIC REACTION FOR AMPICILIN

SYNTHESIS

332 KG DRY AMPICILIN


1.5 KG HYFLOW

STEP - IV

751 KG. WET AMPICILIN

CRYSTALLIZATION430 KG TO ETP

HYDROLYSIS





200 KG 6 APA

10 KG DMW

0.2 KG EDTA

TOTAL OUT : 2497 KG TOTAL IN : 2497KG

FLOW DIAGRAM AND MATERIAL BALANCING OF AMOXICILLIN TRIHYDRATE

STEP - I

280 Kg Wet HYROXY PHENYL GLYCINE

ESTER

HYDROXY PHENYL GLYCINE ESTER FORMATION

439 KGS MEOH ML FOR DISTILLATION180 KG METHANOL

156 KG SULPHURIC ACID


STEP - III

1.0 KG HYFLOW

STEP - IV

753 KG. WET AMOXICILLIN

CRYSTALLIZATION


10 KG TO ETP 175 KG CAUSTIC LYE

HYDROLYSIS588 KG REACTION MASS


160 KG HCl

332 KG DRY AMOXICILLIN

217 KG HYDROXY PHENYL GLYCIN BASE

217 KG HYDROXY PHENYL GLYCIN ESTER

STEP - II

ENZYMATIC REACTION FOR AMOXICILLIN

SYNTHESIS



1200 KG MDC

85 KG TEOP

5.0 KG PTSA

600 KG ACETONE

0.83 KG ORTHOPHOSPHOEIC ACID

1000 KG METHANOL

10 KG ACTIVATED CARBON

TOTAL OUT :5758 KG TOTAL IN :5758 KG

400 KG DMW

STEP - II

200 KG WET STEP 2 110 KG DRY FROM STEP 1

STEP - III

10 KG HYFLOW

230 KG WET STEP 2

132 KG FROM STEP 2

600 KG DMF

FLOW DIAGRAM AND MATERIAL BALANCING OF CLOBETASOLE PROPIONATE

STEP - I

180 KG WET STAGE 1

1911 KGS MDC + ACETONE FOR

RECOVERY

300 KG TO ETP

100 KG DRY CLOBETASOLE

PROPIONATE

100.0 KG BETAMETHASONE BASE

450 KG DMW

300 KG PYRIDINE

60 KG METHANESULPHONYL CHLORIDE

115 KG LITHIUM CHLORIDE

450 KG DMW

720 KG TO ETP

580 DMF FOR RECOVERY

487 KG TO ETP

115 KG FROM STEP 3

STEP - IV

150 KG. WET WET CLOBETASOLE

15 KG ETHYL ACETATE

1000 KG METHANOL FOR RECOVERY



1200 KG MDC

85 KG TEOP

5.0 KG PTSA

600 KG ACETONE

1000 KG METHANOL


180 KG WET STAGE 1

STEP - I

100 KG DRY

BETAMETHASONE DI

PROPIONATETOTAL OUT : 4730 KG TOTAL IN : 4730 KG

5 KG HYFLOW

STEP - III

140KG WET BETAMETAHSONE

DIPROPIONATE

990 KGS METHANOL FOR RECOVERY120 KG FROM STEP 2

FLOW DIAGRAM AND MATERIAL BALANCING OF BETAMETASONE DI PROPIONATE

STEP - II

330 KG WET STEP 2 110 KG DRY FROM STEP 1

150 KG PYRIDINE

100 KG PROPIONIC ANHYDRIDE630 KG TO ETP

600 KG DMW

650 KG DMW

730 KG TO ETP

1730KGS MDC FROM RECOVERY

100.0 KG BETAMETHASONE BASE



1200 KG MDC

100 KG TEOV

5.0 KG PTSA

500 KG ACETONE

1000 KG ACETONE


10 KG HYFLOW

100 KG DRY

BETAMETHASONE

VALERATE

740 KG DMW800 KG TO ETP

120 KG FROM STEP 1


STEP - II

125 KG WET BETAMETHASONE

VALERATE

900 KG ACETONE FOR RECOVERY

115 KG VAPOUR LOSS

FLOW DIAGRAM AND MATERIAL BALANCING OF BETAMETASONE VALERATE

STEP - I

135 KG WET STAGE 1100.0 KG BETAMETHASONE BASE

1250 KGS MDC FROM RECOVERY

465 KG ACETONE FOR DISTILLATION

5.0 KG ORTHO PHOSPHORIC ACID

600 KG THF

80 KG PYROPHOSPHORYL CHLORIDE

10 KG CHLOROFORM

380 KG DMW

1500 KG ISO PROPYL ALCOHOL


10 KG HYFLOW

100 KG DRY BETAMETHASONE SODIUM

PHOSPHATETOTAL OUT : 3622 KG TOTAL IN : 3622 KG

STEP - II

125 KG WET BETAMETHASONE SODIUM

PHOSPHATE

115 KG FROM STEP 1

800 KG METHANOL

2327 KG IPA FOR RECOVERY

2 KG CAUSTIC

FLOW DIAGRAM AND MATERIAL BALANCING OF BETAMETHASONE SODIUM PHOSPHATE

STEP - I

170 KG WET STAGE 1

600 KGS THF FROM RECOVERY100.0 KG BETAMETHASONE BASE

400 KG TO ETP



600 KG THF

80 KG PYROPHOSPHORYL CHLORIDE

10 KG CHLOROFORM

380 KG DMW

1500 KG ISO PROPYL ALCOHOL


10 KG HYFLOW


2 KG CAUSTIC

100 KG DRY DEXAMETHASONE SODIUM

PHOSPHATE

800 KG METHANOL

STEP - II

125 KG WET DEXAMETHASONE

SODIUM PHOSPHATE

115 KG FROM STEP 1

2327 KG IPA FOR RECOVERY

FLOW DIAGRAM AND MATERIAL BALANCING OF DEXAMETHASONE SODIUM PHOSPHATE

STEP - I

170 KG WET STAGE 1

100.0 KG DEXAMETHASONE BASE600 KGS THF FROM RECOVERY

400 KG TO ETP

800 KG HCl

100 KG CHLOROFORM

100 KG KOH

1000 KG ACETONE


110 KG FROM STEP 3


10 KG HYFLOW

180 KG. WET WET BECLOMETHASONE

DI PROPIONATE

100 KG DRY BECLOMETHASONE DI PROPIONATETOTAL OUT : 5485 KG TOTAL IN : 5485 KG

100 KG DRY FROM STEP 1

85 KG TEOP (TRIETHYL ORTHOPROPIONATE)

STEP - III

260 KG WET STEP 2

600 KG TO ETP

300 KG PYRIDINE

100 KG DRY FROM STEP 2

100 KG PROPIONIC ANHYDRIDE

360 KG DMW

STEP - IV

5.0 KG O P A (ORTHO PHOSPHORIC ACID)

450 KG DMW

5.0 KG PTSA

500 KG ACETONE

1200 KG MDC

STEP - II

175 KG WET STEP 2

1315 KG MDC FOR RECOVERY

400 KG TO ETP


FLOW DIAGRAM AND MATERIAL BALANCING OF BECLOMETHASONE DI PROPIONATE

STEP - I

195 KG WET STAGE 1

100.0 KG DB XI195 KG CHLOROFORM FOR RECOVERY

760 KG TO ETP

50 KG DMW



600 KG ACETONE

200 KG TRI ETHYL AMINE

50 KG METHANE SULFONYL CHLORIDE

100 KG DRY MOMETASONE FUROATE

400 KG TRI ETHYL AMINE

20 KG 2-FUROYL CHLORIDE


160 KG WET STEP 2

772 KG IPA FOR RECOVERY 112 KG DRY FROM STEP 2

800 KG IPA


10 KG HYFLOW

500 KG THF

1500 KG HCl

200 KG DMW

STEP - III

STEP - II

175 KG WET STEP 2100 KG DRY FROM STEP 1

1775 KG TEA + THF FOR RECOVERY100 KG SODIUM BICARBONATE

870 KG TO ETP

FLOW DIAGRAM AND MATERIAL BALANCING OF MOMETASONE FUROATE

STEP - I

145 KG WET STAGE 1

855 KG ACETONE FOR RECOVERY100.0 KG 8 DM

250 KG TO ETP

300 KG DMW



1400 KG ACETONE

220 KG METHANOL

TOTAL OUT : 5490 KG TOTAL IN : 5490 KG100 KG DRY METHYLCOBALAMIN

90 KG METHYL IODIDE

110 KG SODIUM BOROHYDRIDE

500 KG PHENOL

40 KG CHLOROFORM

210 KG DMW

100 KG DMW

STEP - II

140 KG WET METHYLCOBALAMIN

2550 KG CHLOROFORM LAYER FOR

RECOVERY

800 KG AQUOUS LAYER

1920 KG CHLOROFORM


80 KG TO ETP

FLOW DIAGRAM AND MATERIAL BALANCING OF METHYLCOBALAMIN

STEP - I

800 KG AQUOUS LAYER 100.0 KG CYANOCOBALAMIN

250 KG TO ETP

500 KG DRY OFLOXACIN

60 KG DMW


STEP - II

800 KG WET OFLOXACIN

1565 KG METHANOL FOR RECOVERY2155 KG REACTION MASS STEP 1

250 KG METHANOL

100 KG TO ETP

FLOW DIAGRAM AND MATERIAL BALANCING OF OFLOXACIN

STEP - I


500 KG Q ACID (OFLOXACIN)

125 KG DMSO

1000 KG METHANOL

500 KG N-METHYL PIPERAZINE

30 KG DMW



500 KG DRY LEVOFLOXACIN



30 KG DMW

STEP - II

800 KG WET LEVOFLOXACIN

1565 KG METHANOL FOR RECOVERY2155 KG REACTION MASS STEP 1

250 KG METHANOL

100 KG TO ETP60 KG DMW

FLOW DIAGRAM AND MATERIAL BALANCING OF LEVOFLOXACIN

STEP - I

500 KG LEVO ACID

125 KG DMSO

1000 KG METHANOL

500 KG N-METHYL PIPERAZINE

90 KG DMW

TOTAL OUT : 1500 KG TOTAL IN : 1500 KG500 KG DRY QUINONE SULPHATE

27.5 KG SULPHURIC ACID


25 KG HYFLOW

100 KG DMW

STEP - II

622.5 KG WET QUINONE SULPHATE

677.5 KG CLEAR LAYER FROM STEP 1

55 KG CAUSTIC 200 KG TO ETP

FLOW DIAGRAM AND MATERIAL BALANCING OF QUINONE SULPHATE

STEP - I

500 KG QUINONE SULPHATE CRUDE

677.5 KG CLEAR LAYER



500 KG CMIC

11.5 KG ETHYL ACETATE

500 KG LIQ AMMONIA

12.5 KG SODIUM CARBONATE

125 KG SODIUM SULPHATE

250 KG SODIUM CHLORIDE

STEP - III

1120 KG AQUOUS LAYER TO ETP

1029 KG ORAGANIC LAYER

250 KG NACL FOR RECYCLE

500 KG DMW

STEP - II

REACTION

500 KG 6 APA

TOTAL IN : 3963 KGTOTAL OUT : 3963 KG

CONDENSATION

800 KG WET DI CLOXACILLIN

449 KG TO RECOVERY

220 KG SODIUM HEXONATE

1029 KG ORGANIC LAYER FROM STEP 2

500 KG DRY CLOXACILLIN

SODIUM

FLOW DIAGRAM AND MATERIAL BALANCING OF CLOXACILLIN SODIUM

STEP - I

SODIUM 2 ETHYL HEXONATE FORMATION

50 KG 2-EHA

15 KG MIBK

15 KG MIBK FOR RECOVERY

220 KG SODIUM 2 ETHYL HEXONATE

80 KG TO ETP250 KG CAUSTIC LYE 47 %

500 KG PMIC


500 KG LIQ AMMONIA



TOTAL IN : 3963 KG

500 KG DRY OXACILLIN

SODIUM



80 KG TO ETP



TOTAL OUT : 3963 KG

STEP - III

CONDENSATION

800 KG WET OXACILLIN

449 KG TO RECOVERY


STEP - II

1120 KG AQUOUS LAYER TO ETP500 KG 6 APA


500 KG DMW

REACTION


FLOW DIAGRAM AND MATERIAL BALANCING OF OXACILLIN SODIUM

STEP - I


50 KG 2-EHA

15 KG MIBK




500 KG DI CMIC


500 KG LIQ AMMONIA



STEP - II

REACTION

1029 KG ORAGANIC LAYER STEP 2



TOTAL OUT : 3963 KG

1120 KG AQUOUS LAYER TO ETP

TOTAL IN : 3963 KG

STEP - III

CONDENSATION

800 KG WET DI CLOXACILLIN

449 KG TO RECOVERY


500 KG DRY DI

CLOXACILLIN SODIUM

500 KG 6 APA


500 KG DMW

FLOW DIAGRAM AND MATERIAL BALANCING OF DI CLOXACILLIN SODIUM

STEP - I


50 KG 2-EHA


80 KG TO ETP15 KG MIBK





500 KG F CMIC


500 KG LIQ AMMONIA



500 KG DRY

FLUCLOXACILLIN SODIUMTOTAL OUT : 3963 KG TOTAL IN : 3963 KG

500 KG DMW

STEP - III

CONDENSATION

800 KG WET FLUCLOXACILLIN

449 KG TO RECOVERY



REACTION

1120 KG AQUOUS LAYER TO ETP500 KG 6 APA




STEP - II

FLOW DIAGRAM AND MATERIAL BALANCING OF FLUCLOXACILLIN SODIUM

STEP - I


15 KG MIBK FOR RECOVERY 50 KG 2-EHA

220 KG SODIUM 2 ETHYL HEXONATE15 KG MIBK

80 KG TO ETP250 KG CAUSTIC LYE 47 %



Mass Balance – Proposed Products

Di Ethelene Glycol Charge

Catalyst Addition and Heating

Nitrogen Purging

Vacuum

Ethylene Oxide Condensation

Cooling

Poly Ethylene Glycol

PER KG

1 120.00

2 1.50

3 332.000

453.50

MASS BALANCE FOR POLY ETHYLENE GLYCOL

TOTAL TOTAL 453.50

*Note: Per Kg of Product Basis

Ethylene Oxide Poly Ethylene Glycol 453.5

Di Ethelene Glycol Waste Water 0

Catalyst Hazardous Waste 0

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Hydrogenated

Castor OilCharge


Nitrogen Purging

Vacuum


Cooling

Hydrogenated Castor

Oil Ethoxylate

PER KG

1 34.60

2 3.10

3 65.400

103.10


Ethylene Oxide Hydrogenated Castor Oil 103.1

TOTAL TOTAL 103.10

Hydrogenated Castor Oil Waste Water 0


MASS BALANCE FOR HYDROGENATED CASTOR OIL ETHOXYLATE

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Castor Oil Charge


Nitrogen Purging

Vacuum


Cooling

Castor Oil Ethoxylate

PER KG

1 34.60

2 3.10

3 65.400

103.10


Ethylene Oxide Castor Oil Ethoxylates 103.1

TOTAL TOTAL 103.10

Castor Oil Waste Water 0


MASS BALANCE FOR CASTOR OIL ETHOXYLATE

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Nonyl Phenol Charge


Nitrogen Purging

Vacuum


Cooling

Nonyl Phenol

Ethoxylate

PER KG

1 53.22

2 0.80

3 106.460

160.48


Ethylene Oxide Nonyl Phenol Ethoxylates 160.48

TOTAL TOTAL 160.48

Nonyl Phenol Waste Water 0


MASS BALANCE FOR NONYL PHENOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Octyl Phenol Charge


Nitrogen Purging

Vacuum


Cooling

Octyl Phenol

Ethoxylate

PER KG

1 31.90

2 0.50

3 68.100

100.50


Ethylene Oxide Octyl Phenol Ethoxylates 100.5

TOTAL TOTAL 100.50

Octyl Phenol Waste Water 0


MASS BALANCE FOR OCTYL PHENOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Card Phenol Charge


Nitrogen Purging

Vacuum


Cooling

Card Phenol

Ethoxylate

PER KG

1 36.20

2 0.50

3 63.800

100.50


Ethylene Oxide Card Phenol Ethoxylates 100.5

TOTAL TOTAL 100.50

Card Phenol Waste Water 0


MASS BALANCE FOR CARD PHENOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Lauryl Alcohol

EthoxylatesCharge


Nitrogen Purging

Vacuum


Cooling

Lauryl Alcohol

Ethoxylates

PER KG

1 38.10

2 0.60

3 61.900

100.60


Ethylene Oxide Lauryl Alcohol Ethoxylates 100.6

TOTAL TOTAL 100.60

Lauryl Alcohol Ethoxylates Waste Water 0


MASS BALANCE FOR LAURYL ALCOHOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Styrunated Phenol Charge


Nitrogen Purging

Vacuum


Cooling

Styrunated Phenol

Ethoxylate

PER KG

1 31.25

2 1.00

3 68.750

101.00


Ethylene Oxide Styrunated Phenol Ethoxylate 101

TOTAL TOTAL 101.00

Styrunated Phenol Waste Water 0


MASS BALANCE FOR STYRUNATED PHENOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Tridecyl Alcohol Charge


Nitrogen Purging

Vacuum


Cooling

Tridecyl Alcohol

Ethoxylates

PER KG

1 36.20

2 0.50

3 63.800

100.50


Ethylene Oxide Tridecyl Alcohol Ethoxylates 100.5

TOTAL TOTAL 100.50

Tridecyl Alcohol Waste Water 0


MASS BALANCE FOR TRIDECYL ALCOHOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Cestostyryl

AlcoholCharge


Nitrogen Purging

Vacuum


Cooling

Cestostyryl Alcohol

Ethoxylates

PER KG

1 23.00

2 0.50

3 77.000

100.50


Ethylene Oxide Cestostyryl Alcohol Ethoxylates 100.5

TOTAL TOTAL 100.50

Cestostyryl Alcohol Waste Water 0


MASS BALANCE FOR CESTOSTYRYL ALCOHOL ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Tallow Amine Charge


Nitrogen Purging

Vacuum


Cooling

Tallow Amine

Ethoxylates

PER KG

1 30.00

2 0.40

3 70.000

100.40


Ethylene Oxide Tallow Amine Ethoxylates 100.4

TOTAL TOTAL 100.40

Tallow Amine Waste Water 0


MASS BALANCE FOR TALLOW AMINE ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Stearyl Amine Charge


Nitrogen Purging

Vacuum


Cooling

Stearyl Amine

Ethoxylates

PER KG

1 38.00

2 0.40

3 62.000

100.40


Ethylene Oxide Stearyl Amine Ethoxylates 100.4

TOTAL TOTAL 100.40

Stearyl Amine Waste Water 0


MASS BALANCE FOR STEARYL AMINE ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Coco Amine I Charge


Nitrogen Purging

Vacuum


Cooling

Coco Amine

Ethoxylates

PER KG

1 48.50

2 0.40

3 51.500

100.40


Ethylene Oxide Coco Amine Ethoxylates 100.4

TOTAL TOTAL 100.40

Coco Amine I Waste Water 0


MASS BALANCE FOR COCO AMINE ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Oleyl Amine I Charge


Nitrogen Purging

Vacuum


Cooling

Oleyl Amine

Ethoxylates

PER KG

1 19.60

2 0.40

3 100.000

120.00


Ethylene Oxide Oleyl Amine Ethoxylates 120

TOTAL TOTAL 120.00

Oleyl Amine I Waste Water 0


MASS BALANCE FOR OLEYL AMINE ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Sorbitian Mono

LaurateCharge


Nitrogen Purging

Vacuum


Cooling

Poly Sorbate

Ethoxylate

PER KG

1 28.50

2 0.50

3 71.500

100.50


Ethylene Oxide Poly Sorbate Ethoxylate 100.5

TOTAL TOTAL 100.50

Sorbitian Mono Laurate Waste Water 0


MASS BALANCE FOR POLY SORBATE ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg

Stearic Acid Charge


Nitrogen Purging

Vacuum


Cooling

Stearic Acid

Ethoxylate

PER KG

1 50.00

2 0.50

3 50.000

100.50


Ethylene Oxide Stearic Acid Ethoxylate 100.5

TOTAL TOTAL 100.50

Stearic Acid Waste Water 0


MASS BALANCE FOR STREARIC ACID ETHOXYLATES

SR NO

INPUT OUTPUT

INPUT OUTPUT PER Kg



Mass Balance for Metformin Hydrochloride:

INPUT PER KG OUTPUT PER Kg

1 n-butanol 700 System loss 2% 686

2 Dicyandiamide (DCDA) 507.5 Metformin Hydrochloride 1000

3 Dimethyl amine

Hydrochloride (DMA.HCL) 497.4

Total 1000 1000

1400 KG ACETONE

220 KG METHANOL

TOTAL OUT : 5490 KG TOTAL IN : 5490 KG100 KG DRY METHYLCOBALAMIN

90 KG METHYL IODIDE

110 KG SODIUM BOROHYDRIDE

500 KG PHENOL

40 KG CHLOROFORM

210 KG DMW

100 KG DMW

STEP - II

140 KG WET METHYLCOBALAMIN

2550 KG CHLOROFORM LAYER FOR

RECOVERY

800 KG AQUOUS LAYER

1920 KG CHLOROFORM


80 KG TO ETP

FLOW DIAGRAM AND MATERIAL BALANCING OF METHYLCOBALAMIN

STEP - I

800 KG AQUOUS LAYER 100.0 KG CYANOCOBALAMIN

250 KG TO ETP



2.12 Plant Infrastructure and Basic Requirements

The proposed project will require water, power, fuel, human resources, machineries & utilities etc.

The details of all major resources to be required for proposed project area described in subsequent

sections under respective headings.

2.12.1 Land

The total area available at the proposed project site is 3691.10 m2 (0.36911 Ha). The unit has &

will develop green belt area in 1476m2. Layout plan of the project site is given in Figure 2.1 area

calculation for proposed structures is given in Table 2.2.

2.12.2 Plant Equipment/Machineries

The list of plant machineries and utilities required to be installed for the proposed project is given

in Table 2.7 given below.

TABLE 2.7 DETAILS OF PLANT MACHINERIES

BLOCK A – Betalactum Sr. No Equipment Name Equipment ID MOC Capacity

1. Reactor R-101 SS 316 18000 L

2. Reactor R-102 SS 316 18000 L

3. Reactor R-103 SS 316 16000 L

4. Reactor R-104 SS 316 15000 L

5. Reactor R-105 SS 316 20000 L

6. Reactor R-106 SS 316 21000 L

7. Reactor R-107 SS 316 28000 L

8. Reactor R-108 SS 316 28000 L

9. Reactor R-109 SS 316 28000 L

10. Reactor R-110 SS 316 29000 L

11. Reactor R-111 SS 316 29000 L

12. Reactor R-112 SS 316 29000 L

13. Reactor R-113 SS 316 29000 L

14. Reactor R-114 SS 316 30000 L

15. Reactor R-115 SS 316 30000 L

16. Reactor R-116 SS 316 30000 L

17. Reactor R-117 SS 316 30000 L

18. Reactor R-118 SS 316 30000 L

19. Reactor R-119 SS 316 30000 L

20. Reactor R-120 SS 316 30000 L

21. Reactor R-121 SS 316 30000 L

22. Reactor R-122 MS 20000 L

23. Reactor R-123 MS 20000 L

24. Reactor R-124 MS 20000 L

25. Reactor R-125 SS 316 700 L

26. Reactor R-126 Glass Lined 5000 L

27. Reactor R-127 Glass Lined 5000 L



28. Reactor R-128 SS 316 100 L

29. Receiver RC-101 SS 316 1000 L

30. Receiver RC-102 SS 316 1000 L

31. Receiver RC-103 SS 316 700 L

32. Fluid Bed Dryer FBD-101 SS 316 300 Kg




36. Centrifuge CF-101 SS 316 60’’



39. Multi Mill MM-101 SS 316 --



42. Sifter SFT-101 SS 316 --

43. Sifter SFT-102 SS 316 --

44. Compactor COM-101 SS 316 --

45. Compactor COM-102 SS 316 --

46. Blender BLE-01 SS 316 1500 Kg

47. Fermenter FER-101 SS 316 15000 L

48. Fermenter FER-102 SS 316 1500 L

49. SS Tank TK-101 SS 316 15000 L

50. SS Tank TK-102 SS 316 700 L

51. SS Tank TK-103 SS 316 700 L

52. SS Tank TK-104 SS 316 700 L

53. Separator SEP-101 SS 316 --

54. Homogenizer HMG-101 SS 316 --

55. Microfiltration MIF-101 SS 316 --

Utility Sr. No. Equipment Equipment ID Capacity

1 Air Handling Unit AHU-101 7500 CFM


Block B - Methylcobalamin Sr. No Equipment Name Equipment ID MOC Capacity

1 Reactor R-201 Glass Lined 2000 L

2 Reactor R-202 Glass Lined 3000 L

3 Nutsche Filter NF-201 SS 316 30”

4 Bag Filter BF-201 SS 316 6”

5 Vacuum Tray Dryer VTD-201 SS 316 6 Tray

6 Sifter SFT-201 SS 316 12”

7 Blender BL-201 SS 316 100 L

8 Grinder GRD-201 SS 316 1 HP

9 Weighing Balance EB-201 SS 316 3.000 Kg



Utility



Sr. No. Equipment Equipment ID Capacity





5 Cooling Tower CT-03 2000 TR

6 Chilling Compressor Unit CC-04 60 TR

7 Vacuum System VS-01 250 m3/hr.

8 Hot Water System HWS-01 12 KW

Block C – Steroids Sr. No Equipment Name Equipment ID MOC Capacity

1 Reactor R-301 SS 316 1200 L 2 Glass Assembly R-302 Glass 200 L 3 Glass Assembly R-303 Glass 200 L 4 Glass Assembly R-304 Glass 100 L 5 Vacuum Tray Drier VTD-301 SS 316 16 Tray 6 Tray Dryer TRD-301 SS 316 24 Tray 7 Nutsche Filter NF-301 SS 316 100 L 8 Micronizer MCZ-301 SS 316 6” Size (80 CFM) 9 Centrifuge CF-301 SS 316 - 10 Multi Mill MM-301 SS 316 - 11 Weighing Balance EB-301 SS 316 100 Kg


1 Air Handling Unit AHU-301 3000 CFM BLOCK D – Anticancer

Sr. No Equipment Name Equipment ID MOC Capacity

1 Rota Evaporator RER-401 Glass 20 L

2 Glass Assembly GLA-401 Glass 50 L



5 Nutsche Filter NTF-401 SS 316 50 L

6 UV Chamber UVC-401 Powder Coated -

7 Weight Balance WTB-401 - 300 grams

8 Grinder GRI-401 - -





4 Forced Draft Ventilation FDV-401 2000 CFM

Ethoxylates Sr. No. Equipment MOC Capacity

1 EO Batch tank SS 316 3.5 KL



4 nitrogen plant 25 m3/hr.



5 nitrogen receiver tank MS 10 KL

6 Vacuum pump CI 10 HP

7 Vacuum receiver MS 1 KL

8 RM Storage Aluminum 30 KL

9 RM Storage Aluminum 30 KL

10 Gear Pump CI 01 Metformin

Sr No. Name of Equipment MOC

1 GL Reactor Glass lined

2 Sparkler filter SS-316


4 Centrifuge SS-316

5 Storage Tank SS/HDPE


7 Storage Tank SS/HDPE

8 Dryer SS-316

9 Pin mill SS-316

10 Pulvriser SS-316

11 Sifter SS-316

2.12.3 Details of Utilities

Various utilities required for proper functioning of manufacturing plants. These utilities include

Thermic Fluid Heater, cooling tower, D. G. sets, etc. Details of utilities services required for the

proposed project are given in following Table 2.8.

TABLE 2.8 DETAILS OF UTILITIES

Sr. No. Name of utility Capacity Quantity

Existing

1 Thermic Fluid Heater 20 Lac K.Cal 1

2 Air Handling Unit 7500 CFM 2







9 Cooling Tower 600 TR 2

10 Chilling Compressor Unit 60 TR 1

11 Vacuum System 250 m3/hr. 1

12 Hot Water System 12 KW 1

13 Forced Draft Ventilation 2000 CFM 1

14 Chilling Compressor 240 TR 2

15 DM Water Unit 5000 LPH 1

16 Transformer 1500 K.V.A. 1



17 Air Compressor 450 C.F.M 3

18 Air Dryer 150 CFM 1

19 Air receiver 2000 L 1

20 AHU (LAB) 800 C.F.M 1

21 Cold Room 0o to 5oC 1

22 Floating Aerator 5 KW 1

23 ETP 20 KL 1

24 Vacuum System 250 m3/hr. 2

Proposed

1 Thermic Fluid Heater 40 lac K Cal 1

2 DG Set 385 KVA 1

3 Cooling Tower 1000 TR 1

2.12.4 Power Requirement

Power requirement for the project will be 1600KVA, for proposed product 1000KVA, for existing

Products 600 KVA which is supplied by DGVCL. DG Set of 385 KVA installed for backup. No

additional D.G. sets to be installed.

2.12.5 Fuel

Existing Thermic Fluid Heater of 20Lac K.Cal 40 L/Hr. FO/LDO. For Proposed Thermic Fluid Heater

of 40 Lac K.Cal 555Nm3/Hr. Natural Gas & for 385 KVA DG Set 90 L/Hr. HSD will be used.

Fuel Storage & transportation details have been displayed in Table 2.9 & 2.10

TABLE 2.9 FUEL STORAGE DETAILS

Fuel Method of storage

Capacity & MOC Operating Condition Control Measures

Provided Press. Temp. 0C

FO/LDO Tank MS Atm Amb Fire Extinguisher provided. Isolated storage.

Natural Gas Pipeline Atm Amb Fire Extinguisher provided.

High Speed Diesel (HSD)

MS tank 20 KL Atm Amb Fire Extinguisher provided. Isolated storage.

TABLE 2.10 FUEL SOURCE & TRANSPORTATION DETAILS

Fuel Source of Supply Means of

Transportation Distance of supplier

from (Km)

FO/LDO IOCL, Vadodara Road Transport 10

Natural Gas Adani Gas Supply Pipeline 1

High Speed Diesel (HSD)

Mourvi Petroleum Road transport 2 km

2.12.6 Water

This is an existing unit manufacturing Bulk Drugs, Proposed products Ethoxylates & Metformin.

Existing Products - 38 KLD, Proposed Products 249 KLD, 40 KLD Treated Effluent from ETP to be



recycled after RO Plant & MEE hence 247.4 KLD fresh water will be used, which will be met through

GIDC Nandesari Industrial Estate water supply (attached as Annexure 11). Out of which, process

(17 KLD), cooling tower (250 KLD), boiler (0 KLD), Scrubber (1 KLD), Washing (4 KLD) & Domestic

(10 KLD). Total water requirement will be 287 KLD in which 40 KLD Treated Effluent from ETP to

be recycled after RO Plant & MEE Condensate. Hence freshwater requirement will be 247.4 KLD.

2.12.7 Manpower

The manpower is one of the main resource requirements for the operation and maintenance of the

plant in a better and efficient way. Existing 30 + Additional 20 = Total 50 nos. of employees/workers

will be employed due to project activities. During the construction phase 30 persons to be working

at site.

2.13 Source of Pollution & its Management

Project activities will generate pollution many in terms of wastewater generation, gaseous

emission, generation of noise, hazardous waste generation etc. These sources of pollution & its

mitigation measures are described below.

2.13.1 Wastewater Generation& its management

The wastewater generated will be mainly from the washing, Scrubber, Process, Cooling Tower.

Total 40 KLD Industrial w/w will be generated from the existing & proposed manufacturing

activities. The effluent treatment plant shall be so designed that the effluent from the process will

come to the Equalization cum Neutralization tanks for chemical treatment, whereas the domestic

waste goes directly go to the Septic Tank & Soak pit for disposal.

Effluent Treatment Plant of to treat all the effluent generated from Production, Utilities and

Washing is proposed for the project. Cooling tower blowdown to be segregated & taken directly to

the Intermediate sump before filtration. Treated Effluent of 40 KLD will be passed through RO Plant

to recover 50% of the wastewater. 20KLD recovered ETP RO Permeate will be utilized for cooling

tower makeup & 20 KLD ETP RO Reject will be taken to MEE plant for evaporation. 19.6KLD

Condensate of MEE Plant to be recovered and reused.

Mode of discharge of treated effluent

Treated Effluent of 40 KLD will be passed through RO Plant to recover 50% of the wastewater.

20KLD recovered ETP RO Permeate will be utilized for cooling tower makeup & 20 KLD ETP RO

Reject will be taken to MEE plant for evaporation. 19.6 KLD MEE Condensate also to be recovered.

Sewage (domestic wastewater and sanitary wastewater)

8 KLD domestic wastewater will be generated, which will be disposed through Septic tank & Soak

Pit. Detail of water consumption and wastewater generation as per is given in below Table 2.11.



TABLE 2.11 DETAILS OF WATER CONSUMPTION &W/W GENERATION

Water Existing KLD


KLD


KLD

Remarks

(D) Domestic 5 5 10 - (E) Gardening 5 0 5 - (F) Industrial

Process 17 0 17 - Washing 1 4 4 -

Boiler 0 0 0 -- Cooling 10 240 250 -

Others (Scrubber) 0 1 1 -- Industrial Total 28 244 272

Grand Total (A+B+C) 38 249 287 - Recycled 39.6

Fresh Water Required 247.4

Wastewater Existing KLD


KLD


KLD

Remarks

(C) Domestic 4 4 8 Septic Tank & Soak Pit

(D) Industrial Process 18.4 1 19.4 - Washing 1.0 3 4 -

Boiler 0 0 0 -- Cooling 0.6 15 15.6 --

Others (Scrubber) 0 1 1 -- Total Industrial

wastewater 20 20 40 To RO Plant for

Recovery ETP RO Plant Product 20 Reused for

Cooling Tower Makeup

ETP RO Plant Reject Effluent

20 To MEE for Evaporation &

19.6 KLD Condensate

Recovery & Reuse



FIGURE 2.3 WATER BALANCE DIAGRAM

TOTAL WATER

REQUIREMENT

38.0 Total Water

19.8 Recycled

18.2 Fresh Water

PROCESS WASHING

COOLING

TOWER GARDEN DOMESTIC

17.0 1 10 5 5

SEWAGE TO

SEPTICK TK

4

PROCESS

EFFLUENT

WASHING

EFFLUENT Blowdown

18.4 1.0 0.60

REJECT TO

MEE

PRODUCT FOR

REUSE

10.0 10.0

9.8

*All figures in KLD

WATER BALANCE EXISTING

19.4

ETP

ETP INTERMEDIATE COLLECTION - RO FEED

20.0

MEE Condensate Recyceled

TOTAL WATER

REQUIREMENT

249.0 Total Water

19.8 Recycled

229.20 Fresh Water

PROCESS WASHING SCRUBBER

COOLING


0.0 3 1 240 0 5

SEWAGE TO

SEPTICK TK

4

PROCESS

EFFLUENT

WASHING

EFFLUENT

SCRUBBER

EFFLUENT BLOWDOWN

1.0 3.0 1.0 15.0

REJECT TO

MEE

PRODUCT FOR

REUSE

10.0 10.0

9.8

*All figures in KLD

WATER BALANCE PROPOSED

5.0

ETP


20.0

MEE Condensate Recycled



TOTAL WATER

REQUIREMENT

287.0 Total Water

39.6 Recycled

247.40 Fresh Water

PROCESS WASHING SCRUBBER

COOLING


17.0 4 1 250 5 10

SEWAGE TO

SEPTICK TK

8

PROCESS

EFFLUENT

WASHING

EFFLUENT

SCRUBBER

EFFLUENT BLOWDOWN

19.4 4.0 1.0 15.6

REJECT TO

MEE

PRODUCT FOR

REUSE

20.0 20.0

19.6

*All figures in KLD

WATER BALANCE EXISTING + PROPOSED

ETP

24.4


40.0

MEE Condensate Recycled



2.13.1.1 Details of wastewater generation with qualitative and quantitative analysis

Company has an existing ETP that was designed for present products. During the proposed

expansion only 1KLD of process effluent is expected to be generated and remaining 4KLD & 15KLD

will be from Washing & Cooling Tower Blowdown. Hence it was decided to consider the existing

characteristics for ETP. This is given in Table 2.12.

TABLE 2.12 CHARACTERISTICS OF WASTEWATER

Sr. Parameters Analysis Results of Composite Effluent 1 pH 5.0

2 COD mg/L. 10,130

3 BOD mg/L 4990 4 Oil & Grease mg/L 50 5 Ammonical Nitrogen mg/L 150 6 Total Dissolved Solids mg/L 5000

2.13.1.2 Treatment Methodology

1. Chemical Treatment (Existing).

TABLE 2.13 ANALYSIS RESULTS AFTER CHEMICAL TREATMENT (LIME + ALUM):


2 COD mg/L. 6810

3 BOD mg/L 3305 4 Oil & Grease mg/L <10 5 Ammonical Nitrogen mg/L 89 6 Total Dissolved Solids mg/L 4480

2. Secondary Treatment (Activated Sludge Process - Existing)

TABLE 2.14 ANALYSIS RESULTS AFTER SECONDARY / BIOLOGICAL TREATMENT


2 COD mg/L. 1940

3 BOD mg/L 624 4 Oil & Grease mg/L <10 5 Ammonical Nitrogen mg/L 46 6 Total Dissolved Solids mg/L 4350

3. Tertiary Treatment (Polishing - Existing)

TABLE 2.15 ANALYSIS AFTER TERTIARY TREATMENT


2 COD mg/L. 1785

3 BOD mg/L 500 4 Oil & Grease mg/L <10 5 Ammonical Nitrogen mg/L 42.1



Observations:

• Presently the treated effluent confirms with the disposal norms for CETP Nandesari.

However, it is planned to improve the Biological (Secondary) treatment for increasing the

reduction of COD & BOD as this is now proposed to be recovered from RO Plant.

TABLE 2.16 FINAL REDUCTIONS AFTER TREATMENT

Sr. Parameters Analysis Results of Composite Effluent

Analysis Results of Treated Effluent

1 pH 5.0 7.86

2 COD mg/L. 10,130 1785

3 BOD mg/L 4990 500 4 Oil & Grease mg/L 50 <10

5 Ammonical Nitrogen mg/L

150 <50

6 Total Dissolved Solids mg/L

5000 <4500

TABLE 2.17 FINAL REDUCTIONS AFTER TREATMENT

Sr. Parameters Analysis Results of Treated Effluent -

Existing

Analysis Results of Treated Effluent – After

Proposed 2nd Stage Biological Treatment

(Designed) 1 pH 7.86 6.5 – 8.5

2 COD mg/L. 1785 <250

3 BOD mg/L 500 <50 4 Oil & Grease mg/L <20 20 5 Ammonical Nitrogen mg/L 42.1 50 6 Total Dissolved Solids mg/L 4210 - 7 Suspended Solids mg/L < 100 <100

Treated Effluent is proposed to be recovered using RO Plant hence second stage biological

treatment has been proposed in the ETP to achieve better results.

GDI (Pharma Unit) have Existing capacity of 20KLD with the CETP. However, ZLD is planned.



2.13.1.3 Effluent treatment scheme

The process of the Effluent Treatment Plant based on the Treatability study conducted has been

described below:

• 24.4 KLD waste water (Except Cooling Tower Blowdown 15.6 KLD) from process shall pass

though Oil & Grease removal trap (B-101) where Oil & Grease shall be removed with help

of oil & grease removal belt and collected in Oil & Grease collection tank (B-114). Then

effluent shall be collected in Equalisation cum Neutralization tank (B-102) where lime

solution shall be added to neutralize the effluent from Lime Dosing Tank (B-111). Then

neutralized effluent is pumped to Filter Press (FP-103) where solids are removed. Filtrate

from filter press shall be collected in Holding Tank (B-104) and primary sludge to HWSA.

• The effluent from holding Tank shall be pumped to Aeration tank-1 (B-105) and then

Aeration Tank-2 (B-106) for biological treatment where nutrient shall be added from

Nutrient Dosing tank (B-112). Here biodegradation of organic matter of the wastewater

shall be carried out by bacteria (Suspended growth) and for that oxygen shall be supplied

by 2 nos. of air blowers (B-102) through diffusers. Air blowers also keep MLSS in

suspension.

• Then after, wastewater shall go to secondary settling tank (B-107), here the suspended

solids shall be settled. Activated sludge shall be removed from bottom of SST and pumped

to AT to maintain MLSS and excess Activated Sludge shall be sent to Sludge drying beds (B-

113), where dewatering is carried out before storage of sludge in Hazardous waste storage

area (HWSA) and ultimate disposal to TSDF.

• Then overflow (clear supernatant) of SST shall be collected in Intermediate Sump (B-108).

Here 15.6 KLD of cooling tower blowdown will come directly as this will not require

chemical treatment.

• Wastewater from the Intermediate sump is passed through Dual Media Filter (F-109) for

removal of remaining impurities and shall be collected in Treated Effluent Sump (B-110).

• Treated Effluent of 40 KLD from Treated Effluent Sump will be passed through RO Plant

to recover 50% of the wastewater. 20KLD recovered ETP RO Permeate will be utilized for

cooling tower makeup & 20 KLD ETP RO Reject will be taken to MEE plant for evaporation.

MEE Condensate of 19.6 KLD also to be recovered for reuse.

Refer Figure 2.4 for ETP flow diagram.

The disposal permission from CETP Nandesari has also been attached as Annexure-16.

Details of the units have been provided below for ETP design of 24.4 m3/day (1m3/hr.) + 15.6

m3/day Cooling Tower Blowdown to Intermediate collection sump:

TABLE 2.18 DETAILS OF ETP (NAME OF UNIT & CAPACITY)

Sr. No

Name of Unit No. Capacity (KL) D.T. Hrs. Adequacy

1 Oil & Grease Removal Tank (B-101) 1 2 1.6 Adequate 2 Equalization cum Neutralization

Tank (B-102) 1 20 16 Adequate

3 Filter Press (FP-103) 1 5m3/day 1 Adequate 4 Holding Tank (B-104) 1 5 4.2 Adequate

5 Aeration Tank – 1 (B-105) 1 55 45.8 In-

Adequate



6 Aeration Tank – 2 (B-106) 1 55 45.8 In-Adequate

7 Secondary Settling Tank (B-107) 1 5 4.1 Adequate 8 Intermediate Sump (B-108) 1 5 4.1 Adequate 9 Dual media Filter (F-109) 1 1m3/hr. - In-

Adequate 10 Treated Effluent Sump (B-110) 1 20 16.6 In-

Adequate 11 Lime Dosing Tank (B-111) 1 1 - Adequate 12 Nutrient Dosing Tank (B-112) 1 1 - Adequate 13 Sludge Drying Beds (B-113) 2 3m x 4m - Adequate 14 Hazardous Waste Storage Area 1 - - Adequate

Note: 1. Presently ETP Design is of 20KLD. Treated BOD in existing for Aeration Tank is 624mg/L.

As RO plant for recovery is planned, second stage biological treatment is proposed.

2. Aeration tank -2 of 55 KL & Secondary Settling Tank – 2 of 5 KL is proposed for second stage biological treatment.

3. Dual Media Filter is of 1.0KL/Hr. This will need to be replaced with Pressure Sand & Activated Carbon Filter of Dual Media Filter of 3.0KL/Hr. to handle a flow of 40 KLD.

4. Presently the treated effluent sump is of 20KL. This will need to be increased based on the requirements of storage.



FIGURE 2.4 FLOW DIAGRAM OF ETP - EXISTING



2.13.2 Air Pollution and Control System

The main sources of air pollution will be flue gas emission. Flue gas emission will be from One

existing Thermic Fluid Heater & One proposed flue gas stacks of Thermic Fluid Heater & One

proposed flue gas stack of DG set. FO/LDO is being used as existing fuel & Natural Gas will be used

in the proposed Thermic Fluid Heater. Adequate Stack height to be provided as APCM on stack

attached to Thermic Fluid Heater. PM, SO2& NO2 are the main pollutants generated from the flue

gas stack.

Detail of flue gas emission & process gas emission along with stack height, type of fuel, expected

pollutants & air pollution control measures is given in below table 2.19.

TABLE 2.19 DETAILS OF STACKS

FLUE GAS EMISSION EXISTING FOR EXISTING & PROPOSED PRODUCTS

Sr. no.

Source of emission

With Capacity

Stack Height

(meter)

Type of Fuel

Quantity of Fuel

MT/Day

Type of emissions

i.e. Air Pollutants


Measures (APCM)


1 Thermic Fluid



Proposed Flue Gas emissions

1 Thermic Fluid



2 DG Set

(385 KVA) 5 HSD 90 Lit/Hr. PM, SO2, NO2 Adequate

Stack Height

PROCESS EMISSIONS:





2.13.2.1 Details of Scrubber

FIGURE 2.5 APCM



2.13.3 Hazardous Waste Generations and Disposal System

Main sources of hazardous waste generation will be

• ETP Sludge will be Stored at site and then accumulated quantity disposed to TSDF M/s.

NECL Nandesari.

• Discarded containers / barrels / liners used for hazardous wastes/chemicals. will be

Collected, Stored, decontaminated & sold to approved vendor/ recycler.

• Used oil/Spent Oil will Collected, stored, transported, disposed by selling to registered re-

refiners.

• Distillation Liquid Residue - Collection, Storage, Transportation and Disposal at common

incinerator facility of M/s. Nandesari Environment Control Ltd. (NECL).

Hazardous waste generation quantity, physical characteristics and mode of disposal are given in

Table-2.20.

TABLE 2.20 DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL

Sr. no

.

Type/Name of

Hazardous waste


n (Name of


etc.)

Category and

Schedule as per

HW Rules.

Quantity (MT/Annum)

Management of HW

Existing Products

Proposed Products

Total After

Expansion

1 ETP Sludge

ETP Sch-I/ 35.3

12 MT/Annu

m

0 12 MT/Annu

m


treatment, transportation, and disposal at Nandesari Environment Control Ltd


Bags & Containers

Production plant

Sch-I/ 33.1

108 MT/ Annum

0 108 MT/ Annum



factory premises.


and TFH

Sch-I/ 5.1

0.6 KL/Annu

m

0 0.6 KL/Annu

m





residues From

Solvent Recovery

Sch-I/ 20.3

36 MT/Annu

m

30 MT/Annu

m

66 MT/Annu

m

CHWIF incinerator


Environment



Control Ltd. (NECL) /

Coprocessing 5 Spent

Solvent for recovery

Process Sch-I/ 20.2

252 MT/Annu

m

4116 MT/Annu

m

4368 MT/Annu

m

Captive In-house

Recovery.

6 MEE Salt

From Evaporation of RO

Reject

Sch-I/ 37.3

0 MT/Annu

m

144 MT/Annu

m

144 MT/Annu

m


(NECL) TSDF

Hazardous waste will be stored in proper storage room and handed over to GPCB/CPCB approved

vendor for final disposal. The collection, Storage and disposal of hazardous waste will be done as

per Hazardous waste (Management and Handling) Rules 2016.

The unit will get the membership of common facility for TSDF, CHWIF.

2.13.4 Noise Level and Control System

Noise is considered as the unbearable acoustic phenomenon. The noise term is considered as the

increase in sound level above than hearing capacity. This can affect humans to a very large extent.

Due to loud noise, the hearing ability of a person may be damaged. This is also a very serious factor

which has to be considered. The two major categories of noise generating sources are divided in to

static and dynamic sources.

The static sources are including the construction equipment such as plant machineries, DG sets

&vehicular traffic etc. The noise levels were measured near the sources. It is expected that

construction activities will involve noise generation above 90-dB(A). The sound pressure level

generated by a noise source decreases with increasing distance from the source due to wave

divergence. Extensive oiling and lubrication and preventive maintenance will be carried out to

reduce noise generation at source to the permissible limit. However, at place where noise levels can

exceed the permissible limit, Earplugs and Earmuffs will be provided to those working in such area.

2.13.5 Soil

• The unit is located in notified industrial area and have occupied land area of 3691.10 m2

(0.36911 Ha) only there is no negative impact envisaged on soil & Geology of the study area.

• The unit will take full-proof measures to manage all types of hazardous wastes to mitigate

impacts on soil and geology.

• Maintain good green belt within premises.



2.14 Status of Applicable Rules, Acts, Regulation:

Sr.No Permission Approval No. date Authority

1 Consent to Establish

(CTE) CTE No. 55249 24.07.2013 GPCB

2 Environmental

Clearance SEIAA/GUJ/EC/5(f)/94/2014 01.08.2014 SEIAA Gujarat

3

Consent to Establish (CTE) Amendment

(Product Name Correction)

CTE No. 55249 27.01.2015 GPCB

4 Consent to Operate

(CCA) AWH 72360 12.05.2015 GPCB

5 Consent to Establish

(CTE) Product Change Mix

CTE No. 79671 28.06.2016 GPCB

6

Consent to Operate (CCA) – Amendment after Product Change Mix (For 12 Products

Only)

AWH 83065 31.01.2017 GPCB

7

Consent to Operate (CCA) – Amendment (For addition of one

product)

AWH 72360 10.04.2017 GPCB

2.15 Proposed Schedule for Approval and Implementation

This is an existing unit. Schedule Planned is shown in Annexure 17.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 3 Baseline Environmental Status


CHAPTER – 3: BASELINE ENVIRONMENTAL STATUS

3.1 Introduction

The baseline status of environmental quality in the vicinity of project site serves as the basis for

identification, prediction and evaluation of impacts. The baseline environmental quality is assessed

through field studies within the impact zone for various components of the environment, viz. air,

noise, water, land and socio-economic. The baseline environmental quality has been assessed in the

post-monsoon season of October 2018 to December 2018 in a study area of 10 km radial distance

from the project site.

The environmental setting is considered to establish the baseline conditions which are described

with respect to following:

• Land environment

• Land Use Pattern

• Water Environment

• Air Environment

• Meteorology

• Noise Environment

• Ecology

• Topography

• Demography and Socio-economic Environment

3.2 Methodology

Following the guidelines of MoEFCC, the baseline environmental study was conducted. The

details of the study period, frequency of sampling & method of environmental sampling & analysis

are shown below in succeeding paragraphs under respective titles.

3.2.1 Study Period & Frequency of Sampling

The period of study determined was October 2018 to December 2018. The frequency of various

environmental sampling & analysis was determined following the guidelines provided by MoEF in

online EIA Manual. The details of frequency of environmental sampling considered for the study

are illustrated in Table – 3.1.



TABLE 3.1 FREQUENCY OF ENVIRONMENTAL MONITORING

Attributes Sampling

Locations Frequency A. Air Environment

Meteorological Project Site 1 hourly continuous for Study

Period

Ambient Air Quality 10 locations in the study area

(10 km radius from project site) 24 hourly twice a week during

study period

B. Noise Various Locations within the study area

(10 Km radius from project site) Once during Study Period

C. Water

Ground Water Grab samples from 8 Locations from

Study Area (10 km radius from project site)

Once during Study Period

Surface Water

Grab samples from 1 Locations (10 km radius from project site)

Once during Study Period

D. Soil Quality Soil samples from 8 locations within

study area Once during Study Period

E. Land Use & Land Cover

Study area (10 km from Project Site) Once during Study Period

F. Ecological Data Study area (10 km from Project Site) Once during Study Period G. Socioeconomic Data Study area (10 km from Project Site) Once during Study Period

3.2.2 Method of Environmental Sampling & Analysis

The method adopted for environmental sampling & analysis is illustrated in following Table - 3.2.

TABLE 3.2 METHOD OF ENVIRONMENTAL SAMPLING & ANALYSIS

Attributes METHOD

Sampling / Preservation Analysis

A. Air Environment 1) Micro meteorological data 2) Ambient Air Quality

Mechanical/automatic 1) Spectrum weather station &

IMD 2) 2.5 Micron dust samplers &

RSPM samplers having the facility to collect the gaseous samples

-----

IS 5182 & CPCB

B. Noise Instrument : Noise level meter --

C. Water & Wastewater 1) Ground Water 2) Surface Water

Standard Methods for Examination of Water and

Wastewater Analysis, published by APHA 22nd edition, 2012

Standard Methods for Examination of Water and

Wastewater Analysis, published by APHA 22nd

edition, 2012

D. Soil Quality Laboratory Guide for Conducting

Soil Test & Plant Analysis, by J. Benton Jones, Jr.

Laboratory Guide for Conducting Soil Test & Plant Analysis, by J. Benton Jones,

E. Land Use & Land Cover Satellite Imageries (1:25,000), Secondary data from EIC, Delhi

As Secondary data-analysis by EIC, Delhi

F. Geology & Geo-Hydrology Secondary data from EIC, Delhi Secondary data from EIC, Delhi

G. Ecological Data Secondary data from EIC, Delhi Secondary data from EIC, Delhi

H. Socioeconomic Data Secondary data from EIC, Delhi Secondary data from EIC, Delhi



3.2.3 Baseline Environmental Status

The baseline environmental study was carried out for Ambient Air, Water, Land, Noise, Biological

& Socioeconomic environment. The study period was October 2018 to December 2018. The

environmental samples were collected from the selected location of the study area. The scenario of

environmental condition of the area revealed from the sample & data analysis is described below

in subsequent paragraphs.

3.3 Micrometeorology

The climate of Gujarat is varied, as it is moist in the southern districts and dry in the northern

region. The Arabian Sea and the Gulf of Cambay in the west and the forest-covered hills in the east

soften the rigors of climatic extremes, consequently reducing the temperature and render the

climate more pleasant and healthy. Surat lies along the southern part of the state and experiences

a climate with aridity index of 15 to 20 per cent indicating adequate moisture availability in the

soils for most part of the year.

3.3.1 Temperature Details

Minimum, Maximum and Average Temperatures for Vadodara Station of the year 2017 are given in

Table 3.3.

TABLE 3.3 TEMPERATURE DATA

Month (2017)

Minimum Temperature

(0C)

Maximum Temperature

(0C)

Average Temperature

(0C)

January 6.5 35.1 21.0 February 11.3 38.0 24.6

March 12.2 42.7 27.5 April 20.0 43.4 31.7 May 25.0 42.6 33.8 June 26.6 44.1 35.4 July 24.7 35.6 30.2

August 23.6 33.6 28.6 September 24.0 36.5 30.3

October 17.2 35.1 26.2 November 12.6 33.9 23.3 December 11.0 33.2 22.1

3.3.2 Relative Humidity (RH)

Minimum, Maximum and Average Monthly Relative Humidity for Vadodara Station of the year 2017

is given in Table 3.4.

TABLE 3.4 RELATIVE HUMIDITY DATA

Month (2017)

Minimum R.H.% Maximum R.H.% Average R.H.%

January 19 88 54 February 13 84 46

March 14 80 40



April 6 87 42 May 13 86 48 June 25 91 59 July 51 98 78

August 49 98 82 September 45 98 73

October 30 98 68 November 24 83 54 December 21 88 54

3.3.3 Rainfall

Rainfall data for Vadodara Station of the year 2017 is presented in Table 3.5.

TABLE 3.5 RAINFALL DATA

Month (2017)

Monthly Total (mm)

Numbers of Rainy Days

January 0 0 February 0 0

March 0 0 April 0 0 May 1.8 1 June 66.8 4 July 172.2 21

August 313 23 September 129.8 8

October 23.4 5 November 0 0 December 0 0

Total 707 62 Total rainfall, during the monsoon period, has been recorded as 707 mm.

3.3.4 Wind Speed

Wind speed for Vadodara Station of the year 2017 is given in Table 3.6.

TABLE 3.6 WIND SPEED DATA

Sr. No. Month (2017)

Average Wind speed (KMPH)

1. January 8 2. February 9 3. March 8 4. April 12 5. May 14 6. June 16 7. July 13 8. August 13 9. September 11

10. October 6 11. November 6 12. December 7

Average 10.25



3.3.5 Temperature, Relative Humidity & Wind Speed

The site-specific data were collected for October 2018 to December 2018. Data are tabulated in

Table 3.7.

TABLE 3.7 SITE SPECIFIC METEOROLOGICAL DATA (PERIOD: OCTOBER 2018 TO

DECEMBER 2018)

METEOROLOGICAL PARAMETER MONTH

OCTOBER, 2018 NOVEMBER, 2018

DECEMBER, 2018

Temperature (0C) Min. Max. Avg.

18.5 36.3 27.4

13.9 34.8 24.4

12.3 33.6 23.0

Relative Humidity (%) Min. Max. Avg.

35.0 99.0 67.0

26.0 88.0 57.0

23.0 92.0 57.5

Wind Speed (km/h) Min. Max. Avg.

0

10.2 4.0

0

11.7 4.5

0

13.7 5.0

There was no rainfall during the study period.

3.3.6 Wind Rose

Wind rose is a graphical representation of the magnitude and direction of wind speed considering

all the directions. With the help of wind rose diagram one can easily predict the direction and extent

of spreading of the gaseous and particulate matter from the source. Wind rose diagrams & stability

class distribution are prepared for the study area and presented in Figures - 3.1A & 3.1B

respectively.



FIGURE 3.1A WIND ROSE DIAGRAM



FIGURE 3.1B STABILITY CLASS DISTRIBUTION

3.4 Air Environment

The ambient air quality monitoring was carried out in accordance with National Ambient Air

Quality Standards (NAAQS) of CPCB. Ambient Air Quality Monitoring (AAQM) was carried out at

night locations during the study period.

The air quality status in the impact zone is assessed through a network of ambient air quality

monitoring locations. The tropical climatic conditions mainly control the transport and dispersion

of air pollutant emissions during various seasons.

The conventional and project specific parameters such as Suspended Particulate Matter, Respirable

Suspended Particulate Matter (RSPM-PM10), Respirable Suspended Particulate Matter (RSPM-

PM2.5), Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx), Ammonia (NH3), Ozone (O3),

Lead (Pb), Arsenic (As), Nickel (Ni), Benzene (C6H6), Hydro Carbon (HC), HCl, Cl2 & Carbon

Monoxide (CO) were monitored at site.

The values for mentioned concentrations of various pollutants at all the monitoring locations were

processed for different statistical parameters like arithmetic mean, minimum concentration, and

25.5

61.9

9.7

2.80.2 0.0 0.0

0

10

20

30

40

50

60

70

%

Wind Class Frequency Distribution

Wind Class (m/s)

Calms 0.50 - 2.10 2.10 - 3.60 3.60 - 5.70 5.70 - 8.80 8.80 - 11.10 >= 11.10

10.8

9.7

7.26.6 6.5

16.9 16.9

6

8

10

12

14

16

18

20

%

Stability Class Frequency Distribution

Stability Class

A B C D E F G



maximum concentration and percentile values. The baselines levels of Suspended Particulate

Matter, Respirable Suspended Particulate Matter (RSPM-PM10), Respirable Suspended Particulate

Matter (RSPM-PM2.5), Sulphur Dioxide (SO2), Oxides of Nitrogen (NOx), Ammonia (NH3), Ozone

(O3), Lead (Pb), Arsenic (As), Nickel (Ni), Benzene (C6H6), Hydro Carbon (HC), HCl, Cl2 & Carbon

Monoxide (CO) are expressed in terms of various statistical parameters.

To establish the baseline status around the project site of the study region monitoring was

conducted at 10 Ambient Air Quality Monitoring (AAQM) Stations in and around the study region

during October 1, 2018 to December 31, 2018.

FIGURE 3.2 LOCATIONS OF THE AMBIENT AIR, NOISE, WATER AND SOIL



TABLE 3.8 LOCATIONS OF THE AMBIENT AIR, NOISE, WATER AND SOIL

Sr.No. Name of village

bearing w.r.t.

project site

Approximate radial

DISTANCE from Project

site (KM)

Ambient Air

Noise water Soil TYPE OF AREA

1. Project Site

-- -- A1 N1 GW1 S1 Industrial

2. Village: Nandesari

NW 2.09 A2 N2 GW2 S2 Residential

3. Village: Bhetasi

WSW 6.05 A3 N3 GW3 S3 Residential

4. Village: Ambali

W 6.40 A4 N4 GW4 S4 Residential

5. Village: Kotna

SW 6.16 A5 N5 GW5 S5 Residential

6. Village: Anagad


7. Village: Hathipura


8. Village: Undera

SE 7.21 A8 N8 GW8 S8 Residential

9. Village: Padamla

NE 3.49 A9 N9 GW9 S9 Residential

10. Village: Ajod

ENE 7.33 A10 N10 GW10 S10 Residential

11. Bhetasi Pond

WSW 6.05 -- -- SW1 -- --

12. Hathipura Pond

SW 9.90 -- -- SW2 -- --

13. Mahi River

-- -- SW3 -- --

14. Ajod Pond ENE 7.33 -- -- SW4 -- --

TABLE 3.9 AMBIENT AIR QUALITY STATUS (OCTOBER 2018 TO DECEMBER 2018)

SR. NO.

Sampling Location

Sampling DURATION

SPM PM10 PM2.5 SO2 NOx NH3 O3 Pb

g/m3 1. Project-site

(A1) 24 hours 121.6 77.35 47.49 22.19 19.15 BDL 14.33 BDL

2. Nandesari (A2)

24 hours 117.2 76.01 45.38 19.13 17.19 BDL 11.08 BDL

3. Bhetasi (A3)

24 hours 113.2 74.64 42.30 13.11 11.07 BDL 10.34 BDL

4. Ambali (A4)

24 hours 113.5 73.33 42.69 16.58 13.74 BDL 10.18 BDL

5. Kotna (A5) 24 hours 112.9 72.38 42.97 15.15 12.35 BDL 10.09 BDL 6. Anagad

(A6) 24 hours 116.8 75.78 44.52 18.46 15.49 BDL 11.06 BDL

7. Hathipura (A7)

24 hours 112.3 71.94 40.65 17.09 14.28 BDL 10.01 BDL

8. Undera (A8)

24 hours 114.2 74.96 42.80 13.57 11.49 BDL 10.46 BDL



9. Padamla (A9)

24 hours 116.1 75.34 44.23 16.72 14.19 BDL 10.97 BDL

10. Ajod (A10) 24 hours 115.6 74.79 43.85 15.75 11.26 BDL 10.59 BDL NAAQS 500 100 60 80 80 400 180 1

SR. NO

.

Sampling

Location

As H2S Ni C6H6 BaP CO HC VOC

HCl Cl2

ng/m3

g/m3

ng/m3

g/m3

ng/m3

mg/m3

ppm g/m3

1. Project-site (A1)

BDL BDL BDL BDL BDL 1.32 BDL

0.9 BDL

BDL

2. Nandesari (A2)


0.9 BDL

BDL

3. Bhetasi (A3)


0.4 BDL

BDL

4. Ambali (A4)


0.5 BDL

BDL

5. Kotna (A5)


0.6 BDL

BDL

6. Anagad (A6)


0.8 BDL

BDL

7. Hathipura (A7)


0.4 BDL

BDL

8. Undera (A8)


0.6 BDL

BDL

9. Padamla (A9)


0.7 BDL

BDL

10. Ajod (A10)


0.4 BDL

BDL

NAAQS 6 -- 20 5 300 4 -- -- 200 100 Note: BDL = Below Detectable Limit The Minimum Detectable Limits for various parameters are as below:

Parameters Value Ammonia (as NH3) 1.0 g/m3

Lead (as Pb) 0.5 g/m3 Nickel (as Ni) 10 ng/m3

Benzene (as C6H6) 2 g/m3 Arsenic (as as) 2 ng/m3

Benzo (α) Pyrene (BaP) 0.5 ng/m3 Hydrocarbon (HC) 1 ppm

Carbon Monoxide (CO) 1.14 mg/m3



3.4.1 Summary

The statistical interpretation of observed ambient air quality concentrations is presented in Table-

3.9. They represent the cross-sectional distribution of the baseline air quality status of the study

region.

The maximum concentration of SPM (121.6 g/m3), PM10 (77.35 g/m3), PM2.5 (47.49 g/m3),

SO2 (22.19 g/m3), NOx (19.15 g/m3), O3 (14.33 g/m3), CO (1.32 g/m3) & VOC (0.9 ppm) was

recorded in study area.

The minimum concentration of SPM (112.3 g/m3), PM10 (71.94 g/m3), PM2.5 (40.65 g/m3),



The PM10 and PM2.5 concentrations at all the AAQM locations were primarily caused by local

phenomena including industrial & vehicular activities and natural dust getting air borne due to

manmade activities and blowing wind. PM10 and PM2.5 concentrations were observed below

stipulated standards of CPCB for Industrial, Residential, Rural and Other Area at all air quality

monitoring locations during the monitoring period. Results of all parameters are found within limit.

3.5 Noise Environment

The objective of the noise level survey around the project site was to identify existing -noise sources

and to measure background noise levels. Major noise sources in the study area are industries,

commercial, and vehicular movements. Major human settlement in the study area is Nandesari

which is about 2 km away from project site. The noise monitoring locations are given in Table - 3.8

and shown in Figure - 3.2 while the results of noise monitoring are given in Table - 3.10.

METHODOLOGY for Noise Monitoring

The noise monitoring was carried out at ten locations in day time during (6 am to 10 pm) and at

night time (10 pm to 6 am) in the study area covering all the areas i.e. industrial, commercial,

residential and silence zones as mentioned in Noise (Pollution and Control) Rules, 2000. CPCB

Recommendations for community noise exposure are attached as Annexure – 2. Hourly Equivalent

noise levels Leq (day) and Leq (night) were measured at each monitoring locations. One day

monitoring ranging from March 2, 2017 during day and nighttime was carried out at all the

locations.

INDIAN STANDARDS FOR NOISE LEVEL

Sr. No.

Locations Noise Level in

Day Time dB(A)

Noise Level in Nighttime

dB(A)

1 Industrial Area 75 65 2 Commercial Area 65 55 3 Residential Area 55 45



4 Silence Zone i.e. Hospital, Educational institute etc. 50 45

TABLE 3.10 BACKGROUND NOISE LEVELS

Sr. No.

location Noise Level in dB(A) CPCB LIMIT dB(A)

Day TIME NIGHTTIME DAY TIME

NIGHT TIME

Min. max. Min. max. Max. max. RESIDENTIAL AREA

1. Project-site (N1) 61.7 63.9 58.7 60.2 <75 <65 2. Nandesari (N2) 47.8 49.9 41.8 43.3 <55 <45 3. Bhetasi (N3) 51.3 53.6 41.4 43.1 <55 <45 4. Ambali (N4) 49.6 52.7 41.1 42.8 <55 <45 5. Kotna (N5) 46.4 49.8 41.3 43.8 <55 <45 6. Anagad (N6) 50.2 53.5 39.9 41.4 <55 <45 7. Hathipura (N7) 50.7 53.8 40.9 42.7 <55 <45 8. Undera (N8) 50.4 52.3 40.7 42.5 <55 <45 9. Padamla (N9) 48.2 50.1 40.3 42.2 <55 <45

10. Ajod (N10) 52.4 54.7 42.5 44.2 <55 <45 COMMERCIAL AREA (TRANSPORTATION)

9. N1 (T): Near Bhetasi Chowkdi

59.8 64.4 49.3 53.2 <65 <55

10. N2 (T): Near Hathipura Chowkdi

57.4 62.5 48.6 51.3 <65 <55

11. N3 (T): Near Kotna Chowkdi 56.9 61.3 47.6 53.8 <65 <55 12. N4 (T): Near Anagad

Chowkdi 55.4 60.8 46.1 51.0 <65 <55

13. N5 (T): Near Padamla Chowkdi

61.8 63.9 52.4 54.1 <65 <55

14. N6 (T): Near Undera Chowkdi

58.7 63.4 51.9 53.8 <65 <55

3.6 Water Environment

The annual rainfall in the region was 707 mm. The baseline water quality status in the region is

established by analyzing surface water and ground water. Water requirement at site would be met

through GIDC water supply. Range of pre-monsoon water table is 20-25m & Post-Monsoon is 15-

20m as per secondary source.

3.6.1 Methodology for Water Quality Monitoring

10 nos. of ground water and 4 nos. of surface water samples were collected from the study area.

These samples were analyzed for physic-chemical parameters to ascertain the baseline status in

the existing surface water and ground water bodies. Samples were collected during the study

period of December 03 - 09, 2018 and analyzed as per the Standard Methods of Water and

Wastewater Analysis (APHA).



TABLE 3.11 GROUND & SURFACE WATER QUALITY

WATER QUALITY- PHYSICAL PARAMETERS (OCTOBER-DECEMBER 2018)

SR. NO.

SAMPLING LOCATION

pH TEMPERATURE (0C)

turbidity (NTU)

TDS (mg/L)

T.S.S. (mg/L)

1 Project-site (GIDC Water)

6.96 25.0 2.2 156 8

2 Nandesari (GW1) 7.16 25.1 0.48 1902 22

3 Bhetasi (GW2) 7.81 24.9 0.17 590 10

4 Ambali (GW3) 7.99 25.1 3.2 426 18

5 Kotna (GW4) 7.80 25.0 1.9 1868 14

6 Anagad (GW5) 7.90 25.0 5.0 1334 16

7 Hathipura (GW6) 7.80 25.0 0.59 562 16

8 Undera (GW7) 7.45 25.1 31.6 640 32 9 Padamla (GW8) 7.77 25.0 4.6 1850 4

10 Ajod (GW9) 7.53 25.1 28.0 1022 62 11 Bhetasi Pond (SW1) 7.81 25.0 33.0 680 44

12 Hathipura Pond (SW2) 7.92 24.9 32.0 488 34

13 Mahi River (SW3) 8.24 25.0 1.4 144 18

14 Ajod Pond (SW4) 7.45 24.9 0.8 1426 8

GW= Ground water, SW= Surface water

WATER QUALITY - NUTRIENTS, OXYGEN DEMAND AND ORGANIC PARAMETERS

SR. NO.

SAMPLING LOCATION AMMONICAL NITROGEN

DO COD BOD327 OIL & GREASE

(mg/L) 1 Project-site (GIDC Water) <0.4 6.81 2.64 <1.0 <0.4 2 Nandesari (GW1) <0.4 6.72 9.92 <1.0 <0.4 3 Bhetasi (GW2) <0.4 6.72 1.98 <1.0 <0.4 4 Ambali (GW3) <0.4 6.90 3.96 <1.0 <0.4 5 Kotna (GW4) <0.4 6.80 7.27 <1.0 <0.4 6 Anagad (GW5) <0.4 6.81 6.61 <1.0 <0.4 7 Hathipura (GW6) <0.4 6.81 3.30 <1.0 <0.4 8 Undera (GW7) <0.4 6.90 5.29 <1.0 <0.4 9 Padamla (GW8) <0.4 6.81 7.98 <1.0 <0.4

10 Ajod (GW9) <0.4 6.53 5.95 <1.0 <0.4 11 Bhetasi Pond (SW1) <0.4 6.81 11.71 <1.0 <0.4 12 Hathipura Pond (SW2) <0.4 6.72 10.14 <1.0 <0.4 13 Mahi River (SW3) <0.4 6.90 8.45 <1.0 <0.4 14 Ajod Pond (SW4) <0.4 6.72 12.08 <1.0 <0.4




WATER QUALITY - INORGANIC PARAMETERS


T.H. =Total Hardness, C.H. =Calcium Hardness, BDL= Below Detectable Limit

SR. NO.

SAMPLING LOCATION

Total ALKALINITY (as CaCO3)

T.H. (as

CaCO3)

C.H. (as

CaCO3)

Cl-

So4—2

Mg

(mg/L) 1 Project-site (GIDC

Water) 50 34.13 16.06 32.53 2.51 4.39

2 Nandesari (GW1) 395 908.04 419.4 578.71 199.78 118.6 3 Bhetasi (GW2) 415 433.72 114.4 76.38 58.1 77.59 4 Ambali (GW3) 410 355.41 50.2 34.41 23.12 74.16 5 Kotna (GW4) 655 672.68 100.4 673.23 127.66 139.06 6 Anagad (GW5) 765 210.84 100.4 297.03 23.76 26.80 7 Hathipura (GW6) 375 311.24 124.49 49.5 42.36 45.38 8 Undera (GW7) 1000 407.62 279.11 91.46 44.66 31.22 9 Padamla (GW8) 705 608.42 110.4 546.92 172.58 121.01

10 Ajod (GW9) 360 742.96 291.16 188.59 104.10 109.78 11 Bhetasi Pond (SW1) 350 277.10 50.2 144.44 49.52 55.13 12 Hathipura Pond

(SW2) 250 202.80 44.17 82.50 38.07 38.54

13 Mahi River (SW3) 160 148.98 68.27 33.47 23.76 19.02 14 Ajod Pond (SW4) 295 911.63 351.4 179.16 254.34 136.13



WATER QUALITY - HEAVY METALS

SR. NO.

SAMPLING LOCATION

Na T-Cr+3

Cu Pb Fe Zn K Cd F-

(mg / L)

1 Project-site (GIDC Water)

8.20 <0.005 BDL <0.005 0.24 <0.022 0.94 <0.001 BDL

2 Nandesari (GW1)

175.35 <0.005 BDL <0.005 BDL <0.022 6.02 <0.001 BDL

3 Bhetasi (GW2)

30.66 <0.005 BDL <0.005 BDL <0.022 1.34 <0.001 BDL

4 Ambali (GW3) 16.33 <0.005 BDL <0.005 5.16 <0.022 0.88 <0.001 BDL 5 Kotna (GW4) 386.08 <0.005 BDL <0.005 0.16 <0.022 3.16 <0.001 BDL 6 Anagad

(GW5) 347.78 <0.005 BDL <0.005 1.80 <0.022

3.50 <0.001 BDL

7 Hathipura (GW6)

68.6 <0.005 BDL <0.005 BDL <0.022 3.4 <0.001 BDL

8 Undera (GW7)

47.68 <0.005 BDL <0.005 6.86 <0.022 8.77 <0.001 BDL

9 Padamla (GW8)

303.62 <0.005 BDL <0.005 1.34 <0.022 2.14 <0.001 BDL

10 Ajod (GW9) 31.89 <0.005 BDL <0.005 9.72 <0.022 2.79 <0.001 BDL 11 Bhetasi Pond

(SW1) 63.9 0.62 BDL <0.005 1.31 0.07 8.76 <0.001 BDL

12 Hathipura Pond (SW2)

24.46 <0.005 BDL <0.005 0.103 <0.022 8.75 <0.001 BDL

13 Mahi River (SW3)

11.23 <0.005 BDL <0.005 BDL 0.05 4.49 <0.001 BDL

14 Ajod Pond (SW4)

51.18 <0.005 BDL <0.005 BDL <0.022 8.70 <0.001 BDL

Minimum Detection Limit:

**Total

Chromium (as

Cr+3)

: 0.005

mg/L

Total Iron (as

Fe)

: 0.01 mg/L

Copper (as Cu) : 0.05

mg/L

**Zinc (as Zn) : 0.022 mg/L

Fluoride (as F-) : 0.05

mg/L

*Not in our NABL Scope, **Analyzed by Sub Contractor (Not in our NABL Scope)



SUMMARY

The statistical interpretation of observed ground water & surface water quality is presented in

Table-3.11.

3.6.2 Baseline Ground water quality

pH of ground water samples varied from 6.96 to 7.99. Turbidity was found 0.17 to 31.6 NTU, Total

Dissolved Solids varied in the range of 156 to 1902 mg/L. DO and COD are found in range of 6.53

to 6.90 mg/L, and 1.98 to 9.92 mg/L respectively. BOD3 was found to be <1.0. Total Hardness (as

CaCO3) varied from 34.13 to 908.04 mg/L. Total Alkalinity varied from 50 to 1000 mg/L. Chlorides

and Sulfates are found in the range of 32.53 to 673.23 mg/L and 2.51 to 199.78 mg/L respectively.

3.6.3 Baseline Surface Water Quality

pH of surface water samples was found 7.45 to 8.24. Turbidity was found 0.8 to 33 NTU, Total

Dissolved Solids was found 144 to 1426 mg/L. DO and COD are found 6.72 to 6.90 and 8.45 to 12.08

mg/L respectively. BOD3 was found to be <1.0. Total Hardness (as CaCO3) are found 148.98 to

911.63 mg/L. Total Alkalinity varied from 160 to 350 mg/L. Chlorides and Sulfates are found 33.47

to 179.16 mg/L and 23.76 to 254.34 mg/L respectively.

3.7 Land Environment

3.7.1 Soil Quality

Soil samples were collected from 10 locations during December 03-09, 2018 within the study area

to assess its physico-chemical characteristics. The analysis results of soil samples are given in Table

3.12.



TABLE 3.12 PHYSICO-CHEMICALS CHARACTERISTICS OF SOIL

Sr. No.

Parameters

Project Site

Nandesari

Bhetasi

Ambali

Kotna

Anagad

Hathipura

Undera

Padaml

a

Ajod

1 pH 8.58 7.59 7.89 7.89 8.34 7.88 7.67 7.83 7.49 7.15

2 Temper

ature (0C)

24.9 25.1 24.9 25.1 25.0 25.1 24.9 24.9 25.0 25.1

3 Moistur

e (%) 6.83 4.09 2.72 5.30 6.12 2.29 4.01 6.12 1.76 2.18

4 So4—2

(mg/kg) 2198

.1 523.8 970.8 3314.3 351.4 580.7 1714.

9 879.

2 1239.8

587.3

5 Chlorid

es (mg/kg)

130.8

69.76 113.5 34.88 436.0 174.4 17.44 174.4

17.44

8.72

6 Organic Matter

(%)

6.27 4.85 5.35 5.13 5.32 4.33 7.15 5.52 4.78 6.53

7 Bulk

density (g/cm3)

1.22 1.25 1.54 1.67 1.28 1.43 1.42 1.43 1.36 1.25

8 Calcium (mg/kg)

144.8

201.2 120.7 185.1 80.4 80.4 96.5 120.7

48.2 32.1

9 WHC (%)

41.8 53.32 50.80 49.69 52.41 46.24 42.43 61.81

51.33

51.28

10 Porosity

(%) 53.9

6 52.83 41.84 36.98 51.69 45.95 46.08 45.8

3 48.6

0 52.83

11 Grain

Size (%)

Gravel 02 00 02 00 02 03 00 01 01 00

Coarse

sand 03 03 00 00 01 02 00 03 03 01

Medium

sand 05 04 00 05 01 08 01 02 02 03

Fine sand

09 08 12 08 07 06 09 07 07 06

Silt + Clay

81 85 86 87 89 81 90 87 87 90

12 Na

(mg/kg) 1532

.7 229.2 97.10 22.10 343.5 94.5 35.6 136.

4 79.2 93.10

13 Cu+2

(mg/kg) BDL BDL BDL BDL BDL BDL BDL BDL BDL BDL

14 Fe+3

(mg/kg) 66.3

3 53.85 64.82 152.7 38.15 46.32 99.14 54.6

1 112.10

46.97

15 Cd


16 K

(mg/kg) 22.7 32.8 79.1 30.1 26.5 18.4 26.4 87.0 25.7 20.7

17 Ni+2


18 Pb+2


Note:



Minimum Detectable Limit: Nickel – 0.1 mg/kg, Copper – 0.5 mg/kg, Cadmium – 0.001 mg/kg, Lead – 0.001 mg/kg

3.7.2 Summary of Soil Quality

Parameters like Porosity, Water Holding Capacity, Bulk Density, etc. were considered. Based on the

soil analysis report, the following can be concluded: The porosity of soils varied from 36.98% to

53.96% and can be considered as moderate to good for air and water movement in the soil. The

Water Holding Capacity varied from 41.8% to 61.81%. Bulk Density varied from 1.22 to 1.67 g/cm3.

The moisture content varied from 1.76% to 6.83%.pH varied from 7.15 to 8.58. Calcium varied from

32.1 to 201.2 mg/kg. Sodium varied from 22.10 to 1532.7 mg/kg. Organic Matter varied from 4.33

to 7.15 mg/kg. Total Iron varied from 38.15 to 152.7 mg/kg.

3.8 Geological & Hydrological Data

3.8.1 Method of Preparation

The geological classification map has been prepared by extracting the areas under different

geological classification from the 1:2 million scale maps prepared by Geological Survey of India

(GSI) for the State of Gujarat. The map text has been modified in consultations with the Department

of Geology. University of Delhi. The project site, towns and village locations have been added for

ease of spatial reference. Locations of towns and villages have been extracted from CoI maps, SoI

topographical maps and confirmed with satellite data.

3.8.2 Description of Geological Classification & Area Under Different Formations

Following Table provides the major geological features and area under different geological

formations within a distance of 10 km from the project site.

3.8.3 Geological Map

A map depicting the major geological features in the project area is presented in Figure 3.3. The

map also marks the area within 10 km with project site as a Centre. Town and village locations are

also depicted to facilitate ease of reference.

Description of Geological Classification & Area Under Different Formations

Stratigraphy Area

(Sq. km.) Age Description

Q = Undifferentiated fluvial/ Aeolian/

coastal sediments

313.96 Holocene in

Quaternary period (1 million year to

recent)

Some gypsum deposits are found in these Quaternary sediments.

High potential for yielding significant quantities of ground

water. (Courtesy: Environmental Information Centre, New Delhi)



FIGURE 3.3 MAJOR GEOLOGICAL FEATURES

3.9 Land Use Pattern

Land use, in general, reflects the human beings’ activities on land, whereas the word land cover

indicates the vegetation, agricultural and artificial manmade structures covering the land surfaces.

Identification and periodic surveillance of land uses and vegetation covers, in the vicinity of any

developmental activity is one of the most important components for a comprehensive

environmental impact assessment, which would help to determine the impact of the project

development activity on the land use pattern.

To determine the baseline land use pattern, at and around the project site, the required data have

been obtained from Published land use data i.e. census and gazetteer books of Vadodara district,

issued by the State Government.

3.9.1 Method of Data Preparation

The satellite data has been processed using ERDAS Imagine software supported with ground checks

and ground truth verification by qualified and experienced professionals. Area and distance

calculations have been carried out using GIS software after geo-referencing the interpreted data

with the help of SoI topographical maps of 1:50,000 scale.

A map depicting major land use/ land cover classes comprising lands under agriculture, fallow land,

open/degraded vegetation; lands falling under water bodies, marshes and sand beds, open/rocky



lands and lands under inhabitations is presented at Figure 3.4. The map also marks the area within

10 km of the project site as the region of interest.

PROCESS METHODOLOGY

AREAS UNDER DIFFERENT LAND USE

Courtesy: Environmental Information Centre, New Delhi

Procurement of

Satellite Imagery

Preparation of Base

Map using

Data Preparation

- Radiometric correction - Geometric correction

Preparation of

Signature Confusion

First Level Classification

Field

Verification/Ground

Updated information

from field

Second Level

Classification

Accuracy Estimation Area Estimation Map Output

Pre field process

Field process

Post field process



FIGURE 3.4 LAND USE / LAND COVER



3.10 Toposheet

FIGURE 3.5 TOPOSHEET



3.11 Ecological Information

Nandesari is in the middle of Gujarat’s “Golden Corridor” a 400 km belt of industrial estates. It is

located at the bank of Mahi River. The main occupation of inhabitants besides industry is

agriculture.

Drainage Area - Mahi River is Interstate river and cover parts of Gujarat, Rajasthan and Madhya

Pradesh. The contribution of Gujarat state is about 11,694 sq. km (33.6%) of the total drainage area

34,842 sq. km of Mahi.

Topography – A majority of the area covered by Mahi River basin in Gujarat is plains having

elevation less than 300 meter above MSL, whereas less than 50 meter above MSL in the coastal

region.

Soils – The principal soil types found in the Basin of Mahi River are listed in below table. The

percentage distribution of the soil types is also included.

{Courtesy-CPCB Publication-Quality of Major Rivers Gujarat state (The Biennium 1979 & 1980 Survey)} Ground Water Availability – The summary of the ground water availability in the Mahi river basin within the state boundary of Gujarat is given in below table. However, reduction in yield is reported blaming the water and soil pollution from industries.

Pollution of Mahi River was first reported in 1968. Several incidences of death of fishes and cattle

because of consumption of contaminated water from tanks and wells have been reported. The

Government of Gujarat built a 56 km long effluent channel to divert industrial waste from Nandesari

and other estates into the Gulf of Cambay. But the source has been used as a free source of irrigation

water thus contaminating soil.

Sr. No. Type of Soil Mahi River Basin 1 Coastal Alluvial 3.5% 2 Deep Black 12.5% 3 Medium Black 78.0% 4 Grey Brown 6.0% 5 Lateritic Soil -

Total 100%

Sr. No. Classification of Aquifers Mahi River Basin 1 Fairly Extensive Thick Aquifers 10% 2 Aquifers of Limited extent 25% 3 Aquifers of Restricted extent 65% 4 Restricted Aquifers with Saline/Brackish water -

Total 100%



3.11.1 Flora

Some of the flora found in area is listed below:

TABLE 3.13 LIST OF FLORA

Common name Scientific name Family

Kend Diospyros melanoxylon Ebenaceae

Salga Boswellia serrata Burseraceae

Palas Butea frondosa Fabaceae

Chihunt Butea superba Fabaceae

Kachnar Bauhinia purpurea Fabaceae

Bauhinia varigata Fabaceae

Chihor Bauhinia vahlii Fabaceae

Harre Terminalia chebula Combretaceae

Bahera Terminalia bellerica Combretaceae

Amla Embelica officinales

Red cotton tree Salmalia malabaricum

Van kapas Gossypium sp. Malvaceae

Karaunji Sterculia urens Sterculiaceae

Sabai grass Ischoemum augustifolium

Gular Ficus glomerata Moraceae

Mahua Madhuca latifolia Sapotaceae

Bamboo Dendracalamus strictus Poaceae

Ainthia dhamin Helicteres isora Sterculiaceae

Amaltas Cassia fistula Fabaceae

Karjani Abrus precatorius Fabaceae

Dudh koraiya Wrightia tomentosa

Dudhi Holarrhena antidysentrica Apocynaceae

Nepali liliac Hamiltoni suaveolens Fabaceae

Bhorkhorn Hymenodictyon excelsum

Asan Terminalia tomentosa Combretaceae

Kahua Terminalia arjuna Combretaceae

Dhaw Anogeissus latifolia Combretaceae

Silver/bridal creeper Porana paniculata

Mango Mangifera indica Anacardiaceae

Pipal Ficus religiosa Moraceae

Banyan Ficus bengalensis Moraceae

Pakur Ficus infectoria Moraceae

Babul Acacia arabica Fabaceae

Guhiya babul Acacia farnesiana Fabaceae

Sohora Streblus aspher Moraceae

Nim Melia azadirachta Meliaceae

Siris Albizzia lebbek Fabaceae

Jiyal Odina wodier Asteraceae

Palmyra Phoenix flabellifer Arecaceae

Jamun Eugenia jambolana Myrtaceae

Bel Aeglemarmelos Rutaceae



Jackfruit Tree Artocarpus integrefolia Moraceae

Bagnai Capparis horrida Capparaceae

Madar Calotropis gigantea Asclepiadaceae

Samalu Vitex negundo Verbenaceae

Jasmine

Koa Rosa involucarta Rosaceae

Mexican poppy Argemone mexicana Papaveraceae

Source : Environmental Information Centre, New Delhi

3.11.2 Fauna

TABLE 3.14 LIST OF FAUNA

Scientific Name Common Name Suncus murinus House shrew

Cynopterus sphinx Short nosed fruit bat Taphozous longimanus Long armed seathed tailed bat Taphozous nudiventris Naked bellied tomb bat

Manis crassicaudata Indian Pangolin Vulpes bengalensis Common Indian fox Viverricula indica Indian civet Lepus nigricollis Indian hare

Fenambulus pennanti Northern Palm Squirrel Tatera indica Indian Gerbil

Bandicota bengalensis Indian mole rat Grus antigone Saras

Calotes versicolor Typhlops braminus Blind/worm snake

Eryx conicus Russell’s sand boa Chersydrus granulatus Elephant trunk snake

Ptyas mucosus Dhaman Rana cyanophlyctis Skipping frog

Hilsa ilisha Hilsa fish Chela cachius

Source : Environmental Information Centre, New Delhi.

3.12 Socio - Economic Environment

An assessment of socio - economic environment forms an integral part of an EIA study. Therefore,

baseline information for the same was collected during the study period. The baseline socio -

economic data collected for the study region, before the proposed expansion project is operational,

has been identified for the four major indicators viz. demography, civic amenities, economy and

social culture. The baseline status of the above indicators is compiled in forthcoming

sections.

3.12.1 Demography

The population details (i.e. population distribution and population density) of the Taluka Vadodara,

District Vadodara and the study area within 10 km radius are presented in Table-3.16 & its

graphical representation is given in Figure-3.6.



TABLE 3.15 DEMOGRAPHIC DATA (1)

Sr.

No. Village Name

CD Block Name

No. of Househ

old

Total Populati

on

Total

Male

Total Fema

le

Population <06 years

Male<06

years Female<06 years

1 Fajalpur

(Sankarda) Vadoda

ra 950 4740 249

2 2248 604 326 278

2 Anagadh Vadoda

ra 2815 14780 765

0 7130 2112 1130 982

3 Nandesari (CT) Vadoda

ra 1717 8290 437

3 3917 1009 526 483

4 Vasad Vadoda

ra 780 3613 188

6 1727 349 194 155

5 Kanthariya Vadoda

ra 137 574 304 270 59 29 30

6 Bhanpura Vadoda

ra 124 1158 617 541 158 86 72

7 Ambali Vadoda

ra 206 934 487 447 102 53 49

8 Kanvadi Vadoda

ra 638 5214 275

9 2455 665 379 286

9 Amroli Vadoda

ra 444 2234 113

6 1098 297 152 145

10 Dodka Vadoda

ra 716 3724 196

9 1755 524 272 252

11 Rayaka Vadoda

ra 361 1981 102

6 955 262 131 131

12 Sankarda Vadoda

ra 1472 7460 390

8 3552 838 455 383

13 Ajod Vadoda

ra 526 2661 138

8 1273 316 170 146

14 Padmala Vadoda

ra 1059 5446 285

1 2595 676 352 324

15 Dhanora Vadoda

ra 255 1254 655 599 162 89 73

16 Dasharath Vadoda

ra 2349 11438 595

5 5483 1337 702 635

17 Kotna Vadoda

ra 594 2902 146

2 1440 394 207 187

18 Koyli Vadoda

ra 2193 10691 554

4 5147 1144 619 525

19 Ankaliya Vadoda

ra 240 1067 571 496 130 70 60

20 Rajupura Vadoda

ra 216 988 509 479 126 62 64

21 Sundarpura Vadoda

ra 283 1267 655 612 158 77 81

22 Sokhda Vadoda

ra 2454 12610 654

6 6064 1404 767 637

23 Sisva Vadoda

ra 533 2799 144

8 1351 362 185 177

24 Sherkhi Vadoda

ra 1841 9464 487

4 4590 1182 636 546

25 Ankodiya Vadoda

ra 937 4608 240

6 2202 466 260 206



Sr. No. Village Name

CD Block name

Population

Schedule caste

Male Schedule caste

Female Schedule caste

Population

Schedule tribe

Male Schedule tribe

Female Schedule tribe

1 Fajalpur

(Sankarda) Vadoda

ra 154 86 68 24 12 12

2 Anagadh Vadoda

ra 490 260 230 76 41 35

3 Nandesari (CT) Vadoda

ra 211 105 106 107 52 55

4 Gavasad Vadoda

ra 311 162 149 28 15 13

5 Kanthariya Vadoda

ra 33 18 15 226 117 109

6 Bhanpura Vadoda

ra 48 28 20 35 19 16

7 Ambali Vadoda

ra 23 13 10 304 155 149

8 Kanvadi Vadoda

ra 256 168 88 147 79 68

9 Amroli Vadoda

ra 86 42 44 1951 989 962

10 Dodka Vadoda

ra 219 128 91 1 1 0

11 Rayaka Vadoda

ra 133 78 55 0 0 0

12 Sankarda Vadoda

ra 297 150 147 85 43 42

13 Ajod Vadoda

ra 267 150 117 166 87 79

14 Padmala Vadoda

ra 489 264 225 95 46 49

15 Dhanora Vadoda

ra 19 8 11 318 177 141

16 Dasharath Vadoda

ra 982 494 488 670 367 303

17 Kotna Vadoda

ra 14 6 8 0 0 0

18 Koyli Vadoda

ra 464 224 240 309 157 152

19 Ankaliya Vadoda

ra 160 86 74 68 40 28

20 Rajupura Vadoda

ra 103 49 54 209 110 99

21 Sundarpura Vadoda

ra 147 75 72 269 144 125

22 Sokhda Vadoda

ra 571 295 276 698 379 319

23 Sisva Vadoda

ra 212 114 98 125 69 56

24 Sherkhi Vadoda

ra 275 141 134 123 64 59

25 Ankodiya Vadoda

ra 661 342 319 556 286 270



TABLE 3.16 POPULATION DENSITY

Name Population (Persons)

Population Density

(Person / sq. km.)

Sex ratio (No. of females per 1000

males)

Within 5 km Radius (2011)

1,03,532 362 886


1,21,897 426 902

Vadodara Taluka (2011) 20,09,434 488 919 Vadodara District (2011) 41,65,626 552 934

(Courtesy : Census Dept., GOI)

FIGURE 3.6 POPULATION DENSITY



3.12.2 Literacy Rate

The literacy rate is a major factor, which influences the socio-cultural condition of a particular place.

Details of literacy rate in District Vadodara, Taluka Vadodara and within 10 km radius and 5 km

radius of project site are given in Table 3.17 while their graphical representation is shown in Figure

3.7. It is observed that the literacy rate of Vadodara District as per 2011 Census data is 69.45 %,

with 74.94 % among male and 63.57 % among female. Literacy rate in Taluka Vadodara as per 2011

Census data is 80.62 % with 83.59 % among males and 77.39 % among females. Within 10 km

radius of the study area, the literacy rate is 74.97 %, with 80.71 % among male and 68.73 % among

female. Literacy rate in 5 km study area as per 2011 Census data is 46.32 % with 62.14 % among

males and 54.56 % among females.

Literacy rate at District level (Vadodara) is observed lesser then that within 5 km of the study area,

within 10 km of the study area and Taluka Level (Vadodara). But literacy rate at Taluka level

(Vadodara) is observed higher than that within 5 km of the study area, within 10 km of the study

area and District Level (Vadodara).

TABLE 3.17 LITERACY RATE

Name Male Literacy (%)

Female Literacy (%)

Total Literacy (%)

Within 5 km Radius (2011) 62.14 54.56 46.32


80.71 68.73 74.97

Vadodara Taluka (2011) 83.59 77.39 80.62

Vadodara District (2011) 74.94 63.57 69.45

(Courtesy: Census Dept., GOI)

FIGURE 3.7 LITERACY DATA



3.12.3 Occupational Structure

In economic development of the region its geographical location, natural resources, business and

employment, industries and manpower play vital role. Table 3.18 provides the occupational

patterns in all villages falling within the area of interest.

TABLE 3.18 OCCUPATIONAL STRUCTURE

Sr. No.

Village Name

CD Bloc

k nam

e

Total Work Population

Main worke

r Population

Main Cultivator

Population

Main Agriculture Population

Main Household

Population

Main Other Population

Marginal

Worker

Population

Non-Work

er Population

1 Fajalpur (Sankarda)

Vadodara

1941 1333 303 353 15 662 608 2799

2 Anagadh Vadodara

5048 4204 692 991 79 2442 844 9732

3 Nandesari (CT)

Vadodara

3200 2520 268 204 7 2041 680 5090

4 Gavasad Vadodara

1274 1206 215 599 37 355 68 2339

5 Kanthariya Vadodara

279 238 84 127 0 27 41 295

6 Bhanpura Vadodara

379 358 187 71 6 82 24 924

7 Ambali Vadodara

367 313 211 86 2 14 54 567

8 Kanvadi Vadodara

2786 2060 1101 653 30 276 726 3030

9 Amroli Vadodara

1225 553 138 310 5 100 672 1009

10 Dodka Vadodara

1403 1164 503 290 27 344 239 2321

11 Rayaka Vadodara

620 550 114 104 8 324 70 1361

12 Sankarda Vadodara

3178 2557 550 788 72 1147 621 4282

13 Ajod Vadodara

883 869 285 297 0 287 14 1778

14 Padmala Vadodara

1979 1638 161 730 10 737 341 3467

15 Dhanora Vadodara

614 338 166 137 1 34 276 640

16 Dasharath Vadodara

3886 3472 165 734 34 2539 414 7552

17 Kotna Vadodara

909 538 181 175 14 168 371 1993

18 Koyli Vadodara

3832 3225 253 838 25 2109 607 6859

19 Ankaliya Vadodara

648 493 52 394 9 38 155 419

20 Rajupura Vadodara

428 356 66 198 0 92 72 560

21 Sundarpura Vadodara

571 515 42 143 0 330 56 696



22 Sokhda Vadodara

4915 4230 928 1905 30 1367 685 7695

23 Sisva Vadodara

1417 919 188 499 7 225 498 1382

24 Sherkhi Vadodara

3362 2940 1051 776 35 1078 422 6102

25 Ankodiya Vadodara

1736 1683 321 603 13 746 53 2872

3.12.4 Amenities

Infrastructure resource base of the surveyed villages with reference to education, medical, water

resources, post and telegraph, communication, power supply is presented in Table 3.19. There are

40 villages within study area of 10 km radius of plant site. Significant observations with respect to

availability of amenities in study area are as follows.

All of the villages have primary schools, 17 villages have both primary and secondary education

schools. 4 villages have adult education facility. All of the villages in the impact zone have

community health workers, 26 villages have primary health sub center, 27 villages have registered

private practitioners while 14 villages have family planning center, 3 villages have primary health

center. 2 maternity homes, 3 child welfare centers, 1 nursing home, 12 dispensaries and 1 hospital

are also available in the impact zone.

In the study area drinking water facilities are good as tap water and well water is available almost

in all the villages, 3 villages have hand pumps. Tank water is available in 22 villages, 16 villages get

water from tube well, 3 from canal and 1 from nallah also. Post office facility is available in almost

in all villages while 4 villages have post and telegraph facility. Telephone facility is available in 26

villages. 36 villages are well connected through a network of Pucca road. 25 villages have Kuccha

approach road. Bus is the main mode of transportation and is available in 39 villages, 4 villages are

connected with railways and 2 with Navigable waterway. All the villages get electricity for all

purpose i.e. domestic, agriculture and industrial.



TABLE 3.19 DETAILS OF AMMENITIES AVAILABLE IN STUDY AREA Sr. No.

Village Educational Medical Drinking Water

Post & Telegraph

Communication

Approach to

Village

Nearest Town

Power Supply

1 Fajalpur (Sankarda)

P PHS, FPC, CHW T, W, TK, TW PO, Phone BS PR, KR Fertilizer Nagar-12

EA

2 Anagadh P(6), H, Ac MCW, PHS, D, FPC, RP(2), CHW

W, TW, R PO, Phone BS, NW PR, KR Jawahar Nagar-6

EA

3 Nandesari (CT)

P(3), H PHS, D, RP, CHW(3) T, W, TK, TW PO, Phone BS PR Ranoli-3 EA

4 Vasad P(3), H, PUC, Ac

H, PHC, D, RP, CHW T, W, TK, TW, HP, R, C

PTO, Phone BS, RS PR, KR Anand-20 EA

5 Kanthariya P(3) PHS, RP(2), CHW(2) T, W, TK PO, Phone BS PR, KR Borsad-5 EA

6 Bhetasi (Talpad)

P(3), H, PUC

PHS, RP, CHW T, W, C PO, Phone BS, RS PR, KR Borsad-14 EA

7 Bhetasi Ba Bhag

P, H, PUC RP(2), CHW(3) T, W PO, Phone BS PR, KR Borsad-15 EA

8 Bhanpura P CHW T, W, R PO BS PR Borsad-14 EA

9 Betasi Vanto P(2) PHS, RP, CHW T, W PO, Phone BS PR, KR Borsad-13 EA

10 Ambali P(2) RP(2), CHW T, W PO, Phone BS PR Borsad-20 EA

11 Kanvadi P(2), H PHS, CHW(3) T, W PO BS PR, KR Borsad-23 EA

12 Amrol P(3) PHS, CHW T, W PO, Phone BS PR, KR Borsad-15 EA

13 Dodka P, H D, FPC, CHW W, TK, TW PO BS PR, KR Ranoli-9 EA

14 Rayaka P(3), H PHS, D(2), RP(2), CHW W, TK, TW, HP, R

PO -(-5 Kms)

PR, KR Fertilizer Nagar-8

EA

15 Sankarda P PHS, FPC, RP(3), CHW T, W, TK, HP, R, N, O

PO, Phone BS PR Fertilizer Nagar-6

EA

16 Ajod P PHS, FPC, RP, CHW T, W, TK, TW PO BS PR, KR Fertilizer Nagar-2

EA

18 Padmala P PHS, D, FPC, RP(2), CHW

T, W, TK PO, Phone BS PR Fertilizer Nagar-5

EA

19 Dhanora P(2) RP(2), CHW(2) T, W, TK, R PO, Phone BS PR Jawahar Nagar-5

EA

20 Dasharath P(2), H, Tr PHS, D, FPC, RP(4), CHW(4)

T PO, Phone BS PR Fertilizer Nagar-1

EA

21 Kotna P PHS, CHW W, TK, TW, R PO BS PR Jawahar Nagar-8

EA

22 Koyli P(2), H MCW, MH, CWC, PHS, D, RP(7), CHW(8)

T, W, TK PTO, Phone BS PR Jawahar Nagar-1

EA

23 Ankalavdi P(2) PHS, FPC, CHW T, W, TK, TW, C

PO, Phone BS PR, KR Anand-12 EA

24 Rajupura P, O RP, CHW T, W, R PO BS PR, KR Anand-25 EA

25 Sundan P, H, Ac(3) PHS, FPC, RP, CHW T, W, TK PO, Phone BS, RS PR, KR Anand-18 EA

26 Mujkuva P(3) PHS, RP, CHW, O T, W PO, Phone BS PR, KR Borsad-12 EA

27 Anklav (Town)

P(6), H(2), PUC, Tr(2)

MCW, MH, CWC, PHC, D, FPC, NH, RP(5)

T, W, TW PTO, Phone BS, RS PR, KR Borsad-18 EA

28 Asarma P(2) PHS, CHW T, W, R PO, Phone BS PR, KR Borsad-20 EA

29 Hathipura P RP, CHW T, W -(-5 Kms) BS KR Borsad-16 ED, EAG

30 Umeta P, H PHS, D, FPC T, W, R PO, Phone BS PR Borsad-25 EA

31 Khadol (Umeta)

P(3) CHW T, W, TW, R PO BS, NW PR, KR Borsad-24 EA

32 Moksi P, H, Ac PHS, FPC, RP, CHW T, W, TK, TW PO, Phone BS KR Vadodara-28 EA

33 Poicha (Raniya)

P, H RP(2), CHW T, W, TK, TW, R

PO BS KR Vadodara-16 EA

34 Khandi P CHW T, W, R PO BS PR Vadodara-20 EA

35 Vasna-Kotariya

P PHS, CHW T, W, TK PO, Phone BS PR, KR Fertilizer Nagar-10

EA

36 Sokhda P(7), H, PUC

CWC, PHC, D, RP(4), CHW

T, W, TK, TW, R

PTO, Phone BS PR, KR Fertilizer Nagar-6

EA



37 Sisva P PHS, FPC, RP, CHW T, W, TK, TW, O

PO, Phone BS PR, KR Fertilizer Nagar-2

EA

38 Sindrot P(6), H PHS, D, FPC, RP, CHW(3)

T, W, TK, TW, R

PO BS PR, NR Vadodara-24 EA

39 Sherkhi P(4) PHS, FPC, RP, CHW(3) T, W, TK, R PO BS PR Vadodara-8 EA

40 Ankodiya P PHS, RP(2), CHW T, W, TK PO, Phone BS PR Jawahar Nagar-6

EA

(Courtesy : Census Dept., GOI)

ABBREVIATIONS

1. Education P-Primary Elementary School H-Matriculation or Secondary O-Other Educational Institution PUC-Higher Secondary/Intermediate/pre-University/junior College Ac- Adult Literacy Class Tr-Training School

2. Medical Facilities RP-Registered Private Practitioner PHS-Primary Health Sub-Centre FPC-Family Planning Centre PHC-Primary Health Centre D- Dispensary CHW - Community Health Worker/Health Worker H - Hospital NH - Nursing Home MH - Maternity Home PHC - Public Health Centre CWC - Child Welfare Centre TB - T.B Clinic O – Others

3. Drinking Water T-Tap Water HP-Hand Pump TK-Tank Water W-Well Water R-River Water C-Canal N - Nallah S – Spring TW- Tube well Water

4. Post & Telegraph PO-Post Office PTO-Post & Telegraph Phone-Telephone Communication

5. Communication BS-Bus Station NW-Navigable Waterway

6. Approaches to Village PR-Pucca Road KR-Kuchcha Road

7. Power Supply EA-Electricity for all purposes EAG - Electricity for Agriculture ED - Electricity for domestic EO - Electricity for other purpose like Industrial, Commercial etc.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 4 Anticipated Environmental Impacts & Mitigation Measures


CHAPTER – 4: ANTICIPATED ENVIRONMENTAL IMPACTS &

MITIGATION MEASURES

4.1 General

In this chapter, the anticipated environmental impacts and the proposed mitigation measures for

the proposed project have been described.

An impact can be defined as any change in Physical, Chemical, Cultural and/or Socioeconomic

environment that can be attributed to activities related to alternatives under study for meeting

project needs. Impact identification methodology provides an organized approach for prediction

and assessing these impacts. Scientific techniques and methodologies based on mathematical

modelling are available for studying impacts of various project activities on environmental

parameters.

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.

Chemicals manufacturing Industry may cause adverse impacts on surrounding environment unless

proper Environmental Management Plan is implemented. Selecting suitable mitigative measures in

terms of site selection, technology, machinery and operations can minimize the possible negative

impacts.

In this chapter, an attempt has been made to identify and quantify possible impact on various

environmental parameters such as Air, water, land, Noise and socio-economic factors. The

following aspects of environment have been studied to identify the possible impacts due to the

industrial activities.

• Air Environment

• Noise Environment

• Water Environment

• Land Environment

• Occupational health

• Socio-economic Environment



4.2 Details of anticipated environmental impacts due to project location,

project design, project construction, regular operations of a project.

(Impact Assessment Matrix)

Identification of impacts has been carried out by determination of impacting activities of the

proposed project. Then based on the outcome of the first part, further classification of impacts

based on types & nature has been carried out to identify all probable impacts in detail.

From the Table-4.1 significant impacts are identified. They are further elaborated with

characterization and assessment in Table-4.2.

TABLE 4.1 IMPACT IDENTIFICATION MATRIXES

Aspects

Environmental Attribute

Air

Noise

Water

Land & soil

Socio Economi

cs

Aesthetics

Construction Activity

Handling & Charging of Raw Materials

Operation of TFH & DG Operation of Domestic Utilities

Operation of ETP Isolated Storage Facilities Storage Facilities of Liquid Raw material/Products

Storage Facilities of Solid Raw material/Products

Transportation of Raw material/Products Development of Greenbelt

Employment Generation

The proposed project being an existing unit located in GIDC Nandesari, requires water, power, fuel,

human resources, machineries & utilities etc. Considering the details of resource requirements and

potentials of pollution as well as above tabulated identified impacts on environment; impact

statements have been prepared after necessary detailed study. The impacts statements for the

proposed project as predicted & assessed are described in subsequent section under respective

headings.

4.3 Assessment of Significance of Impacts (Criteria for Determining

Significance, Assigning Significance) & Mitigation Measures

For assessing the impact, the baseline data of environmental status were considered. The change

in the environmental parameters due to manufacturing activities of the industry has been

superimposed on the status data.



TABLE 4.2ENVIRONMENTAL IMPACT ASSESSMENTS

Environmental Attributes

Cause / Source

Impact Characteristics

Nature Duratio

n Reversibilit

y

Significance, Mitigative Measures

ACTIVITY: Handling & Charging of Raw Materials/Products

Air Quality (Fugitive

Emissions)

Handling operations for

transfer, charging of

raw materials, final product- manually or

through pipeline: spillage,

fugitive dust / vapor

emission and leakage due to

improper flanges

connection or gland leaks.

Indirect Negativ

e

Long Term

Reversible

Low, management to ensure proper handling of the spillages during

transfer. Preventive

maintenance of flange connections

and glands of pumps.

Besides, the management will

also ensure proper usage of the Personnel Protective

Equipment by the workers.

Regular Workplace Monitoring,

Ambient Air, Stack Air Monitoring to be

done.

Water, Land

Generation of wastewater

from the cleaning of spilled Raw

Material.

Direct Negativ

e

Long Term

irreversible

Wastewater to be treated at the in-house ETP and

Treated Effluent of 40 KLD will be

passed through RO Plant to recover

50% of the wastewater. 20KLD recovered ETP RO Permeate will be

utilized for cooling tower makeup & 20 KLD ETP RO Reject

will be taken to MEE plant for

evaporation. MEE Condensate of

19.6KLD also to be recovered for reuse.

Hazardous Waste

Generation of Hazardous Waste from

the spilled raw materials

Direct Negativ

e

Long Term

Reversible

Hazardous waste to be collected, contained &

disposed as per the spill procedures &




Cause / Source


Nature Duratio

n Reversibilit

y


hazardous waste management rules.

ACTIVITY: Operation of Thermic Fluid Heater (TFH)

Air Quality

Emission of pollutants

(PM, SO2, NO2) along with flue

gas after combustion of

the fuel for operation of

the TFH

Direct Negativ

e

Long Term

Reversible

Adequate Stack height will be

provided as APCM.

The flue gas will be emitted into the

atmosphere through stacks of TFH each with height of 30 m & stack of DG with

height of 5 m.

Noise

Noise generation

due to operation of

TFH & DG set.

Direct Negativ

e

Long Term

Reversible

Noise Generation due to operation of the Pumps & Draft

Fans. Anti-Vibration pads will be

provided wherever necessary. Preventive

Maintenance to be done and PPE like

ear plugs to be provided. DG set to

be acoustically enclosed.

Hazardous Waste

Annual Maintenance for cleaning TFH - solid

waste generation during the

cleaning-up operation.

Direct Negativ

e

Long Term

Reversible

The solid waste generated will be

sent to TSDF/CHWI site for disposal along with other hazardous waste.

Co-Processing

ACTIVITY: Operation & maintenance of Domestic Utilities

Water

Operation of Washroom,

toilets - Wastewater generation

Direct Negativ

e

Long Term

Irreversible

Domestic effluent (sewage) will be

disposed through Septic Tank & Soak

Pit. ACTIVITY: Operation & Maintenance of ETP

Water Treatment of wastewater

Direct Negativ

e

Long Term

Reversible

Wastewater to be treated at the in-house ETP and

Treated Effluent of 40 KLD will be

passed through RO Plant to recover




Cause / Source


Nature Duratio

n Reversibilit

y

Significance, Mitigative Measures 50% of the

wastewater. 20KLD recovered ETP RO Permeate will be

utilized for cooling tower makeup & 20 KLD ETP RO Reject

will be taken to MEE plant for

evaporation. 19.6 KLD MEE

Condensate to be recovered for reuse.

Air Quality Dosing of treatment chemicals

Direct Negativ

e

Long Term

Reversible

To ensure proper handling & dosing of

treatment chemicals.

Spent solvents to be recovered in the Solvent Recovery

plant.

Land

Storage of the treatment chemicals,

wastes, within the premises -

Separate storage area

provision

Direct Negativ

e

Long Term

Reversible

Designated storage area with proper

roof and impervious flooring to avoid soil contamination due

to leachate infiltration during

Monsoon. Leachate collection, conveyance to ETP. Hazardous wastes are to be disposed

as per the hazardous waste

authorization requirements.

Hazardous Waste

Generation of Haz. waste

Direct Negativ

e

Long Term

Reversible

The hazardous waste will be sent to

secured land fill facility for final

disposal ACTIVITY: Storage Facilities

Land

Handling operations of

the Raw material, solid

waste, unloading and

Direct Negativ

e

Long Term

Reversible

Management will ensure good

practices during transfer operations

to avoid any spillage of the solid wastes.




Cause / Source


Nature Duratio

n Reversibilit

y


loading. Collection of the spilled material,

storage and loading the

same into the trucks, for disposal.

Concreted area around storage

facilities to prevent seepage of the

spilled material to the soil.

Air quality

Emissions into the

atmosphere due to the storage of chemicals

during storage resulting in

odor nuisance

Direct Negativ

e

Long Term

Reversible

Chemicals to be kept covered and at

dedicated storage area.

Land

Transfer of material from

drums – spillage /

Leakage of material during

loading, unloading and transfer, due

to gland leakage of

pumps, flange leakage in

pipelines and due to manual

operation. - Generation of solid waste of Spillage clean-

up of the material using Water, sand / gypsum and treatment of

the wash water.

Direct Negativ

e

Long Term

Reversible

Regular maintenance of

pumps and flange connections in

pipelines should be ensured by the management.

Impervious flooring to be provided to avoid contact of

spilled material with soil.

Dyke walls to be constructed

ACTIVITY: Storage of Raw Materials/Products

Hazardous Waste

Storage of all the solid raw materials in

the plant area

Direct Negativ

e

Long Term

Reversible

Chemicals shall be stored, by taking

necessary measures to avoid




Cause / Source


Nature Duratio

n Reversibilit

y


in Drums / HDPE bags

and transfer to the

operational / processing

area – spillage, disposal of used bags.

contamination of Land & water during

monsoon. Ensure safe disposal of the empty containers &

liners to registered/approve

d recyclers. Relevant records to be maintained.

Land, Water

Storage of all the liquid raw

materials within the

plant area and transfer to the operational /

processing area – spillage

/ leakage, disposal of

used drums.

Direct Negativ

e

Long Term

Reversible

Chemicals shall be stored, by taking

necessary measures to avoid

contamination of Land & Water

during monsoon and ensure safe disposal of the empty drums

to registered/approve

d recyclers. Relevant records to be

maintained. Dyke Walls to be made at storage tanks with

valve & Pump arrangements to contain spillages

&Leakages. ACTIVITY: Transportation of Raw Materials/Products, Hazardous Wastes

Transportation

Transportation of all the raw

materials, finished

products and hazardous

wastes

Direct Negativ

e

Long Term

Reversible

Trained transporters to be

engaged for transport of hazardous

materials, spill control & other

emergency actions. MSDS of all raw

materials & finished products shall be kept available at

storage area & with the concerned departments.

The vehicles used for transporting

hazardous materials shall follow the




Cause / Source


Nature Duratio

n Reversibilit

y

Significance, Mitigative Measures applicable

guidelines given in The Motor Vehicles

Act. Activity: Solvent Recovery

Water / Hazardous

waste

Generation of wastewater after solvent

recovery.

Direct Negativ

e

Long Term

Irreversible

Wastewater to be treated in the ETP,

The hazardous waste i.e. Distillation residue to be sent to

CHWI of NECL Nandesari / Co-

Processing

Air Quality

Emissions into the

atmosphere due to the

operation of Solvent

recovery plant.

Direct Negativ

e

Long Term

Reversible

95% solvent to be recovered. Fugitive

emissions to be controlled.

Activity: Employment Generation

Socio Economic Direct & Indirect

Employment

Direct Positive

Long Term

-

Positive Impact due to hiring of manpower.

Benefits in the form of contracts to local

agencies for different services

Employment generation in

transport sector as local conveyance trips and trucks loadings will be

handled regularly. Activity Green Belt Development

Green belt

Development of green belt

for mitigation of pollution, Plantation of

trees within & at periphery of

premises

Direct Positive

Long Term

-

Positive Impact due to development of a

good green belt along the

periphery& within the premises

4.4 Overall Impacts

The impacts arising out of the said projects have been listed and studied in depth.



4.4.1 Impact on Air Environment

Impact due to Vehicular movement

Dust will be generated during excavation and hauling operation and vehicle transportation. Other

exhaust gases may be also slightly released into the local ambient air due to vehicular traffic

movement. Thus, the local ambient air quality may be temporarily affected. It will be confined

within the project boundary and is expected to be negligible outside the plant boundary.

Mitigation measure

Water sprinkling and provision of enclosures will allow the particles to settle down prior to

discharge.

Operation Phase Impacts & Mitigation Measures

The main sources of air pollution will be flue gas emission. Flue gas emission will be from One

existing Thermic Fluid Heater & One proposed flue gas stacks of Thermic Fluid Heater & One

proposed flue gas stack of DG set. FO/LDO is being used as existing fuel & Natural Gas will be used

in the proposed Thermic Fluid Heater. Adequate Stack height to be provided for proposed Thermic

Fluid Heater.

Mitigation measures

Adequate Stack Height to be provided to Thermic Fluid Heater stack. DG to be housed Acoustic

enclosure to attenuate noise.

To ensure that all the pollution control facilities envisaged at the design stage are have been

implemented and are functioning properly. Stack monitoring to ensure proper functioning of

different pollution control facilities attached to all stacks. Adequate plantation will be done in and

around premises. Thus, proposed plant activities will have negligible impact on the air

environment.

4.4.1.1 Fugitive emission

The emissions are normally defined as emissions to the atmosphere resulting from leaking piping

sources and equipment such as valves, flanges, pump seals, connections, and compressor seals

open end lines and pressure relief valves. The emissions are not visually observed but can be

measured in relatively low concentration at each area of source.

Fugitive emissions are expected to be generated during construction and operation stages of the

proposed project. During construction stage, main source of fugitive emission is dust which is

expected mainly due to movement of vehicles carrying construction material and vehicles used for

construction. During operation stage, leakage through valves, pumps, emission from open drum

containing chemicals, open feeding; storage tanks, etc. are the major sources of fugitive emissions.

Excess use of solvent may also result into fugitive emission from the process vessels.

Mitigation measure

General control measures like routine & regular inspection to identify leakage, preventive

maintenance and operational maintenance etc. will be implemented by the unit.



• Management to ensure proper handling of the spillages during transfer, charging operation and provision of a Caustic Scrubber as APCM for existing TFH, the stacks attached to storage tank area wherever applicable.

• Preventive maintenance of flange connections and glands of pumps.

• Adequate ventilation will be provided.

• Regular maintenance of valves, pumps, flanges, joints and other equipment will be done to prevent leakages and thus minimizing the fugitive emissions of VOCs.

• Entire process will be carried out in the closed reactors with proper maintenance of pressure and temperature.

• Periodic monitoring of work area will be carried out to check the fugitive emission.

• To eliminate chances of leakages from glands of pumps, mechanical seal will be provided at all solvent pumps.

• To avoid fugitive emission during sampling, the standard operating procedure shall be followed to draw sample from the sample point valve. During raw material, in-process and final finish product sampling, the due care shall be taken to avoid fugitive emission.

Further, it is emphasized that the mitigation measures discussed in table 4.2 of this chapter and

summarized in the Environmental Management Plan should be followed to maintain the air quality

within norms in the future.

The detailed air modelling for calculation of Ground Level Concentration of various pollutants has

been carried out using AERMOD Model.

4.4.2 Ambient Air Quality Modelling

Introduction

Ambient Air quality impact assessment is an important study; Mathematical modelling is

established to find the impact on environment due to flue gas emission has been assessed with the

help of modelling following the Central Pollution Control Board’s Guidelines. The mathematical

model used for conducting the study is the latest version 8.8.9 of Lakes AERMOD View, which is

entirely in line with the requirements of Central Pollution Control Board, New Delhi.

Project Location

The project site is located at Plot No. 133/4, 133/5, 133/6, GIDC Nandesari, Dist: Vadodara-

391340., Gujarat.

• 22°24'6.96"N, 73° 5'50.04"E

• 22°24'4.98"N, 73° 5'54.30"E

• 22°24'0.30"N, 73° 5'49.80"E

• 22°24'4.32"N, 73° 5'46.50"E

4.4.2.1 Details of Air Dispersion Model

The air quality impact of a source or group of sources is evaluated by the use of mathematical

models. The widely accepted interpretation models simulate the relationships between air

pollutant emissions and its impact on air quality. For the present study, this model is used for the

prediction of maximum ground level concentration (GLC).



Assessment of air pollution is carried out for proposed stacks attached to TFH. The “Aermod-View”

from lakes and Environment is an hour-by-hour steady state Gaussian Plume Model. This model is

widely recognized as predictive tool in impact assessment for air environment. The Aermod view

model has been applied with elevated + flat terrain, gradual plume rise and buoyancy induced

dispersion options in the present study.

The inputs to the model include data relating to emissions, which are determined by formulating

impact scenarios. The meteorology and atmospheric details like ambient temperature, wind speed,

wind direction etc. was taken from Aqua Air Surat for the Period of October 2018 to December

2018. The site specific and monitored details considered for input data for the software “AERMOD View”.

The major point source emissions are the flue/process gases stacks. Details of all the major stacks

are as follow shown in table 4.3:

TABLE 4.3 FLUE GAS STACK EMISSION RATES

Sr.

Stack/Vent

Dia. Height

(m)

Exit Velocity (m/sec)

Temp Emission Rates (After

APCM) (gm/sec)*

No. (m) (°C)

PM SO2 NO2

Flue gas Stacks – Proposed Products

1 TFH Proposed

0.45 30 10 130 0.0925 0.00185 0.468 (40 Lac Kcal)

2 DG Set 0.2 5 10 100 0.004 0.019 0.009

Note:

(*) Actual stack emissions will be well below the permissible stack emissions limits. To consider worst case scenario the emission rates are considered on maximum Stack Emission Limit.

PM Based on maximum expected concentration of PM-150 mg/Nm3

SO2 Based on maximum expected concentration of SO2-100 ppm

NO2 Based on maximum expected concentration of NO2-50 ppm

4.4.2.2 Presentation of Result:

The simulations were made to evaluate Particulate Matter, Sulphur Dioxide and Nitrogen oxides

incremental short-term concentrations due to proposed expansion. These results are based on

considering the emission due to One existing & one proposed stack for thermic fluid heater & one

DG set. In the short-term simulations, the incremental concentrations were estimated to obtain an

optimum description of variations in concentrations within study area of 10 km radius. Maximum ground level concentration will be observed at different distance for Particulate matter,

Sulphur Dioxide and Nitrogen oxides. The maximum ground level concentration for different

parameters is given in below Table for proposed project. Equal concentration contour plots for the

PM, SO2 & NO2 are given in below Figure 4.2(a) & (b), 4.3(a) & (b), 4.4(a) & (b) respectively for

proposed project.



The wind rose diagram for the Month of October 2018 to December 2018 is shown in figure: 4.1

FIGURE 4.1 WIND ROSE DIAGRAM



TABLE 4.4. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF PM, (µG/M3)

Direction Degrees

Distance in Meters

500 2090 2440 3490 5000 6050 6160 6400 7210 7330 9900 10000

360 0.69083 0.11805 0.0949 0.05602 0.0321 0.02338 0.02267 0.02125 0.01735 0.01687 0.01004 0.00986

22.5 0.78425 0.18257 0.15022 0.09594 0.06472 0.05434 0.05352 0.05148 0.04927 0.04894 0.04125 0.04095

45 1.84999 0.38931 0.30898 0.18102 0.1122 0.09089 0.08927 0.08545 0.07481 0.07348 0.05424 0.05372

67.5 0.99617 0.34784 0.29272 0.19287 0.12689 0.10229 0.10021 0.09566 0.08258 0.08085 0.05354 0.05277

90 1.4156 0.38182 0.32066 0.24712 0.19586 0.16933 0.16693 0.16188 0.14647 0.14438 0.10437 0.10312

112.5 0.24873 0.04173 0.03238 0.02033 0.01328 0.01099 0.0109 0.0107 0.00996 0.00986 0.00814 0.00809

135 0.64882 0.19683 0.16181 0.0977 0.05711 0.04603 0.04506 0.04307 0.03773 0.03759 0.03223 0.03197

157.5 0.25283 0.26009 0.26855 0.26259 0.22853 0.20433 0.20192 0.19676 0.18019 0.17787 0.13617 0.13482

180 0.68256 0.18041 0.1796 0.17859 0.18452 0.18469 0.18428 0.18316 0.17603 0.17479 0.14594 0.14482

202.5 0.49305 0.18311 0.15509 0.10187 0.06405 0.0494 0.04818 0.04568 0.03862 0.03773 0.02448 0.02413

225 2.58814 0.66814 0.54985 0.34026 0.27264 0.24468 0.24213 0.23675 0.22016 0.21788 0.17631 0.17483

247.5 1.3654 0.35185 0.30586 0.21114 0.13742 0.10909 0.10877 0.10796 0.10435 0.10373 0.08864 0.08804

270 0.83414 0.14974 0.11054 0.05135 0.02463 0.01827 0.01775 0.01669 0.0138 0.01345 0.00846 0.00833

292.5 0.09839 0.03154 0.02688 0.01852 0.01272 0.01094 0.01085 0.01064 0.00991 0.00981 0.00812 0.00806

315 1.3426 0.57102 0.50245 0.35227 0.22972 0.1788 0.17448 0.16559 0.14018 0.13693 0.08769 0.08634

337.5 0.28103 0.03656 0.03067 0.02302 0.01739 0.01461 0.01436 0.01384 0.0123 0.0121 0.00882 0.00873



FIGURE 4.2 (A) ISOPLETHS MAP FOR PM



FIGURE 4.2 (B)ISOPLETHS IN GOOGLE MAP FOR PM



TABLE 4.5. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF SO2, (µG/M3)

Direction Degrees

Distance in Meters

500 2090 2440 3490 5000 6050 6160 6400 7210 7330 9900 10000

360 0.03816 0.00608 0.00491 0.00295 0.00173 0.00129 0.00125 0.00118 0.00098 0.00096 0.0006 0.0006

22.5 0.04127 0.01202 0.01026 0.00738 0.00611 0.00582 0.0058 0.00568 0.00527 0.00521 0.00425 0.00422

45 0.09206 0.019 0.01524 0.00993 0.00819 0.008 0.00799 0.00788 0.00752 0.00748 0.00669 0.00666

67.5 0.0621 0.01698 0.01433 0.00978 0.00709 0.00647 0.00642 0.00624 0.00568 0.0056 0.00415 0.0041

90 0.08072 0.02129 0.01863 0.01611 0.01573 0.01468 0.01448 0.01406 0.01275 0.01257 0.00939 0.00929

112.5 0.02796 0.00353 0.00275 0.00156 0.00097 0.00082 0.00081 0.00078 0.00071 0.0007 0.00055 0.00054

135 0.03926 0.01043 0.01052 0.01091 0.00841 0.00697 0.00684 0.00657 0.00577 0.00566 0.00461 0.00459

157.5 0.02402 0.0128 0.01312 0.01271 0.01101 0.00984 0.00972 0.00947 0.00867 0.00856 0.00656 0.00649

180 0.03663 0.00857 0.00853 0.00971 0.01242 0.01312 0.01314 0.01317 0.01273 0.01264 0.01055 0.01046

202.5 0.02772 0.0099 0.00874 0.00666 0.00502 0.0043 0.00424 0.00411 0.00372 0.00367 0.00284 0.00282

225 0.15096 0.03703 0.03077 0.01941 0.01374 0.01288 0.0128 0.01266 0.01222 0.01216 0.01098 0.01092

247.5 0.08158 0.01672 0.01453 0.01005 0.00671 0.00558 0.0055 0.00535 0.00497 0.00494 0.00466 0.00466

270 0.04044 0.00711 0.00525 0.00271 0.00153 0.00115 0.00112 0.00106 0.00089 0.00087 0.0006 0.00059

292.5 0.01371 0.00259 0.00212 0.00133 0.0009 0.00077 0.00075 0.00073 0.00066 0.00065 0.00053 0.00053

315 0.07108 0.02834 0.02483 0.01731 0.01126 0.00877 0.00856 0.00812 0.00725 0.00732 0.00816 0.00816

337.5 0.02276 0.0034 0.00276 0.00168 0.00101 0.00084 0.00083 0.0008 0.00071 0.0007 0.00054 0.00053



FIGURE 4.3(A) ISOPLETHS MAP FOR SO2



FIGURE 4.3(B) ISOPLETHS IN GOOGLE MAP FOR SO2



TABLE 4.6. THE 1ST HIGHEST 24-HR AVERAGE CONCENTRATION OF NO2, (µG/M3)

Direction Degrees

Distance in Meters

500 2090 2440 3490 5000 6050 6160 6400 7210 7330 9900 10000

360 0.43686 0.06104 0.05303 0.03552 0.02203 0.01683 0.01639 0.01552 0.01307 0.01276 0.00924 0.00932

22.5 0.38668 0.22032 0.18623 0.12074 0.10589 0.10953 0.10995 0.10889 0.10382 0.10309 0.08887 0.08838

45 0.54224 0.10276 0.08657 0.09767 0.11127 0.13111 0.13295 0.13399 0.13618 0.1364 0.13589 0.1357

67.5 0.66855 0.14465 0.12411 0.10359 0.12527 0.13235 0.13161 0.12875 0.1189 0.11745 0.08942 0.08848

90 0.72389 0.22752 0.27707 0.334 0.27605 0.27637 0.27373 0.26791 0.24821 0.24534 0.1905 0.18866

112.5 0.5413 0.05603 0.04375 0.02676 0.01849 0.0153 0.01503 0.01448 0.01291 0.01271 0.00962 0.00953

135 0.53982 0.18251 0.19918 0.23161 0.1841 0.15432 0.15158 0.14584 0.12862 0.12633 0.09995 0.0994

157.5 0.49333 0.09166 0.08143 0.06607 0.05614 0.04989 0.04928 0.04798 0.04388 0.04331 0.03328 0.03296

180 0.4917 0.13478 0.15923 0.1786 0.15133 0.17219 0.17342 0.17564 0.17087 0.16967 0.14149 0.1404

202.5 0.46478 0.20214 0.18101 0.13851 0.10488 0.09011 0.08881 0.08611 0.07813 0.07708 0.05984 0.05932

225 1.42501 0.30948 0.26354 0.25245 0.21571 0.20003 0.19873 0.19605 0.18832 0.1873 0.17983 0.18063

247.5 0.81013 0.23218 0.18928 0.11504 0.08212 0.06941 0.06828 0.06593 0.05893 0.05799 0.06598 0.06671

270 0.56198 0.07985 0.06428 0.03851 0.02314 0.01784 0.01742 0.01656 0.01421 0.01392 0.00977 0.00966

292.5 0.29713 0.05597 0.04575 0.02823 0.01703 0.01409 0.01385 0.01335 0.01194 0.01176 0.00894 0.00886

315 0.67768 0.23655 0.2117 0.16112 0.12103 0.10356 0.10203 0.09885 0.11882 0.12182 0.16157 0.16212

337.5 0.4768 0.07488 0.0607 0.03674 0.02165 0.01623 0.01579 0.0149 0.01241 0.01211 0.00896 0.00888

Gujarat Dyestuff Industries (Pharma Unit) Chapter 4 Anticipated Environmental Impacts

& Mitigation Measures


FIGURE 4.4(A) ISOPLETHS MAP FOR NO2




FIGURE 4.4(B) ISOPLETHS IN GOOGLE MAP FOR NO2




TABLE 4.7 MAXIMUM GLCS FROM THE DISPERSION MODEL

Description 1st Highest Value

Concentration ( µg/m3) Co-ordinates

X (m) Y (m)

PM 2.59 -353.55 -353.55

SO2 0.151 -353.55 -353.55

NO2 1.43 -353.55 -353.55

Note:

PM: Based on maximum expected concentration of SPM-150 mg/Nm3

SO2: Based on maximum expected concentration of SO2-100 ppm

NO2: Based on maximum expected concentration of NO2-50 ppm

4.4.3 Impact on Water Environment

Water environment may be affected by the proposed project in different ways. As project is in GIDC

Nandesari industrial estate, no ground water will be used for construction work. For operational

activities, water requirement will be fulfilled by GIDC water supply. (Kindly refer letter is attached

as Annexure-11). Water environment may be affected by industrial & domestic wastewater

generation.

Mitigation Measures

The wastewater generated will be mainly from the washing, Scrubber, Process & Cooling Tower.

Total 40 KLD Industrial w/w will be generated from the proposed manufacturing activities. The

effluent treatment plant shall be so designed that the effluent from the process will come to the

Equalization cum Neutralization tanks for treatment, whereas the domestic waste goes directly go

to the Septic tank & Soak Pit for disposal. Treated water from the ETP will be passed through ETP

RO Plant & 20KLD recovered Product to be used for Cooling Tower Makeup. 20 KLD Reject to be

evaporated in MEE. 19.6 KLD MEE Condensate to be recovered for reuse. 8 KLD domestic

wastewater will be generated, which will be disposed through Septic tank & Soak Pit. So, there is

no impact of water due to proposed activities on environment.

Proper storage facility will be provided for raw material and hazardous waste. Hence there will be

no impact on ground water and surface water quality. Proper care will be taken to prevent any

spillage/leakage.

4.4.4 Impact on Land/Soil Environment

Land pollution can be caused due to improper handling of hazardous wastes on the land

environment and spillage or leakage of chemicals.

Mitigation measures

The hazardous solid waste generated will be stored and disposed properly. The storage area will

be of RCC flooring with impervious lining. The unit will make its solid waste storage / treatment

areas impervious to water and leachate migration. This will prevent soil contamination.




Since this is a notified industrial area, no major impact on land is envisaged due to the construction

activities. Hence, soil quality will not be adversely impacted by the plant operations.

Further, it is emphasized that all precautionary measures have to be strictly practiced as mentioned

in the mitigation measures discussed in Table 4.2 of this chapter and summarized in the

Environmental Management Plan given to prevent soil contamination in the future.

The existing land is in Nandesari GIDC, and is of Industrial Land use, this is being used and will be

utilized for Industrial Purpose only. Hence, this is going to cause no impact on land use.

4.4.5 Impact on Noise Levels

Major source of noise is vehicular traffic. The operation of the equipment will generate noise level

ranging between 75 to 90 dB (A). However, this noise level will be near the source only and is not

expected to create any noise pollution problem at places away / outside the plant premises. The

noise generated during the construction phase from different equipment may have some adverse

impact on the operators.

Equivalent sound pressure level, 8 hrs. average, (Leq. 8 hrs.), is used to describe exposure to noise

in workplaces. The damage risk criteria for hearing loss, enforced by Occupational Safety and

Health Administration, (OSHA) USA and stipulated by other organizations, mentions that noise

levels up to 90 dB(A) are acceptable for eight hours exposure per day. Ministry of Labour,

Government of India has also recommended similar criterion vide Factories Act

Mitigation Measures

Personnel Protective equipment such as earplugs, earmuffs etc. will be provided. It will be ensured

that all the equipment and vehicles used are in good working condition, properly lubricated and

maintained to keep noise within the permissible limits and engines turned off when not in use to

reduce noise.

The noise levels of high-speed machinery like DG set, compressors, fans and blowers are in the

range of 90-110 dB(A). Various measures proposed to reduce noise level at source are, acoustic

enclosures, hoods, acoustic lagging for the equipment and suction side silencers, vibration isolators,

selection of low noise equipment, isolation of noisy equipment from working personnel.

Machineries will be provided with silencers and the fan casing will be properly insulated. So that

the sound pressure level exposure in working areas is restricted below 90 dB(A) for 8 hours duty.

4.4.6 Impact on Socio-Economy

The is an existing project into manufacturing of Bulk Drugs, Expansion proposed - Ethoxylates &

Metformin falling under 5(f) & is located in GIDC Nandesari, which is notified industrial area.

Therefore, no displacement of person is envisaged. There may be chances of pollution of air,

pollution of water, pollution of soil and noise pollution in surrounding villages due to proposed

project activities and transportation. But unit will provide proper environmental management




system to control anticipated impacts generated due to industrial activities & unit will also conduct

environment monitoring program at regular intervals. Unit has satisfied its water demand through

GIDC water supply, so there is no chance to affect ground water level. Employment of

unskilled/skilled labour, technical staff (like welder, electrician, plumber etc.) and managerial staff

for proposed construction, though it is less and temporary, will have some beneficial impacts on

economic condition of the local labour/people. Increase opportunities of business potential will

have beneficial impacts on economic condition of local contractors, supplier of construction

materials, transporter and small business owners. Regular CSR activities have been done by unit

for Social welfare & upliftment of local people.

4.5 Irreversible & Irretrievable Commitments of Environmental Components

The project is not expected to create any irreversible and irretrievable impacts because of the

following:

• All the impacts created by the project will be mitigated by adoption of suitable mitigation

measures.

• Relevant mitigation measures against each pollutant attributes have been elaborated above

with quantification; wherever possible.

4.6 Incremental Concentration

Considering above incremental concentration over the existing baseline concentration, total

resultant concentration would be as follows

Sr No.

Location Name

Angle Distance PM10, g/m3

Baseline concentration

Probable Incremental

concentration

Resultant concentration

1 Nandesari (A2) 315 2.09 76.01 0.57102 76.59 2 Bhetasi (A3) 247.5 6.05 74.64 0.10909 74.75 3 Ambali (A4) 270 6.40 73.33 0.01669 73.35 4 Kotna (A5) 225 6.16 72.38 0.24213 72.62 5 Anagad (A6) 225 2.44 75.78 0.54985 76.33 6 Hathipura (A7) 225 9.90 71.94 0.17631 72.12 7 Undera (A8) 135 7.21 74.96 0.03773 75.00 8 Padamla (A9) 45 3.49 75.34 0.18102 75.52 9 Ajod (A10) 67.5 7.33 74.79 0.08085 74.87

Sr No.

Location Name

Angle Distance SO2, g/m3



concentration


1 Nandesari (A2) 315 2.09 19.13 0.02834 19.16 2 Bhetasi (A3) 247.5 6.05 13.11 0.00558 13.12 3 Ambali (A4) 270 6.40 16.58 0.00106 16.58 4 Kotna (A5) 225 6.16 15.15 0.0128 15.16 5 Anagad (A6) 225 2.44 18.46 0.03077 18.49




6 Hathipura (A7) 225 9.90 17.09 0.01098 17.10 7 Undera (A8) 135 7.21 13.57 0.00577 13.58 8 Padamla (A9) 45 3.49 16.72 0.00993 16.73 9 Ajod (A10) 67.5 7.33 15.75 0.0056 15.76

Sr No.

Location Name

Angle Distance NO2, g/m3



concentration


1 Nandesari (A2) 315 2.09 17.19 0.23655 17.43 2 Bhetasi (A3) 247.5 6.05 11.07 0.06941 11.14 3 Ambali (A4) 270 6.40 13.74 0.01656 13.76 4 Kotna (A5) 225 6.16 12.35 0.19873 12.55 5 Anagad (A6) 225 2.44 15.49 0.26354 15.75 6 Hathipura (A7) 225 9.90 14.28 0.17983 14.46 7 Undera (A8) 135 7.21 11.49 0.12862 11.62 8 Padamla (A9) 45 3.49 14.19 0.09767 14.29 9 Ajod (A10) 67.5 7.33 11.26 0.11745 11.38

Hence, above tables show that even after addition of incremental pollutant concentration (arrived

from Air Quality Modelling) to the baseline concentration, the resultant concentration remains

within the acceptable range of National Ambient Air Quality norms for respective pollutants.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 5 Analysis of Alternatives


CHAPTER – 5: ANALYISIS OF ALTERNATIVES

5.1 Analysis of Alternatives

The site has several favorable factors for locating; summarized below:

• M/s. Gujarat Dyestuff Industries (Pharma Unit). located at Plot No. 133/4, 133/5, 133/6,

GIDC Nandesari, Dist: Vadodara-391340., Gujarat.

• This is an existing unit into manufacturing of Bulk Drugs such as Cifixime Trihydrate,

Cefuroxime Axetil, Cefpodoxime Proxetil, Ampicilin, Amoxicillin Trydrydate, Clobetasole

Propionate, Betamethasone Dipropionate, Betamethasone Valerate, Betamethasone

Sodium Phosphate, Dexamethasone Sodium Phosphate, Beclomethasone Dipropionate,

Mometasone Furoate, Methylcobalamine, Ofloxacin, Levofloxacin, Quinon Sulphate,

Cloxacillin Sodium, Oxacillin Sodium, Di Cloxacillin Sodium, Flucoxacillin Sodium.

• New products Ethoxylates, Metformin Hydrochloride, and additional Methylcobalamine

that falls in Schedule 5(f) are planned to be manufactured and hence the application for

Expansion EC is being done.

• Project is located in Nandesari GIDC, which is notified industrial area, so requirement of

industrial land is fulfilled. All other infrastructure facilities such as water, fuel, power,

proper road network for transportation of raw materials & products, skilled & unskilled

manpower etc. are also easily available.

• Uninterrupted availability of sufficient water from GIDC water supply.

• Treated effluent discharge facility.

• Uninterrupted supply of electricity

• No physical displacement of the members of the public.

• Connectivity of the site via road and train to procure the raw material and to dispatch the

products.

• No national park or wildlife sanctuary within 10 radius of the project site

• Rehabilitation and resettlement will not be required, as project is in notified Industrial area

• Vicinity of common environmental infrastructure; like TSDF, CHWIF etc.

The land located in the notified industrial area. So, there will be no alternative for site.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 5 Analysis of Alternatives


5.2 Best Available Technologies

• Research & Development of Gujarat Dyestuff Industries (Pharma Unit). has done extensive

research on the available processes of manufacturing of the selected products. Safe design

of these equipment was studied and evaluated, appropriate MoC for this equipment was

selected based on the material to be handled by the process & project engineering team.

During the selection of the technology emphasis was made on minimal manual handling

and human interface thus the process was designed to be automated using PLC.

• All reactors will be fitted with a Rupture Disc and Pressure Relief Valve.

• Reactors will be fitted with a Rupture Disc and Pressure Relief Valve wherever required.

• The vents of the Rupture Disc, Pressure Relief Valve system will go to roof height.

• All vessels will be designed as per the requirement of different processes.

• All vessels will be pressure tested as per the design rating before use.

• Processes will be automated using Program Logic Controllers and recipe batch.

• A sophisticated IMCC will be used for power distribution to plant equipment.

• Emergency action plan will be in place to handle emergency situations.

• Specially trained personnel will be available in all shifts to handle emergencies.

• SOP’s will be available for all operations.

• Safety will be incorporated in the processes.

• Leak detectors will be placed at strategic locations in tank farm as well as in plant as

required.

• Portable leak detectors will be used by personnel working in the specified jobs.

• Appropriate utilities will be planned for safe operations.

• Emergency exits will be available for all structures.

• All Raw Material and Finished Goods tanks will have a dyke for containment.

• Tanks will be segregated as per statutory and plant requirement.

• Water / Caustic scrubbers with column, circulation / transfer pump provided.

• Chemicals will be handled using all required PPE’s as per their characteristics and

requirements.

• Proper areas will be demarcated for intermediate storages in plant.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 6 Environmental Monitoring Program


CHAPTER –6: ENVIRONMENTAL MONITORING PROGRAM

6.1 Introduction

The monitoring and evaluation of the mitigation measures envisaged are critical activities in

implementation of the Project. Monitoring involves periodic checking to ascertain whether

activities are going in according to the plans. It provides the necessary feedback for project

management to keep the program on schedule. The purpose of the environmental monitoring plan

is to ensure that the envisaged purpose of the project is achieved and results in desired benefits.

To ensure the effective implementation of the proposed mitigation measures, the broad objectives

of monitoring plan are:

• To evaluate the performance of mitigation measures proposed in the EMP.

• To assess the adequacy of Environment Management System

• To suggest improvements in management plan, if required

• To enhance environment quality.

• To implement and manage the mitigation measures defined in EMP.

• To undertake compliance monitoring of the proposed project operation and evaluation of

mitigation measure.

6.2 Implementation Arrangement

The various components of the environment need to be monitored on regular basis during

construction and operation phase of the project, as per the requirements of regulating agencies as

well as for trend monitoring of the pollutant’s levels in various environmental matrices.

6.3 Environmental Aspects to be Monitored

Several measures have been proposed for mitigation of adverse environmental impacts. These shall

be implemented as per proposal and monitored regularly to ensure compliance to environmental

regulation and also to maintain healthy environmental conditions.

A major part of the sampling and measurement activity shall be concerned with long term

monitoring aimed at providing an early warning of any undesirable changes or trends in the natural

environment that could be associated with the plant activity. This is essential to determine whether

the changes are in response to a cycle of climatic conditions or are due to impact of the plant

activities. In particular, a monitoring strategy shall be ensured that all environmental resources,

which may be subject to contamination, are kept under review and hence monitoring of the

individual elements of the environment shall be done.

The environmental aspects to be monitored to ensure proper implementation and effectiveness of

various mitigative measures envisaged/adopted during the design and commissioning stage of the



project proponent are described here under. The frequency of monitoring schedule for different

parameters as mentioned below may increase depending on the requirement.

6.3.1 During Construction Stage

During construction stage, different issues / components involved in environmental monitoring

programme will be looked upon by Project proponent.

TABLE 6.1: ENVIRONMENTAL MONITORING PROGRAMME (DURING CONSTRUCTION

STAGE)

6.3.2 During Operation Phase

The environmental monitoring programme for different environmental components / indicators

which are to be monitored during the operation phase will be as given under different heads.

At the unit, an Environmental Management cell has been formed, which will review the

effectiveness of environmental management plan of the project during operation phase. The data

collected on various EMP measures would be reviewed by this cell and if needed, corrective action

will be formulated for implementation.

It will form short term & long-term plans for environmental issues, which are required for

monitoring and effective implementation. The environmental quality-monitoring program will be

carried out in the impact zone with suitable sampling stations.

6.3.2.1 Ambient Air Monitoring Within Plant Area

All the accessible areas of the plant will be monitored for ambient air.

6.3.2.2 Effluent Monitoring

Performance of Sewage treatment plant and Effluent Treatment Plant will be monitored regularly.

Following things would be monitored regularly.

-Inlet [Raw domestic wastewater] to STP as well as ETP.

-Outlet [Treated domestic wastewater] of STP as well as ETP.

6.3.2.3 Work Zone Noise Levels

The Industry will monitor the noise levels inside and around the plant on a quarterly basis.

Description Nos. of Locations and frequency

Work zone /Noise Cover all shift of operation once every quarter for all the selected

locations.

Component Parameters Location and Frequency of Monitoring

Air PM10, PM2.5, SO2, NOx Plant site.

One sample every month

Noise Noise Levels Leq

Four locations every month.

one at project site and three at 120 degrees

in nearest habitation

Soil As per standard practice Once before starting construction activity



6.3.2.4 Ambient Noise

Ambient noise shall be monitored at eight locations in area surrounding the project, once in each

quarter. The locations selected for monitoring will cover the project site and the sensitive areas of

project study area.

6.3.2.5 Solid / Hazardous Waste Disposal

The hazardous wastes will be disposed as per applicable stipulations of statutory authorities.

Periodic surveillance monitoring will be conducted to ensure that the wastes will be disposed in

the manner as specified.

6.3.2.6 Green Belt Development

The following plan has been made for implementation of green belt at the project site.

• Regular periodic watering of the plants,

• Manuring,

• Weeding,

• Hoeing will be carried out for minimum 3 years after the plantation work.

6.3.2.7 House Keeping

The Industry will maintain housekeeping activities as per standard practice meeting hygienic

norms.



6.4 Environmental Monitoring Plan

TABLE 6.2 PROJECT ENVIRONMENT MONITORING PLAN

6.5 Documents & Records

The environmental department in respect of operation of pollution control facility will maintain

following records.

• Instruction manual for operation and maintenance of pollution control equipment.

• Log sheet for self-monitoring of pollution control equipment.

• Instruction manual for monitoring of water, solid and gaseous parameter discharged from

the factory and also for various parameters of pollution control facilities.

• Statutory records as per the Environmental Acts.

• Monthly and annual progress reports.

• Submission of Compliance report to MoEF.

Sr. No. Activity Parameter Schedule Air Quality Monitoring

1 Ambient air monitoring of parameters specified by GPCB in their air consents from time to time within the M/s. Gujarat Dyestuff Industries (Pharma Unit). premises.

As prescribed by GPCB including PM2.5, PM10, SO2, NO2, HC & VOC.

Every Quarter Up-Wind & Down-Wind/ As per GPCB Consent (by NABL Lab)

2 Stack monitoring of flue gas stacks& process gas stack as given in air consent from time to time

Parameters prescribed by GPCB including PM, SO2, NO2

Every Quarter / As per GPCB Consent (by NABL Lab)

3 Fugitive emissions/ workplace monitoring within the plant side

VOC As per GPCB Consent.

Wastewater Quality Monitoring 1 Untreated & Treated Effluent Colour, pH, TDS,

TSS, Sulphates, Chlorides, O&G, BOD, COD, etc.

Every Quarter / As per GPCB Consent. (by NABL Lab)

Noise Monitoring 1 Noise Monitoring and maintaining records Noise level in dB(A) Every Quarter / As

per GPCB Consent. (by NABL Lab)

Solid Waste Generation Monitoring / Record Keeping 1 Records of generation of solid & Hazardous

waste and records of disposal. ETP waste, Residue/side products, discarded container/ bags/ Drums & Used oil/Spent Oil

To be updated on event basis

2 Records of generation, handling, storage, transportation and disposal of other solid, aqueous and organic hazardous wastes as required by hazardous waste authorization

To be updated on event basis

Soil monitoring 1

At plant site pH, TDS, Chlorides, COD.

Pre and post monsoon season



6.6 Budgetary Provisions for Environmental Protection Measures

TABLE 6.3 COST OF ENVIRONMENTAL PROTECTION MEASURES

Sr. No.




1 Air pollution

control 6.5 2.5 9 5 1.5 6.5

2 Water pollution

control 33 100 133 4.5 90.5 95

3 Hazardous



5 Occupational

health 1 0.5 1.5 0.5 0.5 1

6 Greenbelt


6.7 Updating of EMP

The directives from MoEFCC and the regulations in force at any time shall govern the periodicity of

monitoring. However, it is suggested that the implementation of various measures recommended

in the EMP be taken as EMPs in the system to effectively implement the measures for continual

improvement in environmental performance.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 7 Risk Assessment


CHAPTER – 7: RISK ASSESSMENT

7.1 Risk Assessment

7.1.1 Introduction

Hazard analysis involves the identification and quantification of the various hazards (unsafe

conditions). On the other hand, risk assessment deals with recognition and computation of risks,

the equipment in the plant and personnel are prone to, due to accidents resulting from the hazards

present in the plant.

Risk assessment follows an extensive hazard analysis. It involves the identification and assessment

of risks the neighboring populations are exposed to as a result of hazards present. This requires a

thorough knowledge of failure probability, credible accident scenario, vulnerability of population

etc. Much of this information is difficult to get or generate. Consequently, the risk assessment is

often confined to maximum credible accident studies. It provides basis for what should be type and

capacity of its on-site and off-site emergency plan also what types of safety measures shall be

required.

7.1.2 Objective The main objective of the Risk Assessment study is to determine damage due to major hazards

having damage potential to life and property and provide a scientific basis to assess safety level of

the facility.

The secondary objective is to identify major risk in manufacture of chemicals, storage of chemicals

and provide control thorough assessment. To prepare onsite, off site, disaster management plan

for control of hazards.

7.1.3 Approach to the Study

Risk involves the occurrence or potential occurrence of some accidents consisting of an event or

sequence of events. The risk assessment study covers the following:

• Identification of potential hazard area.

• Identification of representative failure cases.

• Visualization of the resulting scenarios in terms of fire and explosion.

• Assess the overall damage potential of the identified hazardous events and the impact zones

form the accidental scenarios.

• Furnish the recommendations on the minimization of the worst accident possibilities

• Preparation of Disaster Management Plan.

7.2 Quantity of Hazardous Chemicals

Details of quantity of each hazardous chemical (including solvents) to be stored, Material of

Construction of major hazardous chemical storage tanks, dyke details, threshold storage quantity



as per schedules of the Manufacture, Storage & Import of Hazardous Chemicals Rules of major

hazardous chemicals.

TABLE 7.1 STORAGE DETAILS OF RAW MATERIALS

Major Raw Material for Proposed Products

Sr. No. Raw Material Storage

Quantity, CUM/MT

MOC No. of Vessel /

DRUMS

1 n-butanol 20 SS 304 1

2 Di Ethelene Glycol 25 SS 1

3 Castor Oil 25 SS 1

4 Lauryl Alcohol 25 SS 1

5 Tridecyl Alcohol 25 SS 1

6 Ethylene Oxide

This will come by Pipeline

from our GDI VS plant

SS Pipeline -

Major Raw Material for Existing Products

Sr. No. Raw Material Storage

Quantity, in KL

MOC No. of Vessel /

DRUMS

1 Butyl Acetate 25 MS 2 2 Sulphuric Acid 10 MS 1 3 Acetone 20 MS 1 4 Tri ethyl amine 20 MS 1 5 MDC 25 MS 2 6 Methanol 20 MS 3 7 Ethyl Acetate 10 MS 1 8 HCL 20 HDPE 1 9 Formaldehyde 20 SS 1

10 Di Methyl Formamide 20 MS 1



7.3 List of Hazardous Chemicals along with their Toxicity Level as per MSIHC rules

The Toxicity level of hazardous chemicals as per Manufacture, storage and import of Hazardous Chemical (Amendment) Rules, 2000 (MSIHC)

TABLE 7.2 DETAILS OF HAZARDOUS CHARACTERISTICS OF PRODUCT – PROPOSED PRODUCTS

Sr. No

Full Name of the Products

State solid, liquid or gas

Main properties (refer MSDS, Sch-9 of MSIHC Rules)

B.P. °C

F.P. °C

LEL UEL %

TLV mg/m3

LD50 mg/Kg

LC50 mg/l

Specific Gravity

(water =1)

Vapor density (air=1)

Odour threshold

ppm Flammability

1 POLYETHYLENE

GLYCOL or

Liquid - 176 - LD50 - 2000 mg/kg 1.128 - - 1

2 HYDROGENATED

CASTOR OIL or Solid >300 >310 - - LD50 – 10g/kg 0.93 - - -

3 CASTOR OIL

ETHOXYLATES or Liquid >100 257 - - LD50 - >6400 mg/kg 1.05 - - -

4 NONYL PHENOL

ETHOXYLATES or Liquid 271 150

1.0 % & 9.0%

- LD50 - >2000 mg/kg 0.9 - - -

5 OCTYL PHENOL

ETHOXYLATES or Liquid >200 - - - LD50 – 1800 mg/kg 1.06 >1 - -

6 CARD PHENOL

ETHOXYLATES or Liquid 293 >113 - - - - - - -

7 STYRUNATED

PHENOL ETHOXYLATES or

Liquid >250 100 - - - - - - -

8 LAURYL ALCOHOL ETHOXYLATES or

Liquid - 160 - - - 0.95 - -

9 TRIDECYL ALCOHOL

ETHOXYLATES or Liquid >253 180 - - LD50 – 10000 mg/kg - - - 1

11 CESTOSTYRYL

ALCOHOL ETHOXYLATES or

Solid - 110 - - - - - - -

12 TALLOW ALCOHOL ETHOXYLATES or

Liquid 230 123 - - LD50 – 5000 mg/kg - - - -

13 STEARYL AMINE ETHOXYLATES or

Liquid >572 >392 - - - 1.02 - - 0



Sr. No

Full Name of the Products

State solid, liquid or gas

Main properties (refer MSDS, Sch-9 of MSIHC Rules)

B.P. °C

F.P. °C

LEL UEL %

TLV mg/m3

LD50 mg/Kg

LC50 mg/l

Specific Gravity

(water =1)

Vapor density (air=1)

Odour threshold

ppm Flammability

14 COCO AMINE

ETHOXYLATES or Liquid >100 >100 - - LD50 – 1.0 mg/kg - - - -

15 OLEYL AMINE

ETHOXYLATES or Liquid 348 120 - - - 0.84 - - 0

16 POLY SORBATE

ETHOXYLATES or Liquid >100 >149 - - LD50 – 38.9 g/kg 1.1 - - 1

17 STEARIC ACID

ETHOXYLATES or Solid 350 196.11 - - LD50 – 4640 mg/kg 0.94 9.8 20 1

18 METFORMIN

HYDROCHLORIDE Solid - - - - LD50 – 1 g/kg - - - -

TABLE 7.3 DETAILS OF HAZARDOUS CHARACTERISTICS OF RAW MATERIALS – PROPOSED PRODUCTS

S. No. Raw Materials

Physical & chemical composition

B. P F. P LEL UEL

TLV ppm or

mg/Nm3

LD50, mg/Kg LC50

mg/l


V.D. at

(air = 1)

Odour Threshold

ppm or mg/m3

No. of container

& size Chemical Formula

State 0 C 0 C % 200 C 200

C

2 3 4 5 6 7 8 9 10 11 12

1. Ethoxylates

Di Ethelene Glycol

VP-0.01 mm of Hg (@ 20°C) C4H10O3 Liquid 245 138

2%-12.3%

-- LD50 – 2565

mg/kg 1.12 3.66 -- 25 MT

Hydrogenated Castor Oil

VP-NA -- Liquid >100 -- -- --

LD50 – 15000 g/kg

1 -- -- 25 MT

Castor Oil

VP-NA -- Liquid 313 230 -- -- -- 0.962 -- -- 25 MT

Nonyl Phenol

VP-NA -- Liquid -- 279 -- --

LD50 – 1410 mg/kg

1.055 1 -- 77.3 MT

Octyl Phenol

VP-NA (C8H17)C6H4OH Solid 175 -- -- --

LD50 – 4600 mg/kg

-- -- -- 74 MT

Card Phenol -- Liquid -- -- -- -- -- -- -- -- 84 MT



VP-NA

Styrunated Phenol

VP-NA C30H30O Liquid 250 182 -- -- -- 1.02 -- -- 72 MT

Lauryl Alcohol

VP-0.1 hPa at 20 °C C12H26O Solid 260 121

0.6%-4%

-- LD50 – 2.0

mg/kg -- -- -- 25 MT

Tridecyl Alcohol

VP-20.9KPa at 200 °C C13H28O Liquid 254 130 -- --

LD50 – 4.75 mg/kg

0.846 6.9 -- 25 MT

Cetostyryl Alcohol

VP-NA -- Solid -- -- -- --

LD50 – 3200 mg/kg

0.82 9.5 -- 53 MT

Tallow Amine

VP-NA -- Liquid >200 >100 -- --

LD50 – 1950 mg/kg

0.812 >1 -- 69 MT

Stearyl Amine

VP-NA C18H39N Solid 346.8 148 -- --

LD50 – 2395 mg/kg

0.791-0.861

-- -- 88 MT

Coco Amine

VP-NA -- Liquid 180 150 -- --

LD50 – 2000 mg/kg

0.805 -- -- 112 MT

Oleyl Amine

VP-NA C18H37N Liquid 300 154 -- --

LD50 – 1689 mg/kg

0.810 -- -- 38 MT

Sorbitian Mono Laurate

VP-NA

C18H34O6 Liquid -- -- -- -- LD50 - 33600

mg/kg -- -- -- 66 MT

Sorbitian Mono Stearate

VP-NA C24H46O6 Solid -- -- -- --

LD50 – 31000 mg/kg

1 -- -- 66 MT

Sorbitian Mono Oleate

VP-NA C24H44O6 Liquid >100 148.89 -- -- -- 1 -- -- 66 MT

Sorbitian Tri Oleate

VP-NA C60H108O8 Liquid -- -- -- -- -- 0.95 -- -- 66 MT

Stearic Acid

VP-NA C18H36O2 Solid 350 196.11 -- --

LD50 – 4640 mg/kg

0.9408 9.8 20 ppm 116 MT

CAUSTIC POTASH FLAKES KOH solid 1384 - -- LD50-273

mg/kg 2.044 -- -- 7 MT

2. Metformin

N-BUTANOL

VP-6.7 mbar @ 20 °C CH3(CH2)2CH2OH Liquid 117.7 28.9

1.4%, 11.2%

-- 790 mg/kg 0.81 2.55 1.2 ppm 20 MT

DMA.HCL

VP-NA C2-H7-N.ClH Solid -- -- -- -- 1070 mg/kg -- -- -- 58 MT



DCDA VP-NA

C2H4N4 Solid -- -- -- 10

mg/m3 -- 1.40 -- -- 59 MT

Toxic Chemicals: Chemicals having the following values of acute toxicity and which owing to their physical and chemical properties are capable of producing

major accident hazards

TABLE 7.4 TOXICITY INDEX AS PER MSIHC RULE 2000 S.No. Toxicity Oral toxicity

LD50(mg/kg) Dermal toxicity

LD50(mg/kg) Inhalation

toxicity LC50(mg/l)

1. Extremely toxic >5 <40 <0.5 2. Highly toxic >5-50 >40-200 <0.5-2.0 3. Toxic >50-200 >200-1000 >2-10



(i) Very highly flammable liquids: chemicals which have a flash point lower than or equal

to 23oC and initial boiling point higher than 35oC.

(ii) Highly flammable liquids: chemicals which have a flash point lower than or equal to

60oC but higher than 23oC.

(iii) Flammable liquids: chemicals which have a flash point higher than 60oC but lower

than 90oC.

Minimization the Manual Handling of Hazardous Chemicals & Hazardous Waste:

• Chemical Charging of liquids to be done by pumps

• Solids to be done by mechanical arrangement such as monorail hoist with load cell.

• Hazardous waste handling would be done through mechanical aid like forklift.

• Automatic filling of product.

• Providing proper training.

• Providing information, training, instruction and supervision.

• Avoiding spillage or overflow, including overflow protection on equipment and storage.

• PPE like hand gloves, nose mask, apron etc. i.e. suitable PPE will be used.

Kindly find attached the Risk Assessment Report vide Annexure 3.

7.4 MSDS of all the Products & Raw Materials

Details of hazardous characteristics and toxicity of raw materials and products to be handled and

the control measures proposed to ensure safety and avoid the human health impacts. This shall

include the details of Antidotes also. Detailed material handling plan to avoid / minimize human

exposure.

Details of Hazardous characteristics of products & raw materials are given in Table 7.3. Raw

materials & products are plenty in number, so it is not possible to attach MSDS of all products &

raw material with this EIA report. Hard copy of all products & raw materials is available with unit.

Kindly find attached the MSDS for Raw Material Annexure 7

Kindly find attached the MSDS for Finished Products Annexure 8

7.5 Hazard Identification & Preventive Measures

7.5.1 Process hazards and controls

The details of process hazards and controls are given in Table-7.5.

TABLE 7.5 PROCESS HAZARDS AND CONTROLS

Name of hazardous

process and

operation

Type of hazard possible

toxic gas release / fire /

explosion / run away

reaction / rupture, etc.

Control measured provided

Reactor Vessels

• Release of Heat

• Fire, Dust release and

Explosion

a) Raw Materials quantity must be controlled

either volumetrically or gravimetrically.

b) High Temperature indicator valve must be

provided



c) The burner system will be provided with

automatic handling system and safety

control system.

d) Use skilled worker

e) Proper selection of MOC

7.5.2 General Hazards & Controls

The details of general hazards and controls are given in Table-7.6.

TABLE 7.6 GENERAL HAZARDS & CONTROLS

Type of Emergency

Possible Causes Preventive/ control Measures

Fire Fire due to

• Due to leakage

• Fire Protection system having extinguisher.

• Good housekeeping

• Hot work permit system

Explosion

• Burn

• Electrical short circuit

• Open flame

• A gas shut-off/isolation valve is provided

• Gas detector/automatic shut off mechanism

provided

• Hot work permit for hot working in the plant

• Foam fire extinguisher will be provided

• Good ventilated area for Flammable material

storage

Material

handling • Fire and health Hazards

• Trained employee

• Required PPE and Fire Protective equipment

Provided

• Good engineering practices

• Separate storage area as per compactibility of

material

Training to the worker will be provided under experienced person before hiring for process hazard,

general hazard, and chemical hazard. Periodical review of person through safety committee

meeting, safety audit and mock drill.

7.6 Fire & Safety

This includes details of the separate isolated storage area for flammable chemicals, details of flame

proof electrical fittings, DCP extinguishers and other safety measures proposed. Specific safety

details / provisions for various hazardous chemicals and detailed fire control plan for flammable

substances and processes showing hydrant pipeline network, provision of DG Sets, fire pumps,

jockey pump, toxic gas detectors etc.

(i) Firefighting system will be made available.

(ii) Automatic leak detection and fire alarm system will be provided for tanks.

(iii) Fire hydrant network will consist of

• Main electric operated fire Pump

• Diesel operated fire pump



• Jockey pump

• Foam trolley

TABLE 7.7 PROPOSED FIRE EXTINGUISHERS AS PER IS 15683:

Sr.No. Type of Fire Extinguishers & Location Capacity Qty 1 ABC type 6 kg 10

2 Foam type 50 Lit 5

3 CO2 type 4.5 kg 5

4 DCP type 5 kg 5

7.6.1 Safety Measures to be provided

Following are the Safety measures Proposed for EO storage Area

• Reactors will be fitted with a Rupture Disc and Pressure Relief Valve wherever required. • All vessels will be designed as per the requirement of different processes. • All vessels will be pressure tested as per the design rating before use. • Processes will be automated using Program Logic Controllers and recipe batch. • A sophisticated IMCC will be used for power distribution to plant equipment. • Emergency action plan will be in place to handle emergency situations. • Specially trained personnel will be available in all shifts to handle emergencies. • SOP’s will be available for all operations. • Safety will be incorporated in the processes. • Leak detectors will be placed at strategic locations in tank farm as well as in plant as

required. • Appropriate utilities will be planned for safe operations. • Emergency exits will be available for all structures. • All Raw Material and Finished Goods tanks will have a dyke for containment. • Tanks will be segregated as per statutory and plant requirement. • Chemicals will be handled using all required PPE’s as per their characteristics and

requirements. • Proper areas will be demarcated for intermediate storages in plant. • Breather Valve with flame arrestor on tank • Level Indicator with high- and high-level alarm with trip system • Double valve on Tank outlet • Sensor within the dyke area with audio alarm • Double Earthing to tank with separate earth pit • Earthing to pipeline, Flange to flange earthing Jumper on pipeline • Dyke Height should be more than 1.45 Mtr • Flameproof electrical fittings for process and storage tank farm area • Pumps should be outside the Dyke Area • Water Sprinklers system around the tanks, Water cum Foam Monitor • Auto Fire Protection system • Earthing and Relay system for Tanker unloading • Display to Safe Unloading Procedure Health Hazard, Cautionary Notice • Regular Monitoring of Pipelines and Tank – Once in six months • Auto control system with alarm for Distillation Kettle with safety interlock on Temperature

and Flow • Sump and Dyke drain valve • Flange Guard on Flange joint • No Smoking zones • Safety Shower with Eye washer station



7.6.2 Provisions for Human Health Hazards & Workplace

Provisions made to avoid human health hazards:

• Workplace monitoring is being done regularly.

• Periodical medical examination of worker being done regularly.

• Provision of Personal protective equipment.

• Consulting Doctor (Certified Industrial Hygienist) to site regularly.

7.7 Leak Detection & Repair (LDAR)

Source Leak from Control Measures

Pumps Occur at seal

Leak from pumps can also be reduced by using dual

seals with or without barrier fluid.

Valves Occur at stem area of valve caused by failure of valve

packing

Leak from open ended line, sampling connection,

compressors are usually fixed by modifying

equipment. emission from pumps and valves can be

reduced by use of leak less valves and seal less pumps

Connectors Caused from gasket failure, torque bolts on flange

Sampling Connection

Occur at outlet of sampling valve

Compressor Occur from seal

Pressure Relief Device

Occur if valve is not sealed, operating too close to set point, seal is damaged, leaks from rupture disks can

occur around the disk gasket if not installed properly

Open Ended Lines

Occur at point of the line open to atmosphere and controlled by using caps, plug, flanges,

Occur due to incorrect implantation of block and bleed procedure

7.7.1 Following Methodology of LDAR Program will be followed:

• GDI shall Integrate an awareness of the benefits of LDAR into the company’s operating & maintenance program.

• GDI shall prepare LDAR program that includes an overall, facility-wide leak rate goal, procedures for identifying leaking equipment within process units, procedures for repairing and keeping track of leaking equipment.

• GDI shall give training that provides LDAR personnel with technical understanding to implement the written LDAR program and educate LDAR team members on their individual responsibilities shall be provided to EHS team.

• GDI shall get done Internal and third-party audits of a facility LDAR program to ensure the LDAR program is correctly conducted and that issues are identified and corrected.

• GDI shall use internal leak definition for valves and pumps in light liquid or gas vapor service and monitor against that uniform definition. Leak detectors will be placed at strategic locations in tank farm as well as in plant as required.

• GDI shall Include a plan for more frequent component monitoring, especially of those that contribute most to equipment leak emissions. For the same. Portable leak detectors will be used by personnel working in the specified jobs.

• GDI shall ensure that can justify the equipment on the Delay of Repair list and have a plan in place to fix these components.



• GDI shall utilize electronic monitoring and storage of LDAR data. Hence leak detectors will be placed at strategic locations in tank farm as well as plant, over and above Portable leak detectors will be used by personnel working in the specified jobs.

• GDI shall include procedures to ensure the QA/QC review of all data generated by LDAR monitoring technicians is completed on a daily basis or at the conclusion of each monitoring occurrence.

• GDI shall consistently calibrate LDAR monitoring equipment. • GDI shall follow all recordkeeping and reporting requirements and have organized records

readily available to demonstrate that the LDAR program is a component of the organization’s routine operation and management

7.7.2 Following shall be done to Prevent Leaks:

• Leak Free Pumps for transfer of solvents to be used. • MSW Gaskets in solvent pipelines to be used to prevent leakage from flanges. • Minimum number of flanges, joints and valves in pipelines. • To eliminate chances of leakages from glands of pumps, mechanical seal will be provided at

all solvent pumps. • Condenser with Cooling water & Chilled brine and scrubber post Distillation to recover the

solvent. • Sensor within the dyke area with audio alarm.

7.7.3 Following shall be done in case of Spills:

1. Spill of Solid Materials

• In case of spill of the solid Inform QA and EHS department for getting their advice refer the MSDS of the material for safety related guidance.

• Try to stop the source of leak immediately if possible. • Appropriate PPE to be used to prevent the breathing in /inhaling the solid, as per the

guidance given in the MSDS. • Collect the spilled solids material separately and do not mix with earlier collected solids. • Only after dry swiping and collection of spilled material clean the area by using the water

and contaminated water collected in a tank to transfer for treatment and disposal. • Analyse the collected material for reuse / disposal. Disposal to be done • If, the material found not reusable to discarded it and send with ETP Sludge.

2. Spillage/Leakage of Acids & Alkalis from Drum or Tank.

• In case of spill of the solid Inform QA and EHS department for getting their advice refer the MSDS of the material for safety related guidance.

• Use PPE such as Acid resistant suit, SCBA, Hand gloves, Safety shoes etc. . • In case the spillage or leakage observed, first pour the Sand on material and collect the

contaminated sand and send the socked material in the separate drums/bags after collection to ETP.

• In case the spillage or leakage is large, do not use water, as the reaction is highly exothermic. • Wash the area with water. • Inform the effluent treatment plant about additional load.

3. Spillage / Leakage of Flammable Liquids.

• In case of spill of the solid Inform QA and EHS department for getting their advice refer the MSDS of the material for safety related guidance regarding the nature of hazard during the spillage / leakage of solvent i.e. Pyridine is highly flammable & there is possibility of fire.

• In case the small spillage or leakage observed, first pour the sand on material and collect the contaminated sand and send to ETP.

• If the spillage is of inflammable liquid, switch off all the power supply in the area to prevent Electric Spark.



• Do not use any vacuum cleaner or floor cleaning machine to collect the spilled material as the vapors of the spilled material may explode due to electrical circuits and rotating parts of these machine.

• Send the collected spilled material for Incineration.

7.8 Information on Solvent Storage Area and associated reactors

1. List of sensors provided in the system

1.1. Fire detection & alarm system shall be installed in solvent storage area and associated

reactor area.

1.2. Temperature transmitter for reaction vessel will be provided.

1.3. Level Transmitters shall be provided in the storage tank.

2. Rupture discs and PRV’s.

2.1. Reactor shall be provided with RD’s and PRV’s .

2.2. PLC system will be used for monitoring, controlling and maintaining all parameters at

defined values.

2.3. Sufficient freeboard shall be provided for solvent storage tanks.

7.9 On Site Emergency Plan

7.9.1 Purpose:

To develop awareness of potential emergency situation.

Contain & Control the emergency.

Rescue and treatment of causality.

Notify casualty to their relatives and render necessary help to them.

Rehabilitate area affected.

Provide information to media and government agency.

Preserve records for equipment for subsequent investigation.

7.9.2 PESO Permission:

This is attached vide Annexure 22.

7.10 Worst Case Scenario

Risk assessment including prediction of the worst-case scenario and maximum credible accident

scenarios should not be carried out. There is no storage of liquid chemical at site. Based on the same,

proposed safeguard measures including On-Site / Off-Site Emergency Plan should be provided.

7.10.1 Scope:

This plan is applicable for Gujarat Dyestuff Industries (Pharma Unit). at Nandesari.

Kindly find attached Emergency management Plan vide Annexure 4

7.11 Checklist - Do’s & Don’ts for Handling of Chemicals, Working in Chemical Laboratory, Working on Machines, Maintaining good Housekeeping, Working on Height, Work in Confined Space, Fire Prevention, In Case of Fire



MFG, UTILITY, STAFF FOR RELATED SAFETY MEASURES

FIRE PREVENTION

Sr. Do's Sr.

Don’t's

1 Follow "No Smoking" Sign. 1 Do not leave any flammable material at the work area.

2 Deposit oily rags and waste combustible material in the identified containers and dispose them suitably.

2 Do not allow wild grass growth around storage of flammable chemicals and gas cylinders

3 Keep minimum inventory of flammable and combustible substances.

3 Do not obstruct accessibility to the firefighting equipment

4 Take permission before breaking or removal of fire barrier and ensure subsequent relocation of fire barrier

4 Do not destroy the inspection tag provided with the fire equipment

5 Check periodically the operability of firefighting systems

5 Do not misuse the firefighting equipment other than intended purpose

6 Provide earthing or bonding to prevent accumulation of static charges to tanks where flammable chemicals are stored or handled

6 Do not store the flammable material in the open container

IN CASE OF FIRE

Sr. Do's Sr. Dont's

1

On seeing fire please inform control room and warn people nearby by shouting,” Fire”, "Fire" 1 Do not runaway in case of fire but act on it.

2 Tell exact location and place of the occurrence clearly 2 Do not become the hindrance to the fire crew

3 Try to extinguish the fire if you are aware about the firefighting operation. 3 Do not spread rumor in case of fire.

4 Guide the fire crew to the correct location. 4 Do not leave place unattended if possible, till the fire crew arrive.

5 Keep the emergency escape route clear of materials 5 Do not stay there if you feel unsafe.

6 Try to remove the combustible material from the vicinity of the fire if possible. 6

Do not touch any electrical equipment under the influence of fire.

7

Cover the electrical equipment that is situated near or below the area of fire before applying water. 7

Do not use the extinguisher if not in a good condition.



HANDLING OF GAS CYLINDERS

Sr Do's SR Don’t's

1

Use soft pad or ramp for unloading the gas cylinder and avoid knocking / impact while handling and transport. 1 Do not roll the cylinder while handling.

2 Use cylinder cap while handling and transporting the cylinder. 2 Do not use cylinder without pressure gauge.

3

Segregate inert, toxic, non-flammable & flammable cylinders during storage. 3 Do not expose the cylinders to heat and light.

4 Store 'empty' and 'full' cylinder separately, duly marked. 4 Do not change the color of the cylinder.

5 Label the area of storage. 5 Do not strike a cylinder valve with hammer for reopening.

6 Use a cradle while shifting gas cylinder. 6

Do not transfer the gas from one cylinder to another.

7

Keep cylinders always in upright position and round bottomed cylinders horizontally. 7

Do not store the cylinder near elevator or gangways.

8 Display "No Smoking" sign at gas cylinder storage area. 8 Do not store cylinder in locker or cupboard.

9

Store flammable gas cylinders away from the gas cylinder which support combustion. 9

Do not apply force for connecting the cylinder that does not fit.

10 Use trolley for transporting and handling of gas cylinders. 10

Do not transport cylinder on bicycle or two-wheeler.

11

Cylinders should be kept separately chained at the place of storage and 'addition station' 11

Do not start using a gas cylinder without proper identification.

12

Valve caps should be fixed on the valve neck when not connected to 'addition banks'. 12 Do not use cylinder as rollers.

13 Do not store gas cylinders under direct sunlight.

14 Do not use a lifting magnet for loading or unloading of gas cylinder.

HANDLING OF CHEMICALS Sr Do's

Sr Don’t's

1

Use proper lifting tool and tackle having adequate capacity.

1

Do not use the equipment for the purpose other than its design intention.

2

Only authorized persons should operate material handling equipment.

2

Do not allow personnel to move underneath lifted load.



3

Each tool, tackle or equipment should have identification number and safe working load marked on it.

3

Do not load the equipment above its safe working load.

4

Assess weight of the material, distance to be carried, and hazards etc. before lifting the load.

4

Do not use makeshift arrangement for lifting the material.

5

Store the lifting tools and tackles at its designated place.

5

Do not use defective tool and tackles.

6

Inspect and test all the lifting tools and tackles regularly.

6

Do not use altered or repaired lifting equipment without inspection and test.

7

Wear safety boots with metal toe while handling of materials.

7

Do not drag chains, ropes or cables etc. on the floor.

8

When placing a sling of a load, ensure all Sharp corners are covered with pad or soft material.

8

Keep the tools & tackles free from adverse effect of atmosphere by applying suitable protective coating.

9

Bend knees, keep back straight, keep the load close to the body and lift the load.

9

Do not hold the load with tip of the fingers, grasp the load firmly with palm.

HOUSE KEEPING Sr Do's

Sr Don’t's

1

Assign places for everything and maintain things at its assigned place.

1

Do not leave combustible materials in the work area.

2 Clean the area after completion of work. 2 Do not smoke in the area of work

3 Use aisle space free for personnel and material movement. 3 Do not allow dustbin to overflow

4 Ensure adequate illumination and ventilation for the job. 4 Do not generate extra waste

5

Drop paper, plastic, glass, metal and bio- medical waste in a separate bin kept for this purpose. 5

Do not disturb the safety equipment from assigned location

6

Know the emergency equipment where Emergency equipment like first aid box, SCBA, firefighting equipment, stretchers are kept. 6

Do not block emergency switches and on / Off switches of the equipment by storing of materials in front of work

7 Arrest all type of spills such as water, oil, gas, steam etc. and clean up the area immediately 7

Do not leave cleaning agent like acetone, Isopropyl alcohol, kerosene etc. at the work area after completion of work

8 Material and equipment needed for future usage are to be tagged and arranged in order. 8

Do not block fire exit point by storing materials or by means



9 Assign a periodicity for the documents to be weeded out and follow it scrupulously 9 Do not leave a spillage unattended

10

Ensure exits are indicated/ Painted for use during emergency.

WORK IN CONFINED SPACE Sr Do's

Sr Don’t's

1

Isolate, drain, wash, dry and purge for a sufficient time to ensure safe atmosphere inside. 1

Do not work without supervision in a confined space.

2 Obtain a safety work permit and follow the instruction provided in the permit. 2 Do not work if you are medically unfit.

3 Purge the confined space and ensure continuous ventilation on the area 3 Do not smoke in the confined space.

4 Ensure continuous communication with the person standing outside 4

Do not enter in to confined space, if the oxygen concentration is less than 19%

5 Use non-sparking tools in explosive environment 5

Do not enter in to confined space without checking for presence of toxic, explosive or asphyxiating gases.

6 Keep all manholes open and the lowest drain point open. 6

Do not rely on closed valves for isolation. The isolation should be supplemented by suitable banking.

7

The man entering into the tank should be supplied with a safety belt and lifeline, the free end of which is held by a person standing outside. 7

Do not use equipment of voltage more than24V inside a confined space.

8 Get clearance from the competent person before entering in the confined space.

8

Do not take large quantity of cleaning chemicals into the tank than the required quantity of chemicals for a day work.

9 Number of persons entering and leaving the confined space should be counted and tallied. 9

Do not encourage more than one type of work at a time in the confined space.

10

Put up a danger board as "men working in the tank"

10

Do not carry matches / lighter into the confined area.

11

Use SCBA, if the oxygen concentration is less than 19%.

WORK AT HEIGHT Sr Do's Sr Don’t's

1

When any person has to work at height from where he is likely to fall, provision shall be made by fencing or otherwise, to ensure the safety of the person so working. 1

Don't work at unguarded height if you are physically / mentally unfit.

2 Safe means of access and platform should be ensured for working at height. 2

Do not allow two jobs, one above the other simultaneously.

3 keep tools in a safe bag / toolkit 3

Don’t tie safety belt at lower elevation than the working level of person.

4 Use safety belt and safety helmet while working in unguarded area at height. 4

Do not keep loose material on the platform.



5

When person is working at height, warn people below through display of caution board and cordon off the area if necessary. 5

Do not drop material from higher elevation.

6 Entry to areas above the false ceiling should be controlled through work permits. 6

Do not use pipeline and equipment as means of approach to work spot.

7 Ropes, slings, or bucket used for carrying materials to or from an elevated place should be inspected before use. 7

Do not work at height without taking valid safety permit.

8 Work at height should be performed in good day light, preferably when strong winds not existing. 8

Do not use damaged rope for lifting material to higher elevations.

9 Ensure that the persons employed to work at height are medically fit. 9

Do not work without protection near overhead line or uninstalled bus bars.

10

Obtain height pass/safety work permit for working on unguarded height. 10

Do not work without protection near high pressure / steam line.

11

Do not use portable ladder as platform or platform support.

12 Do not use cable tray as portable ladder.

MATERIAL HANDLING Sr Do's

Sr Don’t's

1 Use proper lifting tool and tackle having adequate capacity. 1

Do not use the equipment for the purpose other than its design intention.

2 Only authorized persons should operate material handling equipment 2

Do not allow personnel to move underneath lifted load.

3

Each tool, tackle or equipment should have identification number and safe working load marked on it. 3

Do not load the equipment above its safe working load.

4

Assess weight of the material, distance to be carried, and hazard etc. before lifting the load. 4

Do not use makeshift arrangement for lifting the material.

5 Store the lifting tools and tackles at its designated place. 5 Do not use defective tool and tackles.

6 Wear safety boots with metal toe while handling material. 6

Do not use altered or repaired lifting equipment without inspection and test.

7 Inspect and test all lifting tools and tackles regularly as per factories Act. 7

Do not drag chains, ropes, or cables etc. on the floor.

8

When placing a sling on a load, ensure all sharp corners are covered with pad or soft material. 8

Keep the tools and tackles free from adverse effect of atmosphere by applying suitable protective coating.

9 Whenever possible, mechanical material handling shall be adopted. 9

Do not allow male and female adult to lift a load manually higher than 55 kgs and 30 kgs. Respectively.

10

While lifting a load physically, keep the load as possible to the body with feet properly placed for body balance.

10

Do not hold the load with tip of the fingers; grasp the load firmly with palm.



11

Bend knees, keep back straight, keep the load close to the body and lift the load.

11 Never carry a glass sheet with bare hands.

7.12 Social Impact Assessment R&R Action Plans

The proposed project will have a positive impact on the social and economic conditions of the

people of the region in terms of direct and indirect employment, skill diversification, infrastructure

development, business development etc.

The proposed unit is located in GIDC notified area so there will be no direct impact on Rehabilitation

and Resettlement.

7.13 Mitigation Measures for Seepage & Soil Contamination

• The flooring of manufacturing premises has been made impervious by RCC construction, hence

there is no possibility of soil contamination.

• Any spillage shall be collected in drum/carboy and can be used in next batch.

• Further, following mitigation measures will be taken.

7.14 Chemical Spillage Control Measures

During Storage

• Chemicals are stored within easy reach of everyone and no higher than eye level.

• Do not store chemical bags directly on the floor where they might be knocked over and broken.

• Minimize the number of chemicals and size of containers stored.

• That lighting and ventilation is adequate is the storage area.

• Do not store chemicals in unsuitable bags.

• Regularly inspect chemicals in storage to ensure there are no spillage or torn bags. Some items

to note:

• Keep the bags clean and free of spills and stains.

• Do not store incompatible chemicals together (e.g. acids with bases). Chemicals must be stored

by hazard category and not alphabetically (except within a hazard group).

Handling & Use

• If possible, keep highly toxic or corrosive gases in a fume hood or other ventilated enclosure.

• Ensure you have access and know the location of a suitable chemical spill kit before you start

working with chemicals.

Contaminated soil (accidental outside premises):

• Waste should be disposed of properly to avoid soil pollution. It suggests that acidic and alkaline

waste be neutralized before they are disposed of so they will not contaminate the soil. Waste

that is biodegradable should be broken down in a controlled environment before being disposed

of because it is a much faster, resource-saving method.

• Contaminated soil should be neutralized, and it will be packed in HDPE bag and finally it is

disposed.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 8 Project Benefits


CHAPTER – 8: PROJECT BENEFITS

8.1 Introduction


Nandesari, Dist: Vadodara-391340., Gujarat. India is an existing unit into manufacturing of Bulk

Drugs such as Cifixime Trihydrate, Cefuroxime Axetil, Cefpodoxime Proxetil, Ampicilin, Amoxicillin

Trydrydate, Clobetasole Propionate, Betamethasone Dipropionate, Betamethasone Valerate,

Betamethasone Sodium Phosphate, Dexamethasone Sodium Phosphate, Beclomethasone

Dipropionate, Mometasone Furoate, Methylcobalamine, Ofloxacin, Levofloxacin, Quinon Sulphate,



in Schedule 5(f) are planned to be manufactured and hence the application for EC is being done

The project benefits will be significant in terms of benefit to the local socio-economic status as well

as economic conditions of state & country. The proposed project site is well linked with national

highway and is situated in the Industrial estate of GIDC Nandesari having all required

infrastructures. Therefore, infrastructural development because of proposed project will not be

major but improvement in public infrastructure due to CSR is anticipated.

8.2 Economical Benefits

The development of project plays a key role in the economic growth of any country. The important

factors affecting the operating economics of power generating technologies are capital cost, debt

equity pattern, and interest during construction, discount rate and fuel choice.

8.3 Socio Economic Development of the Region

Skilled and Semi-skilled employment potential in terms of indirect employment of the proposed

project will be non-marginal and will usually remain widespread across a long region. The

proposed project will cause generation of income and employment opportunities the ancillaries

and service units which will came in the vicinity of the plant, specifically, in transport and

manufacturing sectors. The project has generated & expected to generate indirect employment in

other sectors. Overall assessment of the employment and income effects indicates that the project

has strong positive direct as well as indirect impact on employment and income generation of the

area.

8.4 Un-Skilled Manpower

The project has employment generation potential by way of recruiting local people directly for

different activities of the project, specifically at the construction phase. It is expected that

Gujarat Dyestuff Industries (Pharma Unit) Chapter 8 Project Benefits


substantial portion of the investment in this project will trickle down to the local people in the form

of employment and income.

8.5 Socio Economic Development Aspects

1 There will be more employment generated due to the proposed project both during the

construction phase and operation phase. On the basis of technical knowledge acquired by the

local village youths, they will be providing with suitable employment Opportunity in the

company.

2 The labour force required during construction and operation phase shall be sourced from

nearby area.

3 Supporting infrastructure requirement in nearby village schools.

4 Skill & Livelihood development program.

5 Health related program.

6 Sports development program.

TABLE 8.1 BUDGETARY PROVISIONS FOR SOCIAL UPLIFTMENT/YEAR

Sr. No.

Activity Yearly Estimated budgetary provision (Rs)

1 Supporting Infrastructure requirement in nearby village schools.

During the last three FY: 2016-19 the unit had spent

around Rs. 17.55 Lac in 2016-17 and Rs. 14.85 Lac in

2017-18. on the above-mentioned CSR programs.

Proposed

2 Skill & Livelihood development programme 3 Health Related Programme 4 Sports development Programme

CER – Proposed Activity Yearly

Estimated budgetary provision (Rs) We shall allocate Rs. 6.00 Lac (i.e. 2.0 % on the CER based on the additional investment

of 3 Crores

Year 2020 Year 2021 Year 2022 Year 2023

Year 2024

Skill Development Program 10000 10000 10000 10000 10000 Avenue plantation, plantation

in community areas, 10000 10000 10000 10000 10000

Health Related Programme 10000 10000 10000 10000 10000 Education Related Programme 10000 10000 10000 10000 10000

Awareness to local villagers to waste management

4000 4000 4000 4000 4000

Infrastructure development (Toilet Blocks and Sanitation)

0 0 30000 0 30000

rainwater harvesting, soil moisture conservation

programs 0 0 200000 0 0

Infrastructure creation for drinking water supply at

community (RO Plant) 0 0 0 120000 0

Year Total 44000 44000 274000 164000 74000

Gujarat Dyestuff Industries (Pharma Unit) Chapter 9 Environmental Cost Benefit Analysis


CHAPTER – 9 ENVIRONMENTAL COST BENEFIT ANALYSIS

Total existing production is 20MT / Month & Production planned for expansion is 1500.5 MT /

Annum. Total production will be 1520.5 MT/Month. Hence the Environmental cost benefit analysis

has been calculated based on the total Proposed Organic Product and Proposed In-Organic Products

as well as existing In-Organic products.

The management will spend approx. Rs. 112 lacs. as recurring cost per annum on the pollution

control measure, green belt development and other environment management. Recurring cost is

estimated as below:

TABLE 9.1 BUDGET ALLOCATION FOR ENVIRONMENT MANAGEMENT

Sr. No.




1 Air pollution

control 6.5 2.5 9 5 1.5 6.5

2 Water pollution

control 33 100 133 4.5 90.5 95

3 Hazardous



5 Occupational

health 1 0.5 1.5 0.5 0.5 1

6 Greenbelt


Gujarat Dyestuff Industries (Pharma Unit). has spent Approximately Rs. 50 Lac for Existing

Products & proposes Rs. 109 Lac for proposed Product as capital expenditure on environmental

management. With a total of 159 lac.



Considering 112 Lac. / Annum spent on overall environmental management for manufacturing of

1520.5 MT / Month of Product, the loading on the product cost with respect to Environmental

Management works out to be INR 7366/- Per MT of product Manufactured.

Total 40 KLD Industrial w/w will be generated. Generated Industrial w/w will be sent to in house

ETP for treatment. Treated water from the ETP will be passed through ETP RO Plant & 20KLD

recovered Product to be used for Cooling Tower Makeup. 20 KLD Reject to be evaporated in MEE.

MEE Condensate of 19.6 KLD to be recovered for reuse.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 9 Environmental Cost Benefit Analysis


TABLE 9.2 ECONOMICAL AND TECHNICAL VIABILITY OF THE EFFLUENT TREATMENT

SYSTEM

Sr. No. Description Utilities/day Rate Rs. /unit Amount Rs/day

1 Electrical 1000 KWH 7.5 7500

2 Solid waste disposal - NA NA

3 Manpower 5 600 3000

4 Chemical

Consumption 2 kg 5 10

Total 10510

Note: Monthly expenditure for effluent treatment will be around Rs. 3.15 Lac. The total production

capacity will be approximately 1520.5 MT/Month. Expenditure for ETP to the tune of 207.3 Rupees

/ MT of product Manufactured.

MEE Plant to be installed for evaporation of the RO Reject. Operation cost / day of MEE will be

approximately 30,000/- per day. Expenditure to the tune of 592/MT of product Manufactured.

Being Bulk Drug & ethoxylates, the profit margins in the products are fair enough to incorporate

the expenditure for environment management to the tune of 799.3 Rupees / MT of product

Manufactured.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 10 Environmental Management Plan


CHAPTER – 10 ENVIRONMENTAL MANAGEMENT PLAN

10.1 Background

The Environment Management Plan (EMP) is required to ensure sustainable development in the

area surrounding the proposed project. Hence, it needs to be an all en-compassive plan for which

the industry, Government, Regulating agencies; like Pollution Control Board working in the region

and the local residents of the area need to extend their co-operation and contribution.


Nandesari, Dist.: Vadodara-391340., Gujarat. India is an existing unit into manufacturing of Bulk

Drugs such as Cifixime Trihydrate, Cefuroxime Axetil, Cefpodoxime Proxetil, Ampicilin, Amoxicillin

Trydrydate, Clobetasole Propionate, Betamethasone Dipropionate, Betamethasone Valerate,

Betamethasone Sodium Phosphate, Dexamethasone Sodium Phosphate, Beclomethasone

Dipropionate, Mometasone Furoate, Methylcobalamine, Ofloxacin, Levofloxacin, Quinon Sulphate,



in Schedule 5(f) are planned to be manufactured and hence the application for EC is being done

10.2 Objectives of Environmental Management Plan

The aim of environment management plan is to conserve natural resources and water, to prevent

pollution of environment, to ensure effectiveness of control measures and monitoring programme,

to ensure safety, welfare and good health of worker, to minimize generation of waste.

It has been evaluated that the project will have no major impacts on the surrounding areas.

Mitigation measures at the source level and an overall Management Plan at the site level are elicited

so as to preserve the surrounding environment.

Gujarat Dyestuff Industries (Pharma Unit). Carries out & shall carry out the regular monitoring in

future as well as ensure that pollution is limited below prescribed limits and shall take corrective

action by providing new pollution control equipment if required. In case the monitored results of

environment pollution are found to exceed the prescribed limits, remedial actions are taken

through the concerned plant authorities. The actual operation and maintenance of pollution control

equipment of each department is under respective department heads.

10.3 Components of EMP

The following mitigation measures are recommended in order to synchronize the economic

development of the project area with the environmental protection of the region. The construction

phase impacts are mostly short term, restricted to the plot area and not envisaged on the larger

scale. In the operational phase, the environmental impacts are due to continuous operation of the



project; hence, the emphasis in the Environment Management Plan (EMP) is to minimize such

impacts. The emphasis on the EMP development is on the following:

• Mitigation measures for each of the activities causing the environmental impact

• Monitoring plans for checking activities and environmental parameters and monitoring

responsibilities

• Role responsibilities and resource allocation for monitoring

• Implementation schedule and reporting procedures

All the necessary controls w.r.t. management of Liquid / Hazardous / Gaseous pollutants will be

exercised.

For all liquid effluents, full-fledged effluent treatment plant consisting of primary, secondary and

tertiary treatment will be installed to ensure adequate treatment prior to discharge.

DG Set to be housed in Acoustic enclosure. Adequate stack height provided. To handle hazardous

waste as per Hazardous Waste (Management, Handling and Trans-boundary Movement) Third

Amendment Rules, 2016 of Environment Protection Act, 1986. Hazardous waste will be disposed

off at the common Incinerator / secured land fill facility available in the nearby vicinity.

• Workplace monitoring will be carried out regularly through monitoring systems and

periodic checking.

• Ambient air quality will be monitored regularly.

• Good green belt will be maintained inside and outside the premises by planting trees,

developing lawns.

• To work in R&D for continuous improvement in process to reduce Pollution Load & moving

towards adopting cleaner production technology.

10.4 Organogram of Environmental Management Cell

Apart from having an environmental management plan, it is also necessary to have a permanent

organizational set up charged with the task of ensuring effective implementation. In this effect,

Gujarat Dyestuff Industries (Pharma Unit) has assigned responsibilities to coordinate the activities

concerned with management and implementation of environment control measures.

An environment management cell is created to manage all environmental issues. The Head Plant

Operations is responsible for environmental issues at plant. The responsibilities of the various

members of the environment management cell are given in Table 10.1 as follows.



TABLE 10.1 ENVIRONMENT MANAGEMENT CELL

10.4.1 Reporting system on non-compliances/violations of Environmental Laws

Company has developed reporting systems of non-compliances/ violations of environmental

norms to the Board of Directors as follow.

• Identify non-compliance/ violation of environmental norms, which are mentioned

in Consent to operate and letter of Environmental clearance.:

• EHS executive identifies non-compliance/ violation from failure to comply & timely

response to concerned authority for this noncompliance/violation & also inform

about this to technical head of the industry.

• General manager takes it into action, discusses this in Management meeting and

gives necessary guideline to the concerned executives to comply to this non-

compliance/ violation of environmental norms.

• EHS executive takes measures against these non-compliances/violations of

Environmental laws & takes care not to have such violations in the future.

10.5 Environment Management During Construction Phase

The Environment Management plan is meant for mitigation/ management of the adverse impacts

and the strengthening positive impacts during proposed project.

During Construction Phase sanitation facilities will be required. Temporary sanitation facilities will

be provided. Environment Management Plan is tabulated in Table: -10.2

TABLE: 10.2 CONTROL MEASURES FOR CONSTRUCTION PHASE

Activity Environmental

Impacts Mitigation Remarks

Site Clearing, • Air Water Spraying Will be carried out

by GDI PPE’s will be used



Activity Environmental

Impacts Mitigation Remarks

Construction & Erection of Plant

Activity

• Land • Water • Noise

Proper Maintenance of Vehicle will be done

Construction hazardous materials such as lubricating oils, compressed

gases (for welding), paints, varnishes, etc. shall be stored as per the

prescribed / accepted safety norms To mitigate noise generation,

construction labor would be provided with noise protection devises like earmuffs and occupational safety ware, as per requirement. Noise

generating equipment & vehicular movement shall be stopped during

night hours Construction wastes shall be

disposed off by adopting environmentally compatible

methodology

Toilets • Water

Ensure proper sewage collection, conveyance & disposal.

Will be carried out by GDI

domestic wastewater to be disposed through septic tank & soak pit.

Direct / Indirect Employment

• Socio-economic issue

Continue policy of local employment

The hazardous materials used during the construction may include petrol, diesel, welding gas and

paints. These materials would be stored and handled according to the guidelines. Some of the

precautions of storage and handling of the hazardous materials and waste includes the following:

• Dyke enclosures would be provided where-ever necessary for storage of hazardous

materials.

• Diesel and other fuels would be stored in separate dyke enclosures.

• Separate storage for waste paints and thinners, contaminated rags and brushes to facilitate

recycling and reuse.

• Vehicle maintenance area to be selected properly, to prevent contamination of soil and

ground water by accidental spillage of oil, and other wastes

10.6 Environment Management during Operation Phase.

10.6.1 Air Environment

The main sources of air pollution will be flue gas emission from existing & Proposed Thermic Fluid

Heaters & DG Set. DG Set to be housed in Acoustic Enclosure to attenuate noise as pollution control

measure. SPM, SO2 & NO2 are the main pollutants generated from the flue gas stack.

Moreover, proper stack height will control emission from flue gas stack.



TABLE 10.3 DETAILS OF AIR EMISSION

FLUE GAS EMISSION FOR EXISTING AND PROPOSED PRODUCTS

Sr. no.

Source of emission

With Capacity

Stack Height

(meter)

Type of Fuel

Quantity of Fuel

MT/Day

Type of emissions

i.e. Air Pollutants


Measures (APCM)


1 Thermic Fluid




1 Thermic Fluid



2 DG Set


Stack Height

Process Emissions:



10.6.1.1 Fugitive emission

The emissions are normally defined as emissions to the atmosphere resulting from leaking piping

sources and equipment such as valves, flanges, pump seals, connections, and compressor seals open

end lines and pressure relief valves. The emissions are not visually observed but can be measured

in relatively low concentration at each area of source.

Fugitive emissions are expected to be generated during construction and operation stages of the

proposed project. During construction stage, main source of fugitive emission is dust which is

expected mainly due to movement of vehicles carrying construction material and vehicles used for

construction. During operation stage, leakage through valves, pumps, emission from open drum

containing chemicals, open feeding; storage tanks, etc. are the major sources of fugitive emissions.

Excess use of solvent may also result into fugitive emission from the process vessels.

Mitigation measure

General control measures like routine & regular inspection to identify leakage, preventive

maintenance and operational maintenance etc. will be implemented by the unit.

• Preventive maintenance of flange connections and glands of pumps.

• Management will also ensure proper usage of the Personnel Protective Equipment by the

workers.



• Regular Workplace Monitoring, Ambient Air, Stack Air Monitoring to be done

10.6.1.2 VOC Monitoring Plan

Regular Workplace monitoring as per the Factories Act will be conducted and the details

maintained in Form 37.

• Regular Monitoring at workplace to be done for VOC.

• Handy LEL meters will be available at site for various chemicals and this will be

monitored on regular basis in house.

10.6.2 Water Environment

This is existing unit manufacturing Bulk Drugs, Additional products Ethoxylates & Metformin are

planned to be manufactured. Existing Products - 38 KLD, Proposed Products 249 KLD, 20 KLD

Treated Effluent from ETP to be recycled after RO Plant & 19.6 KLD Condensate from MEE Plant.

hence 247.4 KLD fresh water will be used, which will be met through GIDC Nandesari Industrial

Estate water supply (attached as Annexure 11). Out of which, process (17 KLD), cooling tower

(250 KLD), boiler (0 KLD), Scrubber (1 KLD), Washing (4 KLD) & Domestic (10 KLD). Total water

requirement will be 287 KLD in which 20 KLD Treated Effluent from ETP to be recycled after RO

Plant & 19.6 KLD Condensate from MEE Plant. Hence freshwater requirement will be 247.4 KLD.



recovered Product to be used for Cooling Tower Makeup. 20 KLD Reject to be evaporated in MEE &

19.6 KLD condensate to be recovered. 8 KLD domestic wastewater will be generated, which will be

disposed through Septic tank & Soak Pit.

10.6.2.1 Economical and Technical Viability of the Effluent Treatment System

Sr. No. Description Utilities/day Rate Rs. /unit Amount Rs/day

1 Electrical 1000 KWH 7.5 7500

2 Solid waste disposal - NA NA

3 Manpower 5 600 3000

4 Chemical

Consumption 2 kg 5 10

Total 10510

Note: Monthly expenditure for effluent treatment will be around Rs. 3.15 Lac. The total production

capacity will be approximately 1520.5 MT/Month. Expenditure for ETP to the tune of 207.3 Rupees

/ MT of product Manufactured.

MEE Plant to be installed for evaporation of the RO Reject. Operation cost / day of MEE will be

approximately 30,000/- per day. Expenditure to the tune of 592/MT of product Manufactured.

Being Bulk Drug & ethoxylates, the profit margins in the products are fair enough to incorporate

the expenditure for environment management to the tune of 799.3 Rupees / MT of product

Manufactured.



10.6.3 Hazardous Waste Management

Main sources of hazardous waste generation will be ETP Sludge, Residue, discarded container/

bags/ Drums & Used oil/Spent Oil, Spent Solvent for recovery.

10.6.3.1 Storage of Hazardous Waste:

Hazardous waste shall not be stored for a period more than 90 days. And shall maintain records

and make them available for inspection. Store at a designated Onsite-secured area with impervious

floor that affords protection from sun & rain fall, spreading of leachate, mixing of wastes etc.

10.6.3.2 Transportation of Hazardous Waste:

Properly packed & labeled waste transport through dedicated vehicle to a captive facility/

authorized TSDF/CHWI facility.

10.6.3.3 Disposal of Hazardous Waste:


NECL Nandesari.




refiners.

• Distillation Liquid Residue - CHWIF incinerator facility of M/s. Nandesari Environment

Control Ltd. (NECL) / Coprocessing.

Hazardous waste will be stored in proper storage room and handed over to GPCB/CPCB approved

vendor for final disposal. The collection, Storage and disposal of hazardous waste will be done as

per Hazardous waste (Management and Handling) Rules 2016.

Record of hazardous waste generation and disposal shall be maintained on printed logbook. All

necessary precautions shall be taken during handling, loading and unloading of hazardous wastes.

Hazardous waste generation quantity, physical characteristics and mode of disposal are given in

Table-10.4.

TABLE 10.4 DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL

Sr. no

.

Type/Name of

Hazardous waste


n (Name of


etc.)

Category and

Schedule as per

HW Rules.

Quantity (MT/Annum)

Management of HW

Existing Products

Proposed Products

Total After

Expansion

1 ETP Sludge

ETP Sch-I/ 35.3

12 MT/Annu

m

0 12 MT/Annu

m


treatment, transportation, and disposal



at Nandesari Environment Control Ltd


Bags & Containers

Production plant

Sch-I/ 33.1

108 MT/ Annum

0 108 MT/ Annum



factory premises.


and TFH

Sch-I/ 5.1

0.6 KL/Annu

m

0 0.6 KL/Annu

m





residues From

Solvent Recovery

Sch-I/ 20.3

36 MT/Annu

m

30 MT/Annu

m

66 MT/Annu

m

CHWIF incinerator


Environment Control Ltd.

(NECL) / Coprocessing

5 Spent Solvent for recovery

Process Sch-I/ 20.2

252 MT/Annu

m

4116 MT/Annu

m

4368 MT/Annu

m

Captive In-house

Recovery.

6 MEE Salt

From Evaporation of RO

Reject

Sch-I/ 37.3

0 MT/Annu

m

144 MT/Annu

m

144 MT/Annu

m


(NECL) TSDF

10.6.3.4 Methodology of Decontamination of drums/containers

Guideline provided by the Gujarat Pollution Control Board will be followed to decontaminate

drums/Containers/ Barrels.

• For disposal Containers/drums will be totally emptied.

• Containers/drums will be washed properly, checked for pH. This ensures

containers/drums are cleaned before disposal.

• Removal of label & content of product or raw material will be done.

• Then it will be labelled as clean & deposited in the area which demarked for disposal

• Then the drums/containers will be inspected by the authorized agency approved by the

GPCB. Then they check quality of cleaned drums/containers.

• Then the containers are disposed off to actual raw material supplier or to Other Approved

recyclers.

10.6.4 Noise Environment

The sound pressure level generated by a noise source decreases with increasing distance from the

source due to wave divergence. The propagation and attenuation of noise pressure wave is



dependent on many parameters amongst which, the medium of travel and the ambient conditions

are the most significant parameters. In order to minimize adverse impact on the noise environment,

due attention shall be given for implementing noise control measures. Comprehensive measures

shall be taken at design stage for noise from proposed unit. The measures are as under:

• The noise level at the plant boundary shall be restricted to 75 dB (A) during daytime and

70 dB(A) during nighttime.

• Noise level shall be specified for various rotating equipment as per Occupational Safety and

Health Association (OSHA) standards.

• Equipment lay-out shall be done considering segregation of high noise generating sources.

Erection of suitable enclosure, if required, to minimize the impact of high noise generating

sources.

• There may be some addition to the ambient noise level, due to the increased transportation

activities. This creates a slight adverse impact on the sound environment.

• Regular oiling, lubrication and maintenance of the equipment shall be carried out to

minimize noise generation.

The sources of noise generation will be transportation activities, DG Set, cooling tower, plant

machinery etc. The unit will take following measures to control noise pollution.

• Acoustic laggings, enclosures and silencers shall be provided wherever necessary for high

noise generating equipment.

• Soundproof glass paneling shall be provided for all operating stations / control rooms as

well as for shift rooms at critical places.

• Strict implementation/ compliance of all statutory norms w.r.t. noise generation,

occupational exposure shall be done.

• Use of personal protective devices such as earmuffs and earplugs shall be strictly enforced.

• Acoustic barriers / shelter shall be developed in noisy workplaces.

• The company shall develop a green belt around the periphery of the premises, which shall

act as a barrier to the propagation of noise

• Noise generating sources in the plant areas shall be monitored regularly. Monitoring of

ambient noise levels should also be carried out regularly both inside the premises as well

as outside the greenbelt.

• Periodic monitoring for Audiometry in periodic health checkup.

However, due to the attenuation of noise level within the factory and due to the fact that the project

site is situated in a well-developed industrial estate and not in the immediate vicinity of human

settlement, significant impact is not expected in the nearest present human settlement.

10.6.5 Odour Control Plan

Reactors will be closed, charging of chemicals will be mechanized. LDAR will be followed, however

if any spillage or leakage of such chemicals are taken place then following material handling

procedure will be followed to reduce the odor and release of chemical vapor in atmosphere.

Storage & Handling of Hazardous Chemicals:



• Storage of hazardous chemicals will be kept as per requirements.

• All drum / barrels with hazardous chemicals have labels indicating the contents and warning of the hazard.

• Necessary information on safe handling and first aid measures will be available on the label.

• Workers dealing with hazardous chemicals will be trained on health risk and safe handling.

• Direct Exposures to hazardous chemicals will be minimized.

• Hazardous chemicals will be transferred through closed piping system.

• Separate storage section for storage of hazardous and non – hazardous raw materials will be provided.

Process Vessel and other Equipment related:

• Checking of process vessels and equipment will be carried out regularly.

• Records related to equipment maintenance and its planning schedules will be maintained.

Safety related:

• Adequate types of personal protective equipment will be provided and also safety

training will be provided.

• Emergency shower and eye wash station will be available at the worksite.

• Arrangement for 24 hr. medical facilities by contact with nearest health care center

/ hospital.

• Pre – employment medical check – up and annual medical checkup will be carried

out and its records will be maintained.

• Monitoring of occupational hazards like noise, ventilation, chemical exposures etc.

will be carried out regularly and its records will be maintained.

10.7 Occupational Health & Safety

Company will ensure to conduct all business operations in compliance with applicable laws,

regulations and standards related to occupational Health, Safety and Environment.

• An emergency plan has been prepared, rehearsed regularly through periodic mock drills &

fire drills, to deal with firefighting.

• Fire protection system will be provided.

• Portable Fire Extinguishers of CO2 & DCP type are provided.

• Fire hydrant system to be provided.

• Fire Alarm & smoke detectors system is installed.

• Employees are provided with Personal Protective Equipment like earplugs, nose mask,

safety shoes, helmet, earmuffs, body aprons etc. wherever required.

• Training on industrial safety and health shall be conducted periodically for workers and

staff for reinforcement of safety SOP’s.

• Physical and chemical properties of raw materials and products as MSDS are provided in

plant area.

• Good housekeeping will be ensured within the factory premises



• Pre-employment medical check-up at the time of employment & periodic health check-up

of regular employee will be carried out.

10.8 Green Belt Development

Implementation of greenbelt program is prime importance for any development. The total area of

the plot is 3691.10 m2 (0.36911 Ha) . Out of which, 1476 m2 will be greenbelt area of 1m width. It

is around 40% of plot area. Moreover, to fulfill the total greenbelt development area, the company

has planned to develop green belt in surrounding area of Industrial park and nearby villages.

Trees will also help in attenuate the ambient noise level, prevent soil erosion. This will also act as

a barrier between inside & outside environment. This will help in preventing outside pollution to

come in the factory premises.

Purposes:

The stated objectives of our green belt policy are to:

(1) Protect and develop natural or semi natural environments.

(2) Improve air quality within our industry and surrounding areas.

Advantages:

• Green belts are compensatory plantation to restore the ecological balance.

• Green belts insure a minimum distance between the industrial sources of pollution and the

receptors/ residential areas, prone to the health hazards of industrial pollution.

• Green belts can absorb the air and water pollution caused by the industry.

• For Example, Noise can be decreased by up to 10 decibels by green belts.

• Trees not only assimilate carbon dioxide and release oxygen but also play an important role

in trapping some obnoxious gases and particulate matters in the air change green belt

functions both as filter and sink for contaminants.

• Green belts can improve the local microclimate. These occur mainly through their influence

on wind, temperature and humidity.

• Green belts provide picnic spot and recreation grounds.

• In the dryer part of the area, the trees reduce the effect of dryness and desiccate hot wind

and increase the availability of soil moisture

10.8.1 Plants / Trees Should be Selected for Green Belt Area

For the development of greenbelt, plants having simple big leaves are preferred with compound or

pinnate leaves. Native trees are preferable. The plants are suitable for green belt development

based on gaseous exchange capacity of foliage which is ascertained by various characteristics and

hence the following aspects are important while selecting the plant species:

• The species should be fast growing and having thick canopy cover

• It should be perennial and evergreen and should have large area index

• It should be indigenous and suitable to local climatic conditions

• It should be efficient in absorbing pollutants without significant effects on plant growth.

• It should be fruit yielding trees, if possible, especially in wasteland areas.



TABLE 10.5 SPECIES PROPOSED TO BE GROWN FOR GREENBELT DEVELOPMENT

Common name Family Scientific name Neem Meliaceae Azadirachtaindica Gulmohar Fabaceae Delonixregia Champo Apocynaceae Plameria Badam Combretaceae Terminalia Piplo Moraceae Ficus religiosa Papaya Caricaceae Carica papaya Gando baval Mimosaceae Prosopis DC Piludi Salvadoraceae Salvadora persica Bougainvel Nyetaginaceae Bougainvillea spectabilis Daturo Solanaceae Datura metel L Arduso Simaroubaceae Ailanthus excesia Lal Karen Apocynaceae Nerium indicum Jasud Malvaceae Hibiscus rosasinensis Chiku Sapotaceae Achrassapota

Dust Absorbers For Air Pollution Attenuation

Azadirachtaindica (Neem) Terminaliatomentosa (Asan) Meliaazaderach (Mahaneem) Acacia auriculiformis (Babul)

Terminaliaarjuna (Arjun) Polyalthialongifolia (Debdari) Cassia fistula (Amaltas) Ficusbenghalensis (Banyan)

Bauhinia variegate (Kachnar) Mangiferaindica (Aam) Neriumodorata (Kaner) Ficuselastica

TABLE 10.6 BUDGET FOR GREENBELT DEVELOPMENT

Year Budget amount in INR Nos. of trees 1st year 10,000 100 2nd year 10,000 100 3rd year 10,000 100 4th year 10,000 100 5th year 10,000 100

The measures like properly designed greenbelt areas, irrigation facilities, Sapling storage &

maintenance area and storage for greenbelt development resources/tools etc. shall be provided for

the management of greenbelt area in the plant premises. The necessary maintenance shall be done

throughout the extent of operation phase.

10.9 Rainwater Harvesting

Rainwater Harvesting is a way to capture rainwater when it rains, store that water above ground

or charge underground water table with it. Rain water harvesting refers to the collection and

storage of rain water and also other activities aimed at harvesting surface and ground water,

prevention of losses through evaporation and seepage and all other hydrological studies and

engineering interventions, aimed at conservation and efficient utilization of the limited water

endowment of physiographic unit such as a watershed.

Advantages of rainwater harvesting.



• Effective rise in ground water levels

• Prevent evaporation and runoff of rainwater

• Solution to water scarcity problems

• It’s economical and energy saving

• Easy operation and maintenance.

However, as the unit is located in GIDC Nandesari, it would not be permitted to dig well for

rainwater harvesting. However, the unit would consult the local authority and look out the possible

contribution to undertake rainwater recharging / harvesting in the nearby area.

10.10 Cleaner Production

The following objective would be adopted for effective implementation of Cleaner Production (CP):

• The concept of Four -R’s- reduce, reuse, Recover and recycle would be implemented as

much as possible.

• Industrial effluent will be generated from the proposed project activities, which will be

treated in in-house ETP. Total 40 KLD Industrial w/w will be generated. Generated

Industrial w/w will be sent to in house ETP for treatment. Treated water from the ETP will

be passed through ETP RO Plant & 20KLD recovered Product to be used for Cooling Tower

Makeup. 20 KLD Reject to be evaporated in MEE, 19.6KLD MEE Condensate to be recovered.

8 KLD domestic wastewater will be generated, which will be disposed through Septic tank

& Soak Pit.

• The feeding of solid raw material would be done by hopper so that there is least spillage

due to fugitive emission.

• Liquid raw materials would be fed through metering pumps to reduce manual contact.

• Reuse of solvent after recovery.

• Optimum operating conditions would be maintained to get maximum yield.

• Housekeeping will be regularly maintained. Dedicated staff for the purpose will be

employed.

10.11 Flora & Fauna

The proposed project is situated within the GIDC Nandesari & looking to the Environmental

Management Plan, there shall not be any significant impact on the flora and fauna of surrounding

area

10.12 Capital Cost for Environmental Management

Environment Management The management will spend approx. Rs. 112 lacs. as recurring cost per

annum on the pollution control measure, green belt development and other environment

management. Recurring cost is estimated as below:

TABLE 10.7 BUDGET ALLOCATION FOR ENVIRONMENT MANAGEMENT

Sr. No.






1 Air pollution

control 6.5 2.5 9 5 1.5 6.5

2 Water pollution

control 33 100 133 4.5 90.5 95

3 Hazardous



5 Occupational

health 1 0.5 1.5 0.5 0.5 1

6 Greenbelt


10.13 Prevention of Storm Water Contamination.

1 The ETP tanks shall have sufficient freeboard to prevent overflowing of effluent &

contamination of storm water.

2 pH Sensor at storm water outlet has been provided to constantly monitor the pH of outgoing

storm water from the premises.

3 Gate arrangement at the storm water outlet provided to stop outflow of contaminated storm

water outside the premises.

4 Pump at the storm water outlet will be provided to convey the contaminated storm water to

the ETP for treatment.

5 No raw material & sludge to be kept in open during rainy days.

6 Sludge drying beds will be covered with rain protection shed to prevent rainwater directly

falling on the sludge.

7 Storm water drains will be kept dry and the outlet gates closed during except during monsoon

season.

8 Close monitoring will be done to prevent any contamination of the storm water.

9 ETP area, Sludge handling area, Material Handling area, Plant & premises housekeeping will be

maintained all year round.

10 CCTV observation will be practiced within the premises.

11 Storm water treatment plant has been made by the unit for the contingency measures.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 11 Summary & Conclusion


CHAPTER – 11 SUMMARY & CONCLUSION

11.1 Introduction











11.2 Location of the Project

The Project is located at coordinates

• 22°24'6.96"N, 73° 5'50.04"E

• 22°24'4.98"N, 73° 5'54.30"E

• 22°24'0.30"N, 73° 5'49.80"E

• 22°24'4.32"N, 73° 5'46.50"E

Distance from the project site

• The site is well connected with NH8. The site comes under tehsil Ta. Vadodara.

• Road: Site is 4km aerial distance away from NH-8. Via NH-8 site is well connected to

Bharuch, Surat, Mumbai, Vadodara, Ahmedabad.

• RAIL: The nearest railway station is Vadodara Junction, Nandesari Railway Station 1.8Km

towards N, Vadodara Railway Station – 13 Km towards SE. Western Railway Connects from

Mumbai-Surat-Bharuch-Vadodara-Godhra-Ratlam-Kota-Delhi.

• AIRPORT: The nearest airport is Vadodara which is in approximately 15 Km (Aerial

Distance). Regular flights from Delhi and Mumbai are available.

11.3 Product & Capacity

The proposed products to be manufactured are listed in Table below with their respective

capacities.

List of Products along with their Production Capacity

The Products fall under Project activity5(f), Category A as per NGT Order dated 23.08.2019 in the matter of O.A.No.1038/2018-Reg GIDC Nandesari & PCCI Estate, Di. Vadodara

Sr. no.


CI no. Quantity

MT/Month* End-use of the

products



Existing (Products)

Proposed (Products)



drug formulation.



5 AMOXICILLIN TRYDRYDATE

or 61336-70-7 20 0

6 CLOBETASOLE PROPIONATE

or 25122-46-7 0.5 0


formulation.

7 BETAMETHASONE DIPROPIONATE or

5593-20-4 0.5 0

8 BETAMETHASONE

VALERATE or 2152-44-5 0.5 0

9 BETAMETHASONE SODIUM

PHOSPHATE or 151-73-5 0.5 0

10 DEXAMETHASONE SODIUM

PHOSPHATE or 2392-39-4 0.5 0

11 BECLOMETHASONE

DIPROPIONTE 4419-39-0 0.5 0


5 0.5 0





of Antibiotic drug

formulation.


4 20 0


1000



soap, detergent,

textile

B HYDROGENATED CASTOR

OIL or 8001-78-3 0

C CASTOR OIL ETHOXYLATES

or 61791-12-6 0

D NONYL PHENOL


E OCTYL PHENOL


F CARD PHENOL


G STYRUNATED PHENOL



68439-50-9 0

I TRIDECYL ALCOHOL




J CESTOSTYRYL ALCOHOL



37335-03-8 0


26635-92-7 0

M COCO AMINE ETHOXYLATES

or 61791-14-8 0

N OLEYL AMINE


O POLY SORBATE


P STEARIC ACID


22 METFORMIN

HYDROCHLORIDE 1115-70-4 0 500


of diabetic drug


11.4 Cost of the Project

Break-up of Project Cost

Particulars Amount in INR (crore) Existing


Proposed

Amount in INR (crore) Total

Land 1.0 - 1.0 Factory Building 0.50 0.50 1.0

Plant & Machineries 1.0 2.50 3.50 Other Assets 1.50 1.00 2.50

Total 4.0 4.0 8.0

11.5 Baseline Environmental Analysis

The Environmental Impact Assessment Report, Environmental Management Plan have been

prepared based on the studies carried out during the Winter Season (October 2018 to December

2018). Baseline data is available with us for our other industry manufacturing organic chemicals

located at an aerial distance of 200m for 1 complete season for 10Km Radius between October 2018

to December 2018. The parameters done are PM2.5, PM10, SO2, NO2, NH3, HCL, Cl2, CO, HC, VOC, etc.

The environmental attributes (ambient air, water, soil, noise) selected for the study are those,

which are likely to be affected by the project. The study area is defined as an area within 10 KM

radius around the site located at GIDC Nandesari.

11.5.1 Ambient Air Quality

The air quality status in the impact zone is assessed through a network of ambient air quality

monitoring locations. The tropical climatic conditions mainly control the transport and dispersion

of air pollutant emissions during various seasons. Ambient air quality of the study area has been



assessed through a network of 10 ambient air quality stations designed keeping in view the

meteorological conditions of the study region.

The maximum concentration of SPM (121.6 g/m3), PM10 (77.35 g/m3), PM2.5 (47.49 g/m3),



The minimum concentration of SPM (112.3 g/m3), PM10 (71.94 g/m3), PM2.5 (40.65 g/m3),



The PM10 and PM2.5 concentrations at all the AAQM locations were primarily caused by local

phenomena including industrial & vehicular activities and natural dust getting air borne due to

manmade activities and blowing wind. PM10 and PM2.5 concentrations were observed below

stipulated standards of CPCB for Industrial, Residential, Rural and Other Area at all air quality

monitoring locations during the monitoring period.

Conclusions:

Results of all parameters are found within limit.

11.5.2 Water Quality

pH of ground water samples varied from 6.96 to 7.99. Turbidity was found 0.17 to 31.6 NTU, Total

Dissolved Solids varied in the range of 156 to 1902 mg/L. DO and COD are found in range of 6.53

to 6.90 mg/L, and 1.98 to 9.92 mg/L respectively. BOD3 was found to be <1.0. Total Hardness (as

CaCO3) varied from 34.13 to 908.04 mg/L. Total Alkalinity varied from 50 to 1000 mg/L. Chlorides

and Sulfates are found in the range of 32.53 to 673.23 mg/L and 2.51 to 199.78 mg/L respectively.

Surface water quality

pH of surface water samples was found 7.45 to 8.24. Turbidity was found 0.8 to 33 NTU, Total

Dissolved Solids was found 144 to 1426 mg/L. DO and COD are found 6.72 to 6.90 and 8.45 to 12.08

mg/L respectively. BOD3 was found to be <1.0. Total Hardness (as CaCO3) are found 148.98 to

911.63 mg/L. Total Alkalinity varied from 160 to 350 mg/L. Chlorides and Sulfates are found 33.47

to 179.16 mg/L and 23.76 to 254.34 mg/L respectively.

11.5.3 Noise level

A variety of sources produce noise, potentially hazardous to hearing depending upon the intensity

and duration of exposure. These include transportation systems, construction equipment,

industrial activities and many common appliances.

The noise levels during daytime varied from 46.4-61.7 dB (A) Leq to 49.8-63.9 dB (A) Leq in the

study area. The noise level in the study area is within the permissible Limits.

The nighttime noise level in the study area is in the range of 40.3-58.7 dB (A) Leq to 41.4-60.2 dB

(A) Leq. The nighttime noise was also within stipulated standards of CPCB.



11.5.4 Soil Quality

Soil samples were collected from 10 locations during December 03-09, 2018 within the study area

to assess its physico-chemical characteristics. The analysis results of soil samples are given in Table

3.12.

11.6 Anticipated Environmental Impacts & Mitigation Measures

11.6.1 Water Requirement, Wastewater Generation and Treatment:

This is existing unit manufacturing Inorganic products; Additional inorganic products are planned

to be manufactured. Existing Products - 38 KLD, Proposed Products 249 KLD, 20 KLD Treated

Effluent from ETP to be recycled after RO Plant, & 19.6 KLD condensate from MEE Plant hence

247.4 KLD fresh water will be used, which will be met through GIDC Nandesari Industrial Estate

water supply (attached as Annexure 11). Out of which, process (17 KLD), cooling tower (250 KLD),

boiler (0 KLD), Scrubber (1 KLD), Washing (4 KLD) & Domestic (10 KLD). Total water requirement

will be 287 KLD in which 20 KLD Treated Effluent from ETP to be recycled after RO Plant & 19.6KLD

from MEE Condensate. Hence freshwater requirement will be 247.4 KLD.



recovered Product to be used for Cooling Tower Makeup. 20 KLD Reject to be evaporated in MEE &

19.6 KLD MEE Condensate to be recovered for reuse. 8 KLD domestic wastewater will be generated,

which will be disposed through Septic tank & Soak Pit.

11.6.2 Air Pollution source and Mitigation measure

The main sources of air pollution will be flue gas emission. Flue gas emission will be from Existing

& Proposed Thermic Fluid Heaters & DG Set. FO/DLO is being used as fuel & Natural Gas will be the

fuel proposed for the proposed Thermic Fluid Heater. PM, SO2& NO2 are the main pollutants

generated from the flue gas stack.

Detail of flue gas emission & process gas emission along with stack height, type of fuel, expected

pollutants & air pollution control measures is given in below table.

FLUE GAS EMISSION FOR EXISTING AND PROPOSED PRODUCTS

Sr. no.

Source of emission

With Capacity

Stack Height

(meter)

Type of Fuel

Quantity of Fuel

MT/Day

Type of emissions

i.e. Air Pollutants


Measures (APCM)


1 Thermic Fluid


30 F.O / LDO 40 Lit./Hr. PM, SO2, NO2 Caustic Scrubber




1 Thermic Fluid


30 Natural Gas 555 Nm3/Hr. PM, SO2, NO2 Adequate Stack Height

2 DG Set


Stack Height

Process Emissions:



11.6.3 Hazardous Waste Generations and Disposal


NECL Nandesari.




refiners.

• Distillation Liquid Residue - CHWIF incinerator facility of M/s. Nandesari Environment

Control Ltd. (NECL) / Coprocessing).

The collection, Storage and disposal of hazardous waste will be done as per Hazardous waste

(Management and Handling) Rules 2016.

11.6.4 Noise Level and Mitigation Measure

The noise will generate due to activities of TFHs, cooling towers, compressors, Generator set and

other plant machineries. Regular oiling and lubrication and preventive maintenance will be carried

out to reduce noise generation at source to the permissible limit. However, at place where noise

levels can exceed the permissible limit, Earplugs and Earmuffs will be provided to those working in

such area.

11.6.5 Soil & Geology

The unit is located in notified industrial area & have occupied land area of 3691.10 m2 (0.36911

Ha). There is no negative impact envisaged on soil & Geology of the study area. The unit will take

full-proof measures to manage all types of hazardous wastes to mitigate impacts on soil and

geology.

11.6.6 Impacts on Socio Economy & Mitigation measures:

There is a potential for direct/indirect employment for the locals due to the proposed project. The

project is located in notified industrial area of Nandesari GIDC, so no rehabilitation or resettlement

is required.



11.7 Green Belt:

The total area of the green belt is 1476m2. It is around 40 % of plot area. Moreover, to fulfill the

total greenbelt development area, the company has planned to develop green belt in surrounding

area of Industrial area and nearby villages.

11.8 Environmental Monitoring Programme

A detailed monitoring schedule has been prepared to ensure effectiveness of the environmental

management plan.

11.9 Environmental Management Plan

ENVIRONMENT ISSUE/COMPONENT REMEDIAL MEASURES Hazardous waste generation & Disposal

Proper collection, Safe Handling, Storage within premises and disposal of waste at approved TSDF, CHWI, re-cyclers, re-processors.

Effluent generation and Treatment

Total 40 KLD Industrial w/w will be generated. Generated Industrial w/w will be sent to in house ETP for treatment. Treated water from the ETP will be passed through ETP RO Plant & 20KLD recovered Product to be used for Cooling Tower Makeup. 20 KLD Reject to be evaporated in MEE & 19.6 KLD MEE Condensate to be recovered.

Emission from stack Adequate pollution control system will be provided for control of gaseous emission.

➢ Adequate stack height for better dispersion of pollutants.

➢ Caustic Scrubber provided as APCM for existing TFH.

Noise Acoustic enclosure on Generator sets, engineering control at high noise level areas like compressors etc, wherever feasible, proper oiling, lubrication and maintenance of equipment, development of greenbelt around plant boundary and inside plant

Greenbelt Around 40% of the plant area will be developed as greenbelt.

Information and awareness about hazardous chemicals plant

Awareness training to workers on safe operating procedures and periodic reinforcement. Personal hygiene practice training shall be provided.

Preparedness to handle onsite & offsite emergency

Onsite Emergency Management Plan prepared

Monitoring of Environmental parameters

Regular monitoring of various environmental parameters will be carried out to check the effectiveness of the control system.

11.10 Additional Studies

EIA study conducted with reference to the following

• Hazard identification

• Assessment of risk on the basis of the necessary evaluations



• Preparation of an onsite Emergency Plan.

• Consequence analysis of failures and accidents resulting in fire, explosion,

hazardous releases etc.

11.11 Project Benefits

Project will assisted many local and some skilled persons from surrounding villages and give

stability for their growth. They are financially benefited for the same. With more increase in such

processing units more local people will get employment opportunities in future.

11.12 Conclusion

The study brings out the following points:

• Ambient air quality, ground water quality and noise levels shall remain within acceptable

limits after commencement of proposed project activities due to effective design and

implementation of environmental management plans.

• Risk to flora/fauna and soil is negligible due to effective management and handling of

hazardous wastes and wastewater.

• Socio-economic benefits due to creation of direct / indirect employment.

Thus, it can be concluded on a positive note that after the implementation of the mitigation

measures and Environmental Management Plan, the regular operations of M/s. Gujarat Dyestuff

Industries (Pharma Unit). will have negligible impact on environment and will benefit the local

people.

Gujarat Dyestuff Industries (Pharma Unit) Chapter 12 Disclosure of Consultants Engaged


CHAPTER 12: DISCLOSURE OF CONSULTANTS ENGAGED

12.1 Disclosure of Consultant

The EIA report has been prepared by ECO-CARE SOLUTIONS (ECS) Vadodara; providing specialty-

consulting services in Environment Management solutions. The company has a team of professional

engineers and scientists, with extensive accumulated experience in diversified fields such as

Environmental Engineering, Civil Engineering, Chemical Engineering, Analytical Chemistry,

Microbiology, Safety & Health. An extensive complement of specialized instrumentation and

computing facilities supports the engineering and scientific staff. This, along with the technical and

managerial experience of the Principals, ensures the firm’s clients of the highest quality of

professional service.

ECO-CARE SOLUTIONS is working in this field since the year 2005. ECS is in the field of

environmental consultancy for environment clearance from MoEF & SEAC, Consent to Establish

(NOC) and Consent to Operate (CCA) from GPCB, Effluent Treatment Plant Design, Sewage

Treatment Plants, ETP & STP trouble shooting solutions, Packaged plants etc.

ECS has installed testing laboratory, for monitoring and analysis in the areas of ambient air, water,

soil and hazardous waste. For establishing the confidence in the work done, the laboratory has

received reorganization as Schedule – II Auditor from GPCB for Water/ Waste water, Ambient Air,

Stack and Noise. ECS is 17025:2005 Accredited Laboratory.

The extended branch of ECS is in the field of Designing, supply and installation of air pollution

control equipment and pollution control chemicals.

J.H.Bhavnani B.E (Civil), ME Environmental Engineering (MSU)

Gaurang V. Parmar

B.E (Chemical), PG Diploma in Industrial Env. Management, Diploma in Industrial Safety.

Rinal Patel M.Sc. Environmental Science Uchit Padariya M.Sc. Environmental Science Hitesh Umletiya BE Environmental Engineering

Mayur Vaghela B.E., CSP, DIS, PGDIEM, MISNT, FIV, Competent Person,

Chartered Engineer, Industrial Safety Consultant. Deepak Chanchad Expert On Site Emergency Plan & Safety Audit

Note: Baseline data has been procured from Aqua-Air Environmental Engineers Pvt. Ltd. Surat, for

the Period October 2018 to December 2018. for an adjacent industry.

ECO-CARE SOLUTIONS has obtained Hon. High Court Stay Order. The details of the stay order has

been enclosed herewith vide Annexure 13.

Gujarat Dyestuff Industries (Pharma Unit) Annexures


Annexure 1 – ToR Letter



Annexure 2 – Plot Allotment Letter from GIDC



Annexure 3 – Risk Assessment Report



Annexure 4 – Emergency Management Plan



Annexure 5 – Undertaking



Annexure 6 – Safety Audit



Annexure 7 – MSDS Raw Materials



Annexure 8 – MSDS Finished Products



Annexure 9 – Layout Plan Factory Premises



Annexure 10 – Details of CETP Nandesari



Annexure 11 – Water Supply Letter from GIDC



Annexure 12 – Membership for Hazardous Waste



Annexure 13 – Hon. High Court Stay Order



Annexure 14 – MoEF CERTIFED COMPLIANCE REPORT



Annexure 15 – SoP Index



Annexure 16 – CETP NANDESARI Permission for Disposal of Treated

Effluent



Annexure 17 – Project Implementation Schedule



Annexure 18 – XGN Generated Reports



Annexure 19 – Adequacy of Existing EMS



Annexure 20 – COPY OF EXISTING EC



Annexure 21 –Baseline Data Certificate



Annexure 22 –Existing PESO License



Annexure 23 –PLI Copy



Annexure 24 –COPY OF CTE & CTO



Annexure 25 – Traffic Survey