m/s. nutraplus india ltd. (unit-ii) plot no. c-198

M/s. NUTRAPLUS INDIA LTD. (UNIT-II)

PLOT NO. C-198, SAYAKHA INDUSTRIAL ESTATE,

TAL: VAGRA, DIST. BHARUCH GUJARAT

ENVIRONMENTAL IMPACT & RISK ASSESMENT REPORT FORPROPOSED BULK DRUGS AND BULK DRUG INTERMEDIATES PLANTIN SAYAKHA GIDC

March, 2017 to May, 2017

NABL Accredited Testing Laboratory

ISO 9001:2008 Certified Company

Aqua-Air Environmental Engineers P. Ltd.

403, Centre Point, Nr. Kadiwala School, Ring

Road, Surat – 395002 (Guj.)

Prepared By:

ENVIRONMENTAL IMPACT &

RISK ASSESSMENT REPORT

CLIENT

PROJECT TITLE

PROJECT NO.

:

:

:

M/s. NUTRAPLUS INDIA LTD. (UNIT-2)

PLOT NO. C-198, SAYKHA INDUSTRIAL ESTATE,

TAL: VAGRA, DIST. BHARUCH (GUJ.)

ENVIRONMENTAL IMPACT & RISK ASSESMENT REPORT FOR

PROPOSED BULK DRUGS AND BULK DRUG INTERMEDIATES PLANT IN

SAYAKHA GIDC

515000





Road, Surat - 395002

Prepared By:











Prepared By:

December 28, 2017

UNDERTAKING

WE NUTRA PLUS INDIA LTD (UNIT-2), OWN THIS EIA REPORT FOR BULK DRUG AND

BULK DRUG INTERMEDIATE IN PLANT AT PLOT NO.C-198, SAYKHA INDUSTRAIL

ESTATE, TAL. VAGRA, DIST. BHARUCH, GUJARAT

DECLARATION BY EXPERTS CONTRIBUTING TO THE EIA REPORT OF

M/s. Nutraplus India Ltd. (Unit-2)

PLOT NO. C-198, SAYKHA INDUSTRIAL ESTATE,

TAL: VAGRA, DIST. BHARUCH (GUJ.)

DECLARATION BY HEAD OF THE ORGANIZATION

I, Jayeshkumar S. Patel hereby confirm that the above mentioned team members were

involved in preperation of EIA Report of M/s. Nutrtaplus India Ltd. (Unit-2). I also

confirm that I shall be fully accountable for any misleading information mentioned in

this statement.

1

INDEX

SR. NO. TITLE PAGE NO.

1 CHAPTER 1: INTRODUCTION

1.1 JUSTIFICATION & BACKGROUND 40

1.1.1 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND

OR REGION

40

1.1.2 PROMOTERS& THEIR BACKGROUND 41

1.1.3 REGULATORY FRAMEWORK 41

1.1.4 BREAK UP OF DIFFERENT LAND USE OF FACTORY 42

1.2 PROJECT SETTING 46

1.2.1 KEY INFRASTRUCTURAL FEATURES AND SETTLEMENTS 47

1.2.1.1 METHOD OF DATA PREPARATION 47

1.2.1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT

SITE

47

1.2.1.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 47

1.3 PURPOSE OF EIA 51

1.4 OBJECTIVES OF EIA 51

1.5 METHODOLOGIES FOR EIA 51

1.5.1 BASE LINE ENVIRONMENTAL CONDITION 51

1.5.1.1 AMBIENT AIR ENVIRONMENT 51

1.5.1.2 GROUND AND SURFACE WATER ENVIRONMENT 52

1.5.1.3 NOISE ENVIRONMENT 52

1.5.1.4 SOIL ENVIRONMENT 52

1.5.1.5 BIOLOGICAL ENVIRONMENT 52

1.5.1.6 SOCIO-ECONOMIC ENVIRONMENT 53

1.5.2 IDENTIFICATION OF POLLUTION SOURCE 53

1.5.3 EVALUATION OF POLLUTION CONTROL AND ENVIRONMENTAL

MANAGEMENT SYSTEM

53

1.5.4 EVALUATION OF IMPACT 53

1.5.5 PREPARATION OF ENVIRONMENTAL MANAGEMENT PLAN 53

1.6 STRUCTURE OF REPORT 54

2 CHAPTER 2: PROJECT DESCRIPTION AND INFRASTRUCTURAL FACILITIES

2

2.1 BACKGROUND 57

2.2 MANUFACTURING ACTIVITIES 57

2.3 RAW MATERIAL CONSUMPTION, STORAGE AND HANDLING 166

2.4 INFRASTRUCTURE FACILITIES 180

2.4.1 LAND 180

2.4.2 TRANSPORTATION FACILITIES 180

2.4.3 WATER AND WASTEWATER 180

2.4.3.1 SEGRIGATION OF WASTE STREAMS 183

2.4.3.2 TREATMENT PROCESS 184

2.4.3.3 EXPECTED CHARACTERISTICS OF WASTEWATER/TREATABILITY STUDY 198

2.4.4 AIR POLLUTION AND CONTROL SYSTEM 210

2.4.5 NOISE LEVEL AND CONTROL SYSTEM 211

2.4.6 HAZARDOUS AND SOILD WASTE GENERATIONS AND DISPOSAL SYSTEM 211

2.5 DETAILS OF UTILITIES 213

2.6 ELECTRICITY REQUIREMENT & FUEL REEQUIREMENT 213

2.7 DETAILS OF GREEN BELT 213

2.8 IMPLIMENTATION SCHEDULE 214

3 CHAPTER 3: BASELINE ENVIRONMENTAL STATUS

3.1 MICRO-METEOROLOGY OF THE AREA 215

3.1.1 TEMPERATURE DETAILS 216

3.1.2 RELATIVE HUMIDITY (RH) 217

3.1.3 RAINFALL 218

3.1.4 WIND SPEED 219

3.2 AIR ENVIRONMENT 223

3.2.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING

LOCATIONS

223

3.2.2 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING 224

3.3 NOISE ENVIRONMENT 230

3.3.1 METHODOLOGY FOR NOISE MONITORING 230

3.4 WATER ENVIRONMENT 234

3.4.1 RECONNAISSANCE 234

3.4.2 METHODOLOGY FOR WATER QUALITY MONITORING 234

3

3.5 LAND ENVIRONMENT 239

3.5.1 METHODOLOGY FOR SOIL MONITORING 239

3.5.2 SOIL CLASSIFICATIONS 242

3.5.2.1 METHOD OF PREPARATION 242

3.5.2.2 DESCRIPTION OF SOIL CHARACTERISTICS AND AREA UNDER DIFFERENT

SOIL TYPES

242

3.5.2.3 SOIL CHARACTERISTICS MAP 242

3.6 GEOLOGICAL DATA 245

3.6.1 METHOD OF PREPARATION 245

3.6.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER

DIFFERENT FORMATIONS

245

3.6.2.1 GEOLOGY 245

3.6.2.2 HYDROLOGY 245

3.6.2.3 GROUND WATER UTILIZATION (CRITICAL BLOKS) 246

3.6.2.4 DRAINAGE PATTERN 247

3.6.3 GEOLOGICAL MAP 248

3.7 LAND USE PATTERN 250

3.7.1 METHOD OF DATA PREPARATION 250

3.8 ECOLOGICAL INFORMATION 254

3.8.1 PHYSIOGRAPHY 255

3.8.2 FOREST 255

3.8.3 FLORA 256

3.8.4 FAUNA 259

3.9 SOCIO-ECONOMIC ENVIRONMENT 261

3.9.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN 261

3.9.1.1 METHOD OF DATA PREPARATION 261

3.9.1.2 DEMOGRAPHIC DATA WITHIN THE REGION 261

3.9.1.3 LITERACY RATE 266

3.9.2 VEGETATION COVER AND FOREST BOUNDARIES 269

3.9.2.1 METHODS OF PREPARATION 269

3.9.2.2 AREA UNDER DIFFERENT VEGETATION CLASSIFICATION 270

3.9.2.3 MAP OF VEGETATION CLASSIFICATION AND FOREST BOUNDARIES 270

3.9.3 OCCUPATIONAL STRUCTURE 272

4

3.9.4 AMENITIES 273

3.9.5 GROUND WATER HYDROLOGY 278

3.9.6 DRAINAGE PATTERN 283

3.9.7 DIGITAL TERRAIN MODEL 283

4 CHAPTER 4: ANTICIPATED ENVIRONMENTAL IMPACTS & MITIGATION MEASURES

4.1 IDENTIFICATION OF IMPACTS 287

4.2 PREDICTION AND EVALUATION OF IMPACTS 294

4.2.1 WATER ENVIRONMENT 294

4.2.2 AIR ENVIRONMENT 295

4.2.3 NOISE ENVIRONMENT 306

4.2.4 HAZARDOUS WASTE DETAILS 306

4.2.5 INFRASTRUCTURE AND SERVICES 306

4.2.6 ENVIRONMENTAL HAZARDS 307

4.2.7 HOUSING 307

4.2.8 ECOLOGY 307

4.2.8.1 NATURAL VEGETATION 307

4.2.8.2 CROPS 308

4.2.8.3 FISHIRIES AND AQUATIC LIFE 308

4.2.8.4 AESTHETIC ENVIRONMENT 308

4.2.8.5 DEMOGRAPHY, ECONOMICS, SOCIOLOGY AND HUMAN SETTLEMENT 308

4.2.8.6 FOREST, NATIONAL PARKS / SANCTUARIES 311

4.2.8.7 PLACES OF ARCHAEOLOGICAL/HISTORICAL/RELIGIOUS/TOURIST

INTEREST

311

4.3 MATRIX REPRESENTATION 311

4.3.1 CUMULATIVE IMPACT CHART 312

5 CHAPTER 5: ENVIRONMENTAL MONITORING PLAN

5.1 PROJECT ENVIRONMENT MONITORING PLAN 317

5.1.1 LABORATORY FACILITIES 319

5.1.2 DOCUMETATION & RECORDS 319

6 CHAPTER 6: RISK ASSESSMENT & DMP

6.1 RISK ASSESSMENT 320

5

6.1.1 INTRODUCTION 320

6.1.2 APPROACH TO THE STUDY 321

6.1.3 METHODOLOGY 321

6.1.4 HAZARD IDENTIFICATION 324

6.1.4.1 IDENTIFICATION OF HAZARDOUS AREAS 324

6.1.4.2 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS 324

6.1.4.3 MAJOR HAZARDOUS AREAS 325

6.1.4.4 CONTROL MEASURES WHILE STORAGE OF HAZARDOUS CHEMICALS 334

6.1.4.5 PRECAUTIONS DURING STORAGE AND TRANSPORTATION OF

HAZARDOUS CHEMICALS LIQUIDS

342

6.1.5 CONSEQUENCE ANALYSIS 353

6.1.5.1 DAMAGE CRITERIA 354

6.1.5.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS 360

6.1.5.2.1 CONSEQUENCE ANALYSIS CALCULATIONS 360

6.1.5.2.2 SOFTWARE USED FOR CALCULATIONS 361

6.1.5.2.3 SCENARIOS 364

6.1.6 RISK ASSESSMENT SUMMARY 432

6.1.6.1 PROCESS SAFETY 432

6.1.6.2 FOR HAZARDOUS STORAGE TANK FARM 433

6.1.6.3 FOR DRUM/CARBOY STORAGE AREA 433

6.1.6.4 TRANSPORTATION 435

6.1.7 OTHER RISK REDUCTION OPPORTUNITIES 435

6.1.8 RECOMMENDATIONS FOR ALARP 436

6.1.9 FIRE FIGHTING SYSTEM 438

6.2 DISASTER MANAGEMENT PLAN 439

6.2.1 DEFINING THE NATURE OF EMERGENCY 439

6.2.1.1 LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE CATEGORIES. 439

6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM 440

6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM 441

6.2.3.1 CHIEF EMERGENCY CONTROLLER 443

6.2.3.2 INCIDENT CONTROLLER AND DEPUTY INCIDENT CONTROLLER

444

6.2.3.3 SITE MAIN CONTROLLER 446

6

6.2.3.4 KEY PERSONNELS 447

6.2.3.5 ESSENTIAL WORKERS 448

6.2.3.6 ASSEMABLY POINT 449

6.2.3.7 EMERGENCY CONTROL CENTER 449

6.2.3.8 FIRE CONTROL ARRANGEMENTS 450

6.2.3.9 MEDICAL SERVICES 450

6.2.3.10 OTHER ARRANGEMENTS 450

6.3 COMMMUNICATION SYSTEM 451

6.3.1 RAISING THE ALARM 460

6.3.2 DECLARING THE MAJOR EMERGENCY 461

6.3.3 TELEPHONE MESSAGES 462

6.3.4 COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION 462

6.3.4.1 COMMUNICATION OF EMERGENCY 462

6.3.4.2 STATUTORY INFORMATION 464

6.4 ACTION ON SITE 465

6.4.1 PRE-EMERGENCY ACTIVITIES 465

6.4.1.1 INTERNAL SAFETY SURVEY 465

6.4.1.2 THIRD PARTY SURVEY 466

6.4.1.3 PRESSURE VESSEL TESTING/ EXAMINATION 466

6.4.1.4 NON-DESTRUCTIVE TESTING (NDT) 467

6.4.1.5 SAFETY RELIEF VALVES TESTING 467

6.4.1.6 FIRE SYSTEM TESTING 467

6.4.1.7 MUTUAL AID SCHEME 467

6.4.1.8 MOCK-DRILLS 468

6.4.1.9 SAFETY TRAINING 468

6.4.1.10 PERSONAL PROTECTIVE EQUIPMENT 469

6.4.1.11 COMMUNICATION 469

6.4.1.12 EMERGENCY LIGHTS 469

6.4.1.13 EMERGENCY CONTROL ROOM 470

6.4.1.14 ASSEMBLY POINTS 470

6.4.1.15 LIAISON WITH STATE AUTHORITIES 470

6.4.1.16 HOSPITAL FACILITIES 470

6.4.1.17 OUTSIDE SHELTER 471

7

6.4.1.18 STATUTORY INFORMATION 471

6.4.1.19 PROTECTIVE DEVICES & ENGINEERING MAINTENANCE 471

6.4.1.20 LIST OF SUPPLIERS OF SAFETY EQUIPMENT 472

6.4.1.21 FIRE PREVENTION PLAN 472

6.4.2 POST EMERGENCY ACTIVITIES 472

6.4.3 EMERGENCY TIME ACTIVITIES 473

6.4.3.1 FLAMMABLE RELEASES 473

6.4.3.2 TOXIC RELEASES 474

6.4.3.3 CHEMICAL SPILL 475

6.4.4 EVACUATION & TRANSPORTATION 475

6.4.5 SAFE CLOSE-DOWN 475

6.4.6 USE OF MUTUAL AID 475

6.4.7 HELP OF EXTERNAL AUTHORIES 476

6.4.8 MEDICAL TREATMENT 476

6.4.9 ACCOUNTING FOR PERSONNEL 476

6.4.10 ACCESS TO RECORDS 476

6.4.11 PUBLIC RELATIONS 476

6.4.12 REHABILITATION 477

6.5 OFF – SITE EMERGENCY PLAN 477

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN 478

6.5.2 STRUCTURE OF THE OFF-SITE EMERGENCY PLAN 478

6.5.3 ROLE OF FACTORY MANAGEMENT 478

6.5.4 ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO) 479

6.5.5 ROLE OF THE FIRE AUTHORITIES 479

6.5.6 ROLE OF THE HEALTH AUTHORITIES 479

6.5.7 ROLE OF TELEPHONE DEPARTMENT 480

6.5.8 ROLE OF POLICE AND EVACUATION AUTHORITIES 480

6.5.9 ROLE OF THE MUTUAL-AID AGENCIES 480

6.6 OCCUPATIONAL HEALTH AND SAFETY 481

6.6.1 OCCUPATIONAL HEALTH 481

6.6.1.1 CONSTRUCTION AND ERECTION 481

6.6.1.2 OPERATION AND MAINTENANCE 481

6.6.1.3 HOSPITAL FACILITIES 482

8

6.6.1.4 FACTORY MEDICAL OFFICER 482

6.6.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC 483

6.6.2 SAFEY PLAN 492

6.7 TRAINING, REHERASAL & RECORDS 495

6.8 HAZOP STUDY 497

6.8.1 OBJECTIVE 497

6.8.2 PURPOSE OF HAZOP 497

6.8.3 FEATURES AND HAZOP STUDY 498

6.8.4 HAZOP STUDY PROCEDURE 498

6.8.5 PROCESS HAZARD AND ITS CONTROL 502

6.8.6 PLANNING FOR HAZOP 505

CHAPTER-7

7 CHAPTER 7: ENVIRONMENTAL MANAGEMENT PLAN

7.1 BACKGROUND 506

7.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN 506

7.3 ENVIRONMENTAL MANAGEMENT CELL 507

7.3.1 ENVIRONMENT POLICY 509

7.3.2 CORPORATE ENVIRONMENT RESPONSIBILITY 510

7.3.3 MANAGEMENT RESPONSIBILITY 510

7.4 ENVIRONMENTAL MANAGEMENT PLAN 512

7.4.1 CONSTRUCTION PHASE 512

7.4.2 WATER ENVIRONMENT 515

7.4.3 AIR ENVIRONMENT 516

7.4.4 NOISE ENVIRONMENT 520

7.4.5 LAND ENVIRONMENT 522

7.5 GREEN BELT DEVELOPMENT 526

7.6 OCCUPATIONAL HEALTH AND SAFETY 529

7.7 MEASURES FOR CONSERVATION OF ENERGY 530

7.8 NATURAL RESOURCES CONSERVATION 531

7.9 SKILLED AND TRAINED MANPOWER 532

7.10 SOCIO ECONOMIC DEVELOPMENT ACTIVITIES 532

7.11 SOLVENT RECOVERY PLAN 534

9

7.12 VOC MONITORING PLAN 537

7.13 ODOUR CONTROL PLAN 540

7.14 METHODOLOGY OF DE-CONTAMINATION AND DISPOSAL OF DISCARDED

CONTAINERS AND ITS RECORD KEEPING

542

7.15 TECHNICAL DETAILS OF THE PLANT /S ALONG WITH DETAILS ON BEST

AVAILABLE TECHNOLOGY (BAT)

543

7.16 CAPITAL COST FOR ENVIRONMENTAL MANGEMENT 545

CHAPTER-8

8 CHAPTER 8: EXECUTIVE SUMMARY & CONCLUSION

8.1 PROJECT DESCRIPTION 546

8.2 DISCRIPTION OF ENVIRONMENT 547

8.3 ANTICIPATED ENVIRONMENTAL IMPACTS 551

8.4 ENVIRONMENT MONITORING PLAN 555

8.5 ADDITIONAL STUDIES 556

8.6 PROJECT BENEFITS 558

8.7 ENVIRONMENT MANAGEMENT PLAN 559

8.8 CONCLUSION 560

9 CHAPTER 9: DISCLOSURE OF CONSULTANTS ENGAGED

10.0 ANNEXURES 561

10

LIST OF TABLES

TABLE

NO.

TITLE PAGE NO.

1.1 BREAK UP OF PROJECT COST 42

1.2 LAND BREAKUP 42

1.3 LIST OF PRODUCTS ALONGWITH PRODUCTION CAPACITY 45

1.4 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT

SITE

47

2.1 RAW MATERIAL REQUIREMENT 166

2.2 WATER CONSUMPTION & WASTE WATER GENERATION 181

2.3 ETP DIMENSIONS 186

2.4 PRODUCTWISE EFFLUENT CHARACTERISTIC 199

2.5 AIR POLLUTION AND CONTROL SYSTEM 210

2.6 HAZARDOUS & SOILD WASTE GENERATION QUANTITY, PHYSICAL

CHARACTERISTICS AND MODE OF DISPOSAL

211

2.7 FUEL REQUIREMENT 213

2.8 GREENBELT DEVLOPMENT PROGRRAME 214

3.1 TEMPERATURE DETAILS 216

3.2 RELATIVE HUMIDITY DETAILS 217

3.3 RAINFALL DETAILS 218

3.4 WIND SPEED DETAILS 219

3.5 SITE SPECIFIC METEOROLOGICAL DATA 220

3.6 WIND ROSE DIAGRAM 221

3.7 STABILITY CLASS DISTRIBUTION 222

3.8 DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS 225

3.9 AMBIENT AIR QUALITY STATUS 227

3.10 DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS 231

3.11 BACKGROUND NOISE LEVELS 233

3.12 NOISE LEVELS DUE TO TRANSPORTATION 233

3.13 SAMPLING LOCATIONS FOR MONITORING SURFACE WATER AND GROUND

WATER QUALITY

235

3.14 WATER QUALITY- PHYSICAL PARAMETERS 237

11

3.15 SAMPLING LOCATIONS: SOIL QUALITY 239

3.16 PHYSICO-CHEMICAL CHARACTERISTICS OF SOIL 241

3.17 SOIL CHARACTERISTICS UNDER PROJECT AREA 243

3.18 AREAS UNDER DIFFERENT LANDUSE 252

3.19 FLORA 256

3.20 FAUNA 259

3.21 DEMOGRAPHIC DATA 262

3.22 POPULATION DENSITY 264

3.23 LITERACY RATE 266

3.24 AREA UNDER DIFFERENT VEGETATION CLASSIFICATION 270

3.25 OCCUPATIONAL STRUCTURE 272

3.26 DETAILS OF AMENITIES AVAILABLE IN THE STUDY AREA 274

4.1 DETAILS OF EMISSION FROM STACKS & VENTS 297,298

4.2 SUMMARY OF ISCST3 MODEL OUTPUT FOR SPM, SO2, NOX , HCL 305

4.3 PREDICTED AMBIENT AIR QUALITY FOR SPM, SO2, NOX, HCL 306

4.4 IMPACT IDENTIFICATION MATRIX 312

4.5 CONSTRUCTION & OPERATION STAGE POTENTIAL IMPACTS & MITIGATIVE

MEASURES

314

4.6 ENVIRONMENTAL IMPACT MATRIX 315

4.7 CUMULATIVE IMPACT CHART 316

5.1 PROJECT ENVIRONMENT MONITORING PLAN 318

6.1 STORAGE DETAILS OF HAZARDOUS CHEMICALS 326

6.2 OTHER HAZARDS AND CONTROL 328

6.3 HAZARDOUS PROPERTIES OF CHEMICALS 330

6.4 TRANSPORTATION, UNLOADING AND HANDLING PROCEDURE 344

6.5 POSSIBLE ACCIDENT SCENARIOS 364

6.6 FIRE AND TOXICITY CONTROL ARRANGEMENT 438

6.7 OCCUPATIONAL HEALTH IMPACT 486

7.1 ENVIRONMENT MANAGEMENT PLAN 514

7.2 FUND FOR CSR ACTIVITIES 534

12

LIST OF FIGURES

FIGURE

NO.

TITLE PAGE NO.

1.1 LOCATION OF THE PROJECT SITE 43

1.2 PLANT LAYOUT 44

1.3 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS 48

1.4 SATELLITE IMAGERY 49

1.5 TOPOSHEET OF THE AREA 50

1.6 ACTIVITIES, SOURCES OF INFORMATION AND CONTENTS OF EIA REPORT 55

2.1 WATER BALNCE DIAGRAM 182

2.2 SEGRIGATION OF WASTE STREAMS 183

2.3 FLOW DIAGRAM OF SPENT SOLVENT MANAGEMENT SYSTEM 189

2.4 TECHNICAL DETAILS OF R.O 190

2.5 SPRAY DRYDER PLANT 194

2.6 TYPICAL AIR INLET FILTER 195

2.7 ETP DIAGRAM & STP (ADDED DOMESTIC WASTE WATER IN ETP UNIT

AERATION TANK

197

3.1 A WIND ROSE DIAGRAM 221

3.1 B STABILITY CLASS DISTRIBUTION 222

3.2 LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS 226

3.3 LOCATION OF NOISE LEVEL MONITORING STATIONS 232

3.4 LOCATIONS OF WATER SAMPLING STATIONS 236

3.5 LOCATIONS OF SOIL SAMPLING STATIONS 240

3.6 SOIL CHARACTERISTICS MAP 244

3.7 MAJOR GEOLOGICAL FEATURES 248

3.8 DRAINAGE PATTERN 249

3.9 PROCESS METHODOLOGY 251

3.10 LAND USE/ LAND COVER 253

3.11 POPULATION DENSITY 265

3.12 LITERACY DATA 268

3.13 VEGETATION CLASSIFICATION AND FOREST BOUNDARIES 271

3.14 GROUND WATER HYDROLOGY 284

13

3.15 DRAINAGE PATTERN 285

3.16 DIGITAL TERRAIN MODEL 286

4.1 IMPACT NETWORK 288-293

4.2 ISOPLETHS FOR PM, SO2, NOx , HCl, Cl2, NH3 299-304

6.1 QRA METHODOLOGY 322

6.2 FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT 323

6.3 HAZARDOUS CHEMICAL STORAGE AREA (SITE PLAN) 325

6.4 HAZOP STUDY PROCEDURE 499

6.5 HAZOP STUDY FLOW CHART 500

7.1 ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL 508

7.2 ENVIRONMENTAL POLICY 509

7.3 HAZARDOUS WASTE PREMISES 524

7.4 VOC CONTROL MECHANISM 537

7.5 PROCESS VENTS CONTROL MECHANISM 539

7.6 ODOUR CONTROL PLAN 541

14

COPY OF TORs LETTER

22

Annexure-I

GENERIC TERMS OF REFERENCE (TOR) IN RESPECT OF INDUSTRY SECTOR – MoEFCC, NEW DELHI

1. Executive Summary

2. Introduction

i. Details of the EIA Consultant including NABET accreditation

ii. Information about the project proponent

iii. Importance and benefits of the project

3. Project Description

i. Cost of project and time of completion.

ii. Products with capacities for the proposed project.

iii. If expansion project, details of existing products with capacities and whether adequate

land is available for expansion, reference of earlier EC if any.

iv. List of raw materials required and their source along with mode of transportation.

v. Other chemicals and materials required with quantities and storage capacities

vi. Details of Emission, effluents, hazardous waste generation and their management.

vii. Requirement of water, power, with source of supply, status of approval, water balance

diagram, man-power requirement (regular and contract)

viii. Process description along with major equipments and machineries, process flow sheet

(quantities) from raw material to products to be provided

ix. Hazard identification and details of proposed safety systems.

x. Expansion/modernization proposals:

a. Copy of all the Environmental Clearance(s) including Amendments thereto obtained for

the project from MOEF/SEIAA shall be attached as an Annexure. A certified copy of the

latest Monitoring Report of the Regional Office of the Ministry of Environment and

Forests as per circular dated 30th May, 2012 on the status of compliance of conditions

stipulated in all the existing environmental clearances including Amendments shall be

provided. In addition, status of compliance of Consent to Operate for the ongoing I

existing operation of the project from SPCB shall be attached with the EIA-EMP report.

b. In case the existing project has not obtained environmental clearance, reasons for not

taking EC under the provisions of the EIA Notification 1994 and/or EIA Notification 2006

shall be provided. Copies of Consent to Establish/No Objection Certificate and Consent

to Operate (in case of units operating prior to EIA Notification 2006, CTE and CTO of FY

2005-2006) obtained from the SPCB shall be submitted. Further, compliance report to

the conditions of consents from the SPCB shall be submitted.

4. Site Details

i. Location of the project site covering village, Taluka/Tehsil, District and State, Justification for

selecting the site, whether other sites were considered.

ii. A toposheet of the study area of radius of 10km and site location on 1:50,000/1:25,000 scale

on an A3/A2 sheet. (Including all eco-sensitive areas and environmentally sensitive places)

iii. Details w.r.t. option analysis for selection of site

iv. Co-ordinates (lat-long) of all four corners of the site.

v. Google map-Earth downloaded of the project site.

vi. Layout maps indicating existing unit as well as proposed unit indicating storage area, plant

area, greenbelt area, utilities etc. If located within an Industrial area/Estate/Complex, layout

of Industrial Area indicating location of unit within the Industrial area/Estate.

vii. Photographs of the proposed and existing (if applicable) plant site. If existing, show

photographs of plantation/greenbelt, in particular.

23

viii. Landuse break-up of total land of the project site (identified and acquired),

government/private - agricultural, forest, wasteland, water bodies, settlements, etc shall be

included. (Not required for industrial area)

ix. A list of major industries with name and type within study area (10km radius) shall be

incorporated. Land use details of the study area

x. Geological features and Geo-hydrological status of the study area shall be included.

xi. Details of Drainage of the project upto 5km radius of study area. If the site is within 1 km

radius of any major river, peak and lean season river discharge as well as flood occurrence

frequency based on peak rainfall data of the past 30 years. Details of Flood Level of the

project site and maximum Flood Level of the river shall also be provided. (Mega green field

projects)

xii. Status of acquisition of land. If acquisition is not complete, stage of the acquisition process

and expected time of complete possession of the land.

xiii. R&R details in respect of land in line with state Government policy

5. Forest and wildlife related issues (if applicable):

i. Permission and approval for the use of forest land (forestry clearance), if any, and

recommendations of the State Forest Department. (if applicable)

ii. Landuse map based on High resolution satellite imagery (GPS) of the proposed site

delineating the forestland (in case of projects involving forest land more than 40 ha)

iii. Status of Application submitted for obtaining the stage I forestry clearance along with latest

status shall be submitted.

iv. The projects to be located within 10 km of the National Parks, Sanctuaries, Biosphere

Reserves, Migratory Corridors of Wild Animals, the project proponent shall submit the map

duly authenticated by Chief Wildlife Warden showing these features vis-à-vis the project

location and the recommendations or comments of the Chief Wildlife Warden there on

v. Wildlife Conservation Plan duly authenticated by the Chief Wildlife Warden of the State

Government for conservation of Schedule I fauna, if any exists in the study area

vi. Copy of application submitted for clearance under the Wildlife (Protection) Act, 1972, to the

Standing Committee of the National Board for Wildlife

6. Environmental Status

i. Determination of atmospheric inversion level at the project site and site-specific

micrometeorological data using temperature, relative humidity, hourly wind speed and

direction and rainfall.

ii. AAQ data (except monsoon) at 8 locations for PM10, PM2.5, SO2, NOX, CO and other

parameters relevant to the project shall be collected. The monitoring stations shall be based

CPCB guidelines and take into account the pre-dominant wind direction, population zone

and sensitive receptors including reserved forests.

iii. Raw data of all AAQ measurement for 12 weeks of all stations as per frequency given in the

NAQQM Notification of Nov. 2009 along with – min., max., average and 98% values for each

of the AAQ parameters from data of all AAQ stations should be provided as an annexure to

the EIA Report.

iv. Surface water quality of nearby River (100m upstream and downstream of discharge point)

and other surface drains at eight locations as per CPCB/MoEF&CC guidelines.

v. Whether the site falls near to polluted stretch of river identified by the CPCB/MoEF&CC, if

yes give details.

vi. Ground water monitoring at minimum at 8 locations shall be included.

vii. Noise levels monitoring at 8 locations within the study area.

viii. Soil Characteristic as per CPCB guidelines.

24

ix. Traffic study of the area, type of vehicles, frequency of vehicles for transportation of

materials, additional traffic due to proposed project, parking arrangement etc.

x. Detailed description of flora and fauna (terrestrial and aquatic) existing in the study area

shall be given with special reference to rare, endemic and endangered species. If Schedule-I

fauna are found within the study area, a Wildlife Conservation Plan shall be prepared and

furnished.

xi. Socio-economic status of the study area.

7. Impact and Environment Management Plan

i. Assessment of ground level concentration of pollutants from the stack emission based on

site-specific meteorological features. In case the project is located on a hilly terrain, the AQIP

Modelling shall be done using inputs of the specific terrain characteristics for determining

the potential impacts of the project on the AAQ. Cumulative impact of all sources of

emissions (including transportation) on the AAQ of the area shall be assessed. Details of the

model used and the input data used for modelling shall also be provided. The air quality

contours shall be plotted on a location map showing the location of project site, habitation

nearby, sensitive receptors, if any.

ii. Water Quality Modelling – in case of discharge in water body

iii. Impact of the transport of the raw materials and end products on the surrounding

environment shall be assessed and provided. In this regard, options for transport of raw

materials and finished products and wastes (large quantities) by rail or rail-cum road

transport or conveyor-cum-rail transport shall be examined.

iv. A note on treatment of wastewater from different plant operations, extent recycled and

reused for different purposes shall be included. Complete scheme of effluent treatment.

Characteristics of untreated and treated effluent to meet the prescribed standards of

discharge under E (P) Rules.

v. Details of stack emission and action plan for control of emissions to meet standards.

vi. Measures for fugitive emission control

vii. Details of hazardous waste generation and their storage, utilization and management.

Copies of MOU regarding utilization of solid and hazardous waste in cement plant shall also

be included. EMP shall include the concept of waste-minimization, recycle/reuse/recover

techniques, Energy conservation, and natural resource conservation.

viii. Proper utilization of fly ash shall be ensured as per Fly Ash Notification, 2009. A detailed plan

of action shall be provided.

ix. Action plan for the green belt development plan in 33 % area i.e. land with not less than

1,500 trees per ha. Giving details of species, width of plantation, planning schedule etc. shall

be included. The green belt shall be around the project boundary and a scheme for greening

of the roads used for the project shall also be incorporated.

x. Action plan for rainwater harvesting measures at plant site shall be submitted to harvest

rainwater from the roof tops and storm water drains to recharge the ground water and also

to use for the various activities at the project site to conserve fresh water and reduce the

water requirement from other sources.

xi. Total capital cost and recurring cost/annum for environmental pollution control measures

shall be included.

xii. Action plan for post-project environmental monitoring shall be submitted.

xiii. Onsite and Offsite Disaster (natural and Man-made) Preparedness and Emergency

Management Plan including Risk Assessment and damage control. Disaster management

plan should be linked with District Disaster Management Plan.

25

8. Occupational health

i. Plan and fund allocation to ensure the occupational health & safety of all contract and casual

workers

ii. Details of exposure specific health status evaluation of worker. If the workers’ health is being

evaluated by pre designed format, chest x rays, Audiometry, Spirometry, Vision testing (Far

& Near vision, Colour vision and any other ocular defect) ECG, during pre placement and

periodical examinations give the details of the same. Details regarding last month analyzed

data of above mentioned parameters as per age, sex, duration of exposure and department

wise.

iii. Details of existing Occupational & Safety Hazards. What are the exposure levels of hazards

and whether they are within Permissible Exposure level (PEL)? If these are not within PEL,

what measures the company has adopted to keep them within PEL so that health of the

workers can be preserved

iv. Annual report of heath status of workers with special reference to Occupational Health and

Safety.

9. Corporate Environment Policy

i. 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.

ii. 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.

iii. What is the hierarchical system or Administrative order of the company to deal with the

environmental issues and for ensuring compliance with the environmental clearance

conditions? Details of this system may be given.

iv. Does the company have 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 shall be detailed in the EIA report

10. Details regarding infrastructure facilities such as sanitation, fuel, restroom etc. to be provided to

the labour force during construction as well as to the casual workers including truck drivers during

operation phase.

11. Enterprise Social Commitment (ESC)

i. Adequate funds (at least 2.5 % of the project cost) shall be earmarked towards the

Enterprise Social Commitment based on Public Hearing issues and item-wise details along

with time bound action plan shall be included. Socio-economic development activities need

to be elaborated upon.

12. Any litigation pending against the project and/or any direction/order passed by any Court of Law

against the project, if so, details thereof shall also be included. Has the unit received any notice

under the Section 5 of Environment (Protection) Act, 1986 or relevant Sections of Air and Water

Acts? If so, details thereof and compliance/ATR to the notice(s) and present status of the case.

13. ‘A tabular chart with index for point wise compliance of above TORs.

14. The TORs prescribed shall be valid for a period of three years for submission of the EIA-EMP

reports.

The following general points shall be noted:

i. All documents shall be properly indexed, page numbered.

ii. Period/date of data collection shall be clearly indicated.

iii. Authenticated English translation of all material in Regional languages shall be provided.

iv. The letter/application for environmental clearance shall quote the MOEF file No. and also

attach a copy of the letter.

26

v. The copy of the letter received from the Ministry shall be also attached as an annexure to

the final EIA-EMP Report.

vi. The index of the final EIA-EMP report must indicate the specific chapter and page no. of the

EIAEMP Report

vii. While preparing the EIA report, the instructions for the proponents and instructions for the

consultants issued by MOEF vide O.M. No. J-11013/41/2006-IA.II (I) dated 4th August, 2009,

which are available on the website of this Ministry shall also be followed.

viii. The consultants involved in the preparation of EIA-EMP report after accreditation with

Quality Council of India (QCl) /National Accreditation Board of Education and Training

(NABET) would need to include a certificate in this regard in the EIA-EMP reports prepared

by them and data provided by other organization/Laboratories including their status of

approvals etc. Name of the Consultant and the Accreditation details shall be posted on the

EIA-EMP Report as well as on the cover of the Hard Copy of the Presentation material for EC

presentation.

TORs’ prescribed by the Expert Appraisal Committee (Industry) shall be considered for preparation

of EIA-EMP report for the project in addition to all the relevant information as per the ‘Generic

Structure of EIA’ given in Appendix III and IIIA in the EIA Notification, 2006. Where the documents

provided are in a language other than English, an English translation shall be provided. The draft EIA-

EMP report shall be submitted to the State Pollution Control Board of the concerned State for

conduct of Public Hearing. The SPCB shall conduct the Public Hearing/public consultation, district-

wise, as per the provisions of EIA notification, 2006. The Public Hearing shall be chaired by an Officer

not below the rank of Additional District Magistrate. The issues raised in the Public Hearing and

during the consultation process and the commitments made by the project proponent on the same

shall be included separately in EIA-EMP Report in a separate chapter and summarized in a tabular

chart with financial budget (capital and revenue) along with time-schedule of implementation for

complying with the commitments made. The final EIA report shall be submitted to the Ministry for

obtaining environmental clearance.

27

Tor points (SEIAA) Gandhinagar

Technical presentation made during the meeting by project proponent.

Committee observed that project proponent has revised their proposal and

submitted revised form-1 & pfr. Project proponent has removed the dye

manufacturing products from the proposed project. Committee put emphasis on

complete zld with sound environmental management system. After deliberation

on various aspects, following additional tor was prescribed for the eia study

covering 10 km radius of the project boundary.

1. Copy of plot holding certificate obtained from gidc saykha.

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

imagery.

3. Layout plan of the factory premises. (show all the production plants including

raw material & products storage area). 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.

4. Technical details of the plant/s along with details on best available

technologies (bat), proposed technology and reasons for selecting the same.

5. Details of manufacturing process / operations of each product along with

chemical reactions, mass balance, consumption of raw materials etc. Details

on strategy for the implementation of cleaner production activities.

6. Full name and chemical formula of all the raw materials and products. Details

on end use of each product.

7. Complete management plan for by-products/spent acids to be generated,

along with the name and address of end consumers to whom the by-

product/s will be sold. Copies of agreement / mou / letter of intent from

them, showing their willingness to purchase said by-products/spent acids

from the proposed project.

8. Action plan to reuse or consume entire quantity of spent acids/waste streams

within premises to convert into valuable,droamts instead of sending such spent

acids to outside premises.

28

9. Detailed mass balance and water balance (including reuse-recycle, if any) along

with qualitative and quantitative analysis of the each waste stream from the

processes.

10. Assessment of source of the water supply with adequacy of the same to meet

with the requirements for the project. Permission obtained from the gidc for

supply of raw water. Undertaking stating that no bore well shall be dug within the

premises.

11. Explore the possibility of reuse / recycle and other cleaner production options for

reduction of wastes. Details of methods to be adopted for the water

conservation.

12. Qualitative and quantitative analysis of waste water to be generated from the

manufacturing process of each product to be manufactured along with mass

balance.

13. Segregation of waste streams and details on specific treatment and disposal of

each stream.

14. 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.

15. Details of etp including dimensions of each unit along with schematic flow

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.

16. Technical details of proposed spray dryer including capacity, fuel to be used,

adequacy etc. Techno-economical viability of the proposed incinerator. Control

measures proposed for the incinerator in order to avoid/reduce gaseous

emissionnoc from incineration of industrial effluent containing solvents & other

chemicals.

17. Technical details of ro/nf system.

18. Undertaking stating that a separate electric meter will be provided for the etp, ro

system, stripper & spray dryer.

19. Economical and technical viability of the effluent treatment system to achieve zero

liquid discharge (zld).

20. Certification of adequacy of proposed zld scheme through credible institutes of

national repute.

21. To estimate & monitor ground water quality & its contamination status,

piezometer wells, one 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

29

established and all the parameters mentioned in is 10:500 for potable water

standard shall be monitored.

22. Proposal to provide and maintain separate electric meter, operational logbook

for effluent treatment systems, online meters for monitoring of flow, ph,

toc/cod, etc.

23. Application wise break-up of effluent quantity to be recycled / reused in various

applications like sprinkling for dust control and green belt development etc. In

case of land application, details on availability of sufficient open land for utilizing

effluent for plantation / gardening. How it will be ensured that treated effluent

won't flow outside the premises linked with storm water during high rainy days.

24. 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.

25. One season site-specific micro-meteorological data using temperature, relative

humidity, hourly wind speed and direction and rainfall should be incorporated.

26. 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.

27. One complete season base line 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 the revised national ambient air quality standards as well as

project specific parameters. Locations of the monitoring stations should be so

decided so as to take into consideration the pre-dominant downwind direction,

population zone and sensitive receptors. There should be at least one monitoring

station in the upwind direction. There should be at least one monitoring station in

the pre dominant downwind direction at a location where maximum ground level

concentration is likely to occur.

28. 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 predominant

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 satellite Image / geographical area

map.

30

29. 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.

30. Specific details of (I) Process gas emission from each unit process with its

quantification, (ii) Air pollution Control Measures proposed for process gas emission,

(iii) Adequacy of the air pollution control measures for process gas emission, measures

to achieve the GPCB norms (iv) Details of the utilities required (v) Type and quantity of

fuel to be used for each utility (vi) Flue gas emission rate from each utility (vii) Air

Pollution Control Measures proposed to each of the utility along with its adequacy (viii)

List the sources of fugitive emission along with its quantification and proposed

measures to control it.

31. Details on management of the hazardous wastes to be generated from the project

stating detail of storage area for each type of waste, its handling, its utilization and

disposal etc. How the manual handling of the hazardous wastes will be minimized.

Methodology of de-contamination and disposal of discarded containers and its record

keeping.

32. Membership of Common Environmental Infrastructure including the TSDF / Common

Incineration Facility, if any.

33. Name and quantity of each type of solvents to be used for proposed production.

Details of solvent recovery system including mass balance, solvent loss, recovery

efficiency feasibility of reusing the recovered solvents etc. for each type of solvent.

34. 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.

35. Permission from PESO, Nagpur for storage of solvents, other toxic chemicals, if any.

36. Occupational health impacts on the workers and mitigation measures proposed to

avoid the human health 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 impact on the workers. Plan for periodic medical checkup of the

workers exposed. Details of work place ambient air quality monitoring plan as per

Gujarat Factories Rules.

37. Details on volatile organic compounds (VOCs) from the plant operations and

occupational safety and health protection measures.

38. Risk assessment including prediction of the worst-case scenario and maximum credible

accident scenarios should be carried out. The worst-case scenario should take into

account the maximum inventory of storage at site at any point of time. The risk

contours should be plotted on the plant layout map clearly showing which of the

facilities would be affected in case of an accident taking place. Based on the same,

proposed safeguard measures including On-Site / Off-Site Emergency Plan should be

provided.

39. MSDS of all the products and raw materials.

40. 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.

31

41. 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, size of the biggest storage

tank to be provided for each raw material & product etc. How the manual handling of

the hazardous

42. Details of the separate isolated storage area for flammable chemicals. Details of flame

proof electrical fittings, DCP extinguishers and other safety measures proposed.

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.

43. Submit checklist in the form of Do's & Don'ts of preventive maintenance, strengthening

of HSE, manufacturing utility staff for safety related measures.

44. Detailed five year greenbelt development program including annual budget, types &

number of trees to be planted, area under green belt development [with map],

budgetary outlay; along with commitment of the management to carry out the tree

plantation activities outside the premises at appropriate places in the nearby areas and

elsewhere.

45. 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.

46. A tabular chart for the issues raised and addressed during public hearing/consultation

and commitment of the project proponent on the same should be provided. An action

plan to address the issues raised during public hearing and the necessary allocation of

funds for the same should be provided.

47. (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.

48. 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.

49. 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.

50. Phase wise project implementation schedule with bar chart and time frame, in terms of

site development, infrastructure provision, EMS implementation etc.

51. Certificate of accreditation issued by the NABET, QCI to the environmental consultant

should be incorporated in the EIA Report.

52. A tabular chart with index for point-wise compliance of above TORs.

32

TOR POINTS SR.

NO.

TERMS OF REFERENCES COMPLIENCE

1 Copy of plot holding certificate obtained from GIDC

saykha.

Please refer Annexure-7, copy

of plot holding certificate page

no.581

2 Present land use pattern of the study area shall be

given based on satellite imagery.

Please refer Fig.1.4 page no.49

Chepter-1 in EIA report

3 Layout plan of the factory premises. (show all the

production plants including raw material &

products storage area). 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 referred as

Figure 1.2, Chapter-1 in EIA

Report (Page No 44).

4 Technical details of the plant/s along with details

on best available technologies (bat), proposed

technology and reasons for selecting the same.

For details of best available

technologies (BAT), Please refer

Section 7.15, Chapter – 7

(Page No. 543) in EIA Report.

5 Details of manufacturing process / operations of

each product along with chemical reactions, mass

balance, consumption of raw materials etc. Details

on strategy for the implementation of cleaner

production activities.

For the details regarding

manufacturing process,

chemical reactions, mass

balance, consumption of raw

materials etc.,

Please refer Section 2.2,

Chapter – 2

(Page No. 57-165) in EIA Report.

6 Full name and chemical formula of all the raw

materials and products. Details on end use of each

product.

For the Chemical name of each

proposed product, Please refer

Table 1.3, Chapter – 1 (Page No.

45) in EIA Report.

Each product will be used as

medicines for different

purposes.

Section 2.3 table-2.1 page no.

166-179 chepter-2

7 Complete management plan for by-products/spent

acids to be generated, along with the name and

address of end consumers to whom the by-

product/s will be sold. Copies of agreement / MOU

/ letter of intent from them, showing their

willingness to purchase said by-products/spent

acids from the proposed project.

Please refer Annexure-11

In EIA report page no. 590

8 Action plan to reuse or consume entire quantity of

spent acids/waste streams within premises to

Fig.2.1 page no.182 chepter-2

33

convert into valuable, droamts instead of sending

such spent acids to outside premises.

9 Detailed mass balance and water balance (including

reuse-recycle, if any) along with qualitative and

quantitative analysis of the each waste stream

from the processes.

For the detailed mass balance

and water balance, Please refer

Section 2.4.3.1, Chapter – 2


For the qualitative and

quantitative analysis of the each

waste stream from the

processes, Please refer Section

2.4.3.3, Chapter – 2 (Page No.

198)

10 Assessment of source of the water supply with

adequacy of the same to meet with the

requirements for the project. Permission obtained

from the GIDC for supply of raw water. Undertaking

stating that no bore well shall be dug within the

premises.

Water requirement shall be met

through GIDC, Saykha

For the permission of water

supply and undertaking letter

for bore well, Please refer

Annexure-8

Page no. 587

11 Explore the possibility of reuse / recycle and other

cleaner production options for reduction of wastes.

Details of methods to be adopted for the water

conservation.

For the possibility of reuse /

recycle and other cleaner

production options for

reduction of wastes, Please

refer Section 7.4.5.2, Chapter –

7 (Page No. 525) in EIA Report.

12 Qualitative and quantitative analysis of waste

water to be generated from the manufacturing

process of each product to be manufactured along

with mass balance.

For the Quality and quantity of

waste water to be generated

from the manufacturing process

of each product to be

manufactured along with mass

balance Please refer Section

2.2, Chapter – 2 (Page No. 57-

165) in EIA Report.

13 Segregation of waste streams and details on specific

treatment and disposal of each stream.

For the Segregation of waste

streams and details on specific

treatment and disposal of each

stream, Please refer Section

2.4.3.1 & 2.4.3.2,2.4.3.3

Chapter – 2 (Page No. 183-209)

in EIA Report.

14 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.

For the Action plan for ‘Zero’

discharge of effluent please

refer Section 2.4.3,


in EIA Report.

Unit has ETP, RO, Spray dryer.

34

There is not any underground

connection taken.

15 Details of ETP including dimensions of each unit

along with schematic flow 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 the details of ETP, Please


2 TABLE 2.3 (Page No. 186) in

EIA Report.

16 Technical details of proposed spray dryer including

capacity, fuel to be used, adequacy etc. Techno-

economical viability of the proposed incinerator.

Control measures proposed for the incinerator in

order to avoid/reduce gaseous emission NOC from

incineration of industrial effluent containing

solvents & other chemicals.

For the Technical details of

proposed Spray dryer, Please


2 (Page No. 193-196) in EIA

Report.

NOC Annexure-10 in EIA report

page no. 589

17 Technical details of RO/NF system. For the Technical details of RO

system, Please refer Section

2.4.3.2, Chapter – 2 (Page

No.190-192) in EIA Report.

18 Undertaking stating that a separate electric meter

will be provided for the ETP, RO system, stripper &

spray dryer.

For the Undertaking stating that

a separate electric meter will be

provided, Please refer Annexure

– 9 in EIA Report.page no. 588

19 Economical and technical viability of the effluent

treatment system to achieve zero liquid discharge

(ZLD).

For the Economical and

technical viability of the effluent

treatment system to achieve

Zero Liquid Discharge (ZLD),

please refer section 2.4.3.2,

Chapter – 2 (Page No. 209) in

EIA Report.

20 Certification of adequacy of proposed ZLD scheme

through credible institutes of national repute.

Annexure-15 page no. 655

21 To estimate & monitor ground water quality & its

contamination status, piezometer wells, one 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 10:500 for potable water standard shall be

monitored.

For the section 3.4 page no.

234-238 chepter-3 in EIA report.

22 Proposal to provide and maintain separate electric

meter, operational logbook for effluent treatment

Company will install and

maintain separate electric

35

systems, online meters for monitoring of flow, ph,

TOC/COD, etc.

meter, operational logbook for

effluent treatment system,

online meters for monitoring of

flow, pH, TOC / COD etc.

Annexure-9 page no.588

23 Application wise break-up of effluent quantity to be

recycled / reused in various applications like

sprinkling for dust control and green belt

development etc. In case of land application,

details on availability of sufficient open land for

utilizing effluent for plantation / gardening. How it

will be ensured that treated effluent won't flow

outside the premises linked with storm water

during high rainy days.

For the Application wise break-

up of effluent quantity to be

recycled / reused in various

application, please refer

Section 2.4.3,


in EIA Report.

24 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.

For the plans for management,

collection and disposal of waste

streams to be generated from

spillage, leakages, vessel

washing, used container

washing etc., Please refer

Section 7.4.5.3, Chapter – 7


25 One season site-specific micro-meteorological data

using temperature, relative humidity, hourly wind

speed and direction and rainfall should be

incorporated.

For the one season Site-specific

micro-meteorological data,

Please refer Table 3.5, Section

3.1, Chapter – 3 (Page No. 220)

in EIA Report.

26 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.

For the anticipated

environmental impacts due to

the proposed project, Please

refer Chapter – 4 in EIA Report.

27 One complete season base line 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 the revised national

ambient air quality standards as well as project

specific parameters. Locations of the monitoring

stations should be so decided so as to take into

consideration the pre-dominant downwind

direction, population zone and sensitive receptors.

There should be at least one monitoring station in

For Ambient Air Quality data,



in EIA Report.

Ambient Air Quality monitoring

carried out during the study

period of March, 2017 to May,

2017.

36

the upwind direction. There should be at least one

monitoring station in the pre dominant downwind

direction at a location where maximum ground

level concentration is likely to occur.

Ambient Air Quality Monitoring

(AAQM) locations were selected

based on guidelines of ambient

air quality network siting

criteria of CPCB.

All AAQM locations were

selected within the study area

of 10 km radial distance from

the project site.

Vagra and juned, villages are in

upwind direction.

Saykha , Kothia, Bhersam,

Khojbal, Keshrol villages are in

Base line study.

28 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 satellite image /

geographical area map.

For the wind rose diagram,

Please refer Figure 3.1A,

Chapter – 3 (Page No. 221)

For the details regarding Air

Dispersion Modeling and

Contours, Please refer Chapter

– 4 (Page No. 209-304) in EIA

Report.

29 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.

For the Base line status of noise,


Chapter – 3 (Page No.230) in

EIA Report.

For the proposed measures for

noise reduction, Please refer

Section 7.4.4, Chapter – 7 (Page

No. 520) in EIA Report.

30 Specific details of

(i) process gas emission from each unit process

with its quantification,

(ii) air pollution control measures proposed for

process gas emission,

(iii) adequacy of the air pollution control measures

For the details of process gas

emission, Please refer Section

2.4.4, Chapter –2, Table-2.6

(Page No.210) in EIA Report.

For the details of Air pollution

Control Measures proposed for

process gas emission, Please

refer Section 2.4.4, Chapter –2

Table-2.6 (Page No.210) in EIA

Report.

37

for process gas emission, measures to achieve the

GPCB norms

(iv) details of the utilities required

(v) type and quantity of fuel to be used for each

utility

(vi) flue gas emission rate from each utility

(vii) air pollution control measures proposed to

each of the utility along with its adequacy

(viii) List the sources of fugitive emission along with

its quantification and proposed measures to

control it.

N.A

For the Details of the utilities

required, Please refer Section

2.5, Chapter – 2 (Page No.217)

in EIA Report.

Type and quantity of fuel to be

used for each utility, Please

refer Section 2.6, Chapter – 2


For the details of Flue gas

emission rate from each utility,

Please refer Section 2.4.4,

Chapter –2 Table-2.6(Page No.

210) in EIA Report.

For the air pollution control

measures, Please refer Section

2.4.4, Chapter –2 Table-

2.6(Page No. 210) in EIA Report

and for the adequacy, please

refer Annexure –15.Page no.

655

For the details of fugitive

emission, Please refer Section

7.4.3.2, Chapter – 7 (Page

No.518) in EIA Report.

31 Details on management of the hazardous wastes to

be generated from the project stating detail of

storage area for each type of waste, its handling, its

utilization and disposal etc. How the manual

handling of the hazardous wastes will be

minimized.

Methodology of de-contamination and disposal of

discarded containers and its record keeping.

For the details on management

of the hazardous wastes Please

refer Section 2.4.6, Chapter – 2

Table-2.6 (Page No. 211) in EIA

Report.

For methodology of

decontamination and disposal

of discarded containers and its

record keeping, Please refer

Section 7.14, Chapter – 7 (Page

No. 542) in EIA Report.

32 Membership of common environmental

infrastructure including the TSDF / common

Please refer Annexure-10 in EIA

report page no.589

38

incineration facility, if any.

33 Name and quantity of each type of solvents to be

used for proposed production. Details of solvent

recovery system including mass balance, solvent

loss, recovery efficiency feasibility of reusing the

recovered solvents etc. For each type of solvent.

For the Name and quantity of

each type of solvents to be used

for proposed production Please


(Page No.534) in EIA Report.

34 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.

Please refer Chepter-7 in EIA

report

35 Permission from peso, nagpur for storage of

solvents, other toxic chemicals, if any.

We shall take permission from

PESO after getting CTE/NOC.

36 Occupational health impacts on the workers and

mitigation measures proposed to avoid the human

health 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 impact on the workers. Plan

for periodic medical checkup of the workers

exposed. Details of work place ambient air quality

monitoring plan as per Gujarat factories rules.

For the information on

occupational health impacts on

the workers and proposed

mitigation measures, Please

refer, Section 7.6, Chapter – 7


37 Details on volatile organic compounds (vocs) from

the plant operations and occupational safety and

health protection measures.

For the Details on volatile

organic compounds (VOCs)

from the plant operations and

occupational safety and health

protection measures, please



38 Risk assessment including prediction of the worst-

case scenario and maximum credible accident

scenarios should be carried out. The worst-case

scenario should take into account the maximum

inventory of storage at site at any point of time.

The risk contours should be plotted on the plant

layout map clearly showing which of the facilities

would be affected in case of an accident taking

place. Based on the same, proposed safeguard

measures including on-site / off-site emergency

plan should be provided.

For the predicted worst-case

scenarios and maximum

credible accident scenarios,

Please refer Section 6.1.5.2.3,

Chapter – 6, (Page No. 364) in

EIA Report.

39 MSDS of all the products and raw materials. Please refer Annexure-12 in EIA

39

Report. page no. 592

40 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.

For the details of hazardous

characteristics and toxicity of

raw materials and products,

Please refer Table 6.3, Chapter

– 6 (Page No. 330) in EIA

Report.

41 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, size of the biggest storage

tank to be provided for each raw material &

product etc. How the manual handling of the

hazardous chemicals will be minimized ?

The details are referred as Table

6.1, Chapter – 6 (Page No.326)

in EIA Report.

42 Details of the separate isolated storage area for

flammable chemicals. Details of flame proof

electrical fittings, DCP extinguishers and other

safety measures proposed. 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.

Flame proof electrical fittings

should be provided.

For the Detailed fire control

plan, please refer Section 6.1.9,


EIA Report.

43 Submit checklist in the form of do's & don'ts of

preventive maintenance, strengthening of HSE,

manufacturing utility staff for safety related

measures.

Please refer Annexure-13 in EIA

report page no. 647

44 Detailed five year greenbelt development program

including annual budget, types & number of trees

to be planted, area under green belt development

[with map], budgetary outlay; along with

commitment of the management to carry out the

tree plantation activities outside the premises at

appropriate places in the nearby areas and

elsewhere.

For the detailed five year

greenbelt development

program, please refer Section

7.5, Chapter – 7 (Page No. 526)

in EIA Report.

45 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.

For Detailed socio-economic

development measures, please



46 A tabular chart for the issues raised and addressed

during public hearing/consultation and

Public hearing is exmpted.

Unit is located Saykha industrial

40

commitment of the project proponent on the same

should be provided. An action plan to address the

issues raised during public hearing and the

necessary allocation of funds for the same should

be provided.

estate, PCPIR

47 (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.

For the detail of Environment

Policy, please refer Section

7.3.1, Chapter – 7 (Page No.

507-509) in EIA Report.

For the detail of Environment

Policy, please refer Section

7.3.1, Chapter – 7 (Page No.

507-510) in EIA Report.

48 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.

For the hierarchical system or

administrative order of the

company to deal with the

environmental issues, please

refer Figure 7.1, Chapter – 7


49 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.

Company will have a system of

reporting of non compliances /

violations of environmental

norms to the Board of

directions of the company.

50 Phase wise project implementation schedule with

bar chart and time frame, in terms of site

development, infrastructure provision, EMS

implementation etc.

For the Phase wise project

implementation schedule,

please refer Section 2.8,


EIA Report.

51 Certificate of accreditation issued by the nabet, qci

to the environmental consultant should be

incorporated in the eia report.

Please refer Annexure- 14 in EIA

Report. page no.650

52 A tabular chart with index for point-wise

compliance of above TORS.

Complied.

M/S. NUTRAPLUS INDIA LTD. (UNIT-II)

ENVIRONMENTAL IMPACT & RISK ASSESSMENT REPORT

EIA Report prepared by: M/s. Aqua-Air Environmental Engineers Pvt. Ltd. 40

CHAPTER – 1:

INTRODUCTION

1.1 JUSTIFICATION AND BACKGROUND

• NPIL was incorporated as a private limited company in Feb., 1990 and was turned

into a public limited company in June, 1992.

• Manufacturing unit was commissioned to make APIs and Intermediates in 1995.

• NPIL is engaged into manufacturing of APIs & intermediates. NPIL has been

undertaking contract manufacturing activities since 1998 for companies like Cemagis

Israel, Kofflok, Israel, Calyx Chemicals, Alkem, India and many more Indian

companies.

M/s. Nutraplus India Ltd. (Unit-II) now proposes Bulk Drugs & Bulk Drug Intermediates unit

at Plot No. C-198, Saykha Industrial Estate, Tal: Vagra, Dist: Bharuch, Gujarat. The proposed

project is to be set up within the land area of 16,067.36 m2 out of which approximately

5,300.36 m2 land area (33 %) will be used for greenbelt development. The total estimated

cost of the project is Rs. 50 Crores. Capital cost of air & water pollution control system and

environmental monitoring equipments will be Rs. 5 Crores. Recurring cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 1.8 Crores

per annum.

1.1.1 NEED FOR THE PROJECT AND ITS IMPORTANCE TO THE COUNTRY AND OR REGION

The demand for products intended to be manufacture is increasing in the international as

well as domestic market. By establishing this unit, M/s. Nutraplus India Ltd. (Unit-II) will be

able to meet the demand of various products in foreign countries. The project will earn

forex. This will also generate direct and indirect employment opportunity for various levels

of people in the state of Gujarat. Based on our informal survey of the market with our




current customers and various traders, we have found that there is a big potential for the

range of the products we are proposing.

1.1.2 PROMOTERS AND THEIR BACK GROUND

Identification of the project proponent

The main promoters are:

• CMD – Mr. Mukesh Dhirubhai Naik (B.E. Chemical) (59 Years): (New Projects, Expansion &

Finance)

• Tech. Director – Mr. Dilip Pimple (B.E. Chemical) (47 years): (Production & Entire Factory

Operations)

• Director – Mr. Uday Mukesh Desai (B. E. Chemical) (31 Years): (Procurement, Business

Development & Office Operations)

• CFO – Mr. Chandresh Shukla ( B. Com , A.C.A.) (28 Years): (Finance, Taxation & Accounts)

• Executive Q. C. – Mr. Bipin Patel (M.Sc.) (47 Years): (Quality Control)

• Executive Q. A. – Mrs. Sonu Uday Desai (M. Pharm) (26 Years): (Quality Assurance)

1.1.3 REGULATORY FRAMEWORK

For proposed project; following assumptions has been considered:

• Project Cost: Rs. 55 Crore.

• Capacity of Plant 400 MT/Month

• Total working days in a year 330

• Land Area: 16,067.36 m2

• The products will be used indigenously as well as exported.

• Indigenous raw materials will be available for the plant.




TABLE 1.1

BREAK-UP OF PROJECT COST

Sr.

No. Description

Project Cost

(Rs in Crores)

1 Land Cost 2.3

2 Building 12.7

3 Plant & Machinery 30

4

Environment Management System (includes cost of

ETP, Tree Plantation, Evaporator System, Rain Water

Harvesting, etc.)

10

Total Project Cost 55

1.1.4 BREAK UP OF DIFFERENT LAND USE OF FACTORY

TABLE 1.2

LAND BREAKUP

Total Plot Area: 16,067.36 m2

SR.

NO.

PLOT AREA USAGE AREA Area (m2)

1 PLANT BUILDING AREA, STORAGE AREA

UTILITY AREA, OFFICE BUILDING AREA

LAB AREA

8000

2 ETP AREA 600

3 GREEN BELT 5,300.36

4 OPEN AREA+ROAD AREA + PARKING AREA 2,167

TOTAL 16067.36




FIGURE - 1.1

LOCATION OF THE PROJECT SITE




FIGURE - 1.2

LAYOUT OF THE PLANT




TABLE 1.3

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

SR.

NO.

PRODUCT NAME CAS NO. PROPOSED

CAPACITY

(MT/MONTH)

END USE

1 Ibuprofen 15867-27-1

400

Anti-Inflammatory

2 Diclofenac Sodium 15307-79-6 Anti

3 Aceclofenac 89796-99-6 Anti

4 Nimesulide 51803-78-2 Anti

5 Chlorzoxasone 95-25-0 Anti

6 Mefenamic Acid 61-68-7 Anti

7 Mesalamine 89-57-6 Anti

8 Albendazole 54965-21-8 Anti-Worm medication

9 Febendazole 43210-67-9 Anti-Trematode therapeutic

10 Mebendazole 31431-39-7 Anti-Worm medication

11 Metronidazole 443-48-1 Antibiotics

12 Metronidazole Benzoate 22916-47-8 Antibiotics

13 Tinidazole 19387-91-8 Antibiotics

14 Ornidazole 16773-42-5 Antibiotics

15 Oxyclozanide 2277-92-1 Anthelmintic

16 Roxarsone 121-19-7 Anthelmintic

17 Chlorpheniramine Maleate

(C.P. Maleate)

113-92-8 Antihistamines

18 Bromhexine Hcl 611-75-6 Antioxident/Expectorant

19 Ambroxol Hcl 23828-92-4 Secretolytic

20 Phenyleffrine Hcl 61-76-7 Decongestant

21 Dexo Metherphan Hbr 6700-34-1 Antihistamines

22 Salbutemol Sulphate 51022-70-9 Antihistamines

23 Theophyllin 58-55-9 Xanthines




24 Caffein 58-08-2

Ergotamine

25 Theobromine 83-67-0 Vasodilator

26 Ciprofloxacin 85721-33-1 Antibiotics

27 Oflaxacin 82419-36-1 Antibiotics

28 Enrofloxacin 93106-60-6 Antibiotics

29 Sildinafil Citrate 171599-83-

0

pulmonary arterial

hypertension

30 Tramadol HCL 27203-92-5 Analgesic

31 Lumefantrine 82186-77-4 Antimalarial

32 Aluminium Hydroxide

Gel/Powder

21645-51-2 Antacid

33 Ampicillin 69-53-4 Antibiotics

34 Amoxicillin 26787-78-0 Antibiotics

35 Cloxacillon 61-72-3 Antibiotics

36 Cephalexin 15686-71-2 Antibiotics

TOTAL 400

MT/MONTH

1.2 PROJECT SETTING

M/s. Nutraplus India Ltd. (Unit-II) is located in Saykha Industrial Estate at longitude 72° 49’

31.70” E and latitude 21° 47’ 04.91” N. Detailed Layout map of the plant is shown in Figure –

1.2.

M/s. Nutraplus India Ltd. (Unit-II) located near Bharuch and Vadodara which are all

important industrial and commercial centers of Gujarat and India. The nearest railway

station is Bharuch on broad gauge section of Western Railway Line. The station is located at

about 21 km from the project site. M/s. Nutraplus India Ltd. (Unit-II) is well connected from

Bharuch-Dahej highway by road transport. Nearest Airport is at Vadodara, which is located

at a distance of about 90 km from project site.




The nearest city is Bharuch, which is about 21 km away. Water for industrial purpose shall

be available from GIDC water supply. Development of Communication systems is good in

the region due to proximity to Bharuch and Vadodara.

The salient features of the site are as under:

1. Minimum distances:

a) From City : Bharuch 21 km

b) Village : Saykha 0.63 km

c) Historical Site : None

d) Sanctuaries : None

e) Highway : State highway No. 64

f) Sea coast : 13 km

2. Use of forest land : None

3. Use of prime agricultural land: None

4. Planned submergence : None

5. Displacement of population : None

1.2.1 KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

1.2.1.1 METHOD OF DATA PREPARATION

Key infrastructure features have been extracted from Survey of India (SoI) topographical

maps of 1:50,000 scale. The features have been updated using satellite data and have been

verified with ancillary information derived from TTK maps and guide maps. The locations of

the settlement have been extracted from Census of India (CoI) maps and verified by using SoI

topographical maps and satellite data.

1.2.1.2 DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

The distance of railways and National and State highways are presented in Table 1.3 below.




TABLE 1.4

___________________________________________________________________________

DISTANCE OF NEAREST KEY INFRASTRUCTURE FEATURES FROM PROJECT SITE

Sr. No. Nearest Infrastructure Feature Distance from Project Area

1 Village Saykha 0.51 km in South Direction

2 NH-8 13 km in East Direction

3 District Headquarter – Bharuch 20 km East Direction

4 SH-6 11 km in East Direction

5 Narmada River 11.0 km in South Direction

6 Ahmedabad Airport 148 km in North Direction

1.2.1.3 MAP OF KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS

A map depicting administrative boundaries up to Taluka level, showing locations of towns

and villages along with National and State highways, major and medium roads and railways

is presented as Figure 1.3. The map also shows the water bodies for better understanding of

project area. The map marks the area within 10 km with the project site as the center.




FIGURE – 1.3

KEY INFRASTRUCTURE FEATURES AND SETTLEMENTS




FIGURE – 1.4

SATELLITE IMAGERY




FIGURE – 1.5

TOPOSHEET




1.3 PURPOSE OF EIA

The EIA study is carried out to assess the pollution potential and evaluate the adequacy and

efficiency of proposed Pollution Control & Environmental Management System.

1.4 OBJECTIVES OF EIA

The main objectives of the study are

1) To assess the background environmental status,

2) To identify potential sources of pollution,

3) To predict and evaluate the impact on environment along with pollution control

measures taken and

4) To prepare a comprehensive Environment Management Plan and Disaster

Management Plan.

1.5 METHODOLOGIES FOR EIA

Taking into consideration proposed expansion project activities and guidelines, an area of 10

km radius from the center of the project has been selected and is designated as the study

area for the purpose of EIA studies.

1.5.1 Base Line Condition

The samples of ambient air, ground and surface water and soil are collected and analyzed as

per the standard methods for establishing the baseline data and to determine the impact of

proposed activity on the same.

1.5.1.1 Ambient Air Environment

The air environment around the plant was studied by setting up seven locations within the

study area of 10 km radius from the project site and collection and monitoring the site

specific meteorological data, viz. wind speed, wind direction, humidity, rainfall and ambient

temperature was carried out. Design of network for ambient air quality monitoring locations

is based on guidelines provided by CPCB. The ambient air samples were collected and

analyzed for SPM, PM10, PM2.5, SO2, NOX, HCl, Cl2, O3, Pb, CO, NH3, C6H6, Benzo (a) Pyrene




(BaP), Arsenic (As), Nickel (Ni) & VOCs for identification, prediction, evaluation and

assessment of potential impact on ambient air environment.

1.5.1.2 Ground And Surface Water Environment

The water required for domestic and industrial use is being made available from surface

water. Hence, to assess the physico-chemical quality of the water, a number of water

samples were collected and analyzed for pollution parameters viz., pH, TDS, Turbidity, BOD3,

COD, Fluorides, Chlorides, Sulphates, Nitrates, Ammonical Nitrogen, Hardness, Alkalinity, Oil

& Grease and some heavy metals in order to find out the contamination, if any.

1.5.1.3 Noise Environment

Noise pollution survey was conducted in the study zone. The anticipated noise sources were

industrial activities, which are likely to be increased due to proposed activity. Noise levels

were also recorded in surrounding villages for evaluating general scenario of the study area.

Hourly equivalent sound levels (Leq) were also recorded for calculating Day and Night noise

levels in the surrounding villages.

1.5.1.4 Soil Environment

Soil sampling and analysis was carried out to assess physico-chemical characteristics of the

soils and delineate existing cropping pattern, existing land use and topography, within the

study area.

1.5.1.5 Biological Environment

Keeping in view, the importance of biological component of total environment due to the

proposed project, biological characterization of terrestrial and aquatic environments,

changes in species diversity of flora and fauna in terrestrial as well as aquatic systems were

studied for impact analysis due to proposed project activity, if any.

1.5.1.6 Socio-economic Environment




Demographic and related socio-economic data was collected from census handbook to

assess socio-economic status of the study area. Assessment of impact on significant

historical, cultural, and archeological sites/places in the area and economic and employment

benefit arisen out from the project is given special attention.

1.5.2 Identification of Pollution Source

Detailed study of manufacturing process for proposed scenario is carried out along with

input and output of materials, water, and wastewater as well as infrastructure facilities

available.

1.5.3 Evaluation of Pollution Control and Environmental Management System

The qualitative and quantitative analysis of various pollution sources as well as evaluation of

pollution control system is carried out.

1.5.4 Evaluation of Impact

A comprehensive evaluation of environmental impact with reference to proposed activities

is carried out.

1.5.5 Preparation of Environmental Management Plan

A comprehensive Environmental Management Plan has been prepared covering all the

aspects of pollution prevention measures, Air and Water Pollution Control measures,

Hazardous Waste Management, Environmental Surveillance and Environmental

Management Plan.

The present report is an EIA conducted during Pre-Monsoon, 2017 (March, 2017 to May,

2017). The baseline environmental conditions have been established through field

monitoring and literature survey. The contents of EIA report, details of data collection and

source of secondary data are presented in Figure 1.6.

1.6 STRUCTURE OF REPORT




The objective of the EIA study is preparation of Environment Impact Assessment (EIA) report

based on the guidelines of the Ministry of Environment, Forest & Climate Change (MoEFCC),

CPCB and GPCB. It incorporates the following.

• Chapter 1 is an Introduction to the Industry, their premises and surrounding areas. It

also expresses the basic objectives and methodologies for EIA studies and work to be

covered under each Environmental component.

• Chapter 2 presents a Description of Project and Infrastructural facilities including all

industrial and environmental aspects of M/s. Nutraplus India Ltd. (Unit-II) as well as

manufacturing process details. This chapter also gives information about raw

material storage and handling, water and wastewater quantitative details, air

pollution and control system, Hazardous Waste generation, storage facility and

disposal and utilities for proposed plant capacity. It also provides information about

proposed Environmental Management Facilities to be available at the project site.

• Chapter 3 covers Baseline Environmental Status including meteorological details,

Identification of baseline status of Environmental components of the surrounding

area covering air, water and land environment. Also presents a study of land use

pattern, Biological Environment & Socio-Economic Environment giving details about

District Bharuch, Taluka Vagra and the study area in terms of land use pattern,

biological environment, and socio-economic environment.

• Chapter 4 deals with Anticipated Environmental Impacts & Mitigation Measures,

which provides quantification of significant impacts of the proposed activities of

plant on various environmental components. Evaluation of the proposed pollution

control facilities has been presented.

• Chapter 5 deals with Environmental Monitoring Plan

• Chapter 6 describes Risk assessment and Disaster management plan that shall be

adopted by the company.

• Chapter 7 describes Environment Management Plan (EMP) to be adopted for

mitigation of anticipated adverse impacts if any and to ensure acceptable impacts.

• Chapter 8 describes Executive Summary of the Project.

• Chapter 9 describes Details of Consultants Engaged.




FIGURE 1.6

____________________________________________________________________________________________________________________

ACTIVITIES, SOURCES OF INFORMATION AND CONTENTS OF EIA REPORT

RECONNAISSANCE SURVEY OF PLANT

ANNUAL REPORT

MARKET ASSESSMENT

PROJECT REPORT

INTRODUCTION

MONITORING OF AIR, WATER & SOIL QUALITY & NOISE

LEVELS

DATA ON METEOROLOGY, SOCIO-ECONOMIC STATUS &

BASIC AMENITIES

SITE VISITS AND INTERVIEWS WITH LOCALS

BASELINE

ENVIRONMENTAL

STATUS

CENTRAL GROUND WATER BOARD

GUJARAT POLLUTION CONTROL BOARD (GPCB)

PUBLIC HEALTH ENGINEERING DEPT

AGRICULTURE DEPARTMENT

FOREST DEPARTMENT

IRRIGATION DEPARTMENT

EMPLOYMENT EXCHANGE

HEALTH CENTER

CENSUS OF INDIA

INDIAN METEOROLOGICAL DEPT

ENVIRONMETAL INFORMATION CENTRE

SOCIOECONOMIC

STATUS &

INFRASTRUCTURE

PROPOSED

PLANT

FACILITY DESCRIPTION

IMPACTS

METHODOLOGY OF

IMPACT

ASSESSMENT

IDENTIFICATION & ASSESSMENT OF IMPACTS

EVALUATION OF IMPACTS BY MATRIX METHOD

SOURCE OF INFORMATION OVERVIEW OF

E. I. A. STUDIES ACTIVITIES

ENVIRONMENTAL

MANAGEMENT PLAN

DESCRIPTION OF EFFLUENT TREATMENT PLAN, AIR

POLLUTION CONTROL, HAZARDOUS WASTE

MANAGEMENT, GREEN BELT DEVELOPMENT

MONITORING PROGRAM

CONSEQUENCE ANALYSIS

PREPARATION OF DISASTER MANAGEMENT PLAN

RISK ASSESSMENT

STUDIES &

DISASTER

MANAGEMENT PLAN

SAFETY, HEALTH & ENVIRONMENTAL POLICY GUIDELINES BY

DIRECTOR GENERAL OF FACTORY SAFETY, MINISTRY OF LABOR




CHAPTER – 2:

PROJECT DESCRIPTION & INFRASTRUCTURAL FACILITIES

2.1 BACKGROUND

M/s. Nutraplus India Ltd. (UNIT-2) proposes Bulk Drugs & Bulk Drug Intermediates unit at Plot

No. C-198, Saykha Industrial Estate, Tal: Vagra, Dist: Bharuch, Gujarat.

2.2 MANUFACTURING ACTIVITIES

Manufacturing activities proposed in the project include various processes. The activities shall

also include operation of various utilities. The manufacturing process is described in details in

following sections. The list of products and their capacity is given in Table 1.1.

PROCESS DESCRIPTION

1. IBUFROFEN

Process Description:

Step 1:Charge IPA,MCA, Sulphuric Acid under stirring at RT. Maintain the temperature for 8 to 9

hrs. Charge soda ash & water at 50-52oC.Star heating and distll out IPA using vacuum. Separate

aqueous layer and transfer batch to other reactor and cool to 40 oC, filter with nutch filter, final

product being Isoproply Chloroacetate

Step 2: Charge EDC, AlCl3, & cool to 9oC. Add acetyl chloride in 2-3 hrs maintaining temp at

8oC.Charge IBB maintaining the reaction mass 3 hrs at 0 to 6

oC.Quench reaction mass 3 to 5 hrs.

Transfer organic layer in reactor and discard aqeous layer. Adjust pH with Ammonia, heat

organic layer to 70oC and distill out EDC. Filter the wet Isobutyl Acetophenone with Nutch filter.

Step 3:Charge IPA ,moisture nmt than 0.20%.Under nitrogen purging ad sodium metal with

slow heating of about 50 oC. Maintain temperature at 65

oC until complete dissolution of sodium

metal.




Step 4:Charge Isobutyl Acetophenone and Isopropyl Chloro Acetate to the above reaction mass,

stir 10-15 mins at RT. Maintain 5-6 hrs at 9-15 oC. Charge water and caustic lye at RT, heat to

90-95 oC and then distill off IPA completely if any. Separate the organic Aldehyde layer.

Stage 5: Charge Sulphuric Acid and water in separate tanks and transfer acid water to reactor

.Charge acetone and mix the solution. Charge sodium dichromate.

Step 6:Transfer acid water to reactor and cool to 10-15 oC. Start addition of Aldehyde pure,

maintain temp between 10-12 oC.

Step 7: Transfer the reaction mass and flush reactor with RO water ,cool to 40oC and add

hexane. Cool the material to 20 oC and maintain 2 hrs, then heat to 35

oC and maintain for 2 hrs

cool to 0-3 oC and maintain for 4 hrs. Centrifuge wash with hexane, unload and dry the

Ibuprofen and send for packing.

Chemical Reaction for Ibuprofen:

STAGE 1

C2H3ClO2

MCA

IPA ,

SOAD ASH ,

SULPHURIC ACID,

ISOPROPYL

CHLOROACETATE

(IPCA)

STAGE 2




Iso Butyl Benzene

ALLUMINIUM

CHLORIDE , ACETYL

CHLORIDE (CH3COCl) ,

AMMONIA SOLUTION ,

HCL

ISO BUTYL ACETO

PHENONE

(IBAP)

STAGE 3

ISO BUTYL ACETO

PHENONE

(IBAP)

ISOPROPYL

CHLOROACETATE

(IPCA)

IPA , FERRIC

CHLORIDE,

SODIUM

METAL, C.S

LYE, WATER

STAGE 4

Na2Cr2O7

(ALDEHYDE PURE) SODIUM DICHROMATE H2SO4,

ACETONE

Ibuprofen (C13H18O2)

[2-(4 ISO

BUTYLPHENYL)-

PROPANIC ACID]




Material Balance:

Input MT Output MT

MCA 0.25 IPA RECOVERED 0.66

IPA 0.91 ML TO ETP 1.34

SULPHURIC

ACID 0.27

EDC RECOVERY 1.28

SODA ASH 0.10 EDC LOSS 0.02

WATER 3.00

ALUMINIUM

HYDROXIDE

MANUF 0.17

ISO BUTYL

BENZENE 0.23

IPA LOSS 0.25

ALUMINIUM

CHLORIDE 0.20

ACETONE LOSS 0.15

EDC 1.30

RECOVERED

ACETONE 1.33

AMMONIA

SOLUTION 0.12

N HEXANE

RECOVERED 1.20

HCL 0.21 IBUPROFEN 1.00

ACETYL

CHLORIDE 0.11

N HEXANE LOSS 0.06

SODIUM METAL 0.17

EFFLUENT TO

SOLVENT

STRIPPER 1.5

C.S.LYE 0.50

ACETONE

RECOVER 1.33

SODIUM

DICHROMATE 0.19

ACETONE 1.48

N-HEXANE 1.26

10.29 10.29




2. DICLOFENAC SODIUM

Process Description

1. Charge 2,6 DCP, Toluene and Potassium carbonate, heat to 110-115 OC for 2 hrs and

remove Toluene. Charge MCA and reflux 4 Hr at temperature 115 OC. Charge Aniline and

sodium Methoxide solution. Chill to 4-7 OC and centrifuge wash with water and spin dry

and unload.

2. Charge Reaction mass from Step 1 with Toluene, Sulphuric acid and heat to 75 OC, distill

out toluene, charge CAC, heat and reflux for 20 HRS. Chill to 15 OC and centrifuge mass.

3. Charge ,stage 2 mass and alluminium chloride and raise temperature to 140 OC, stop

heating temperature will reach up to 190 OC, then quinch in water. Then centrifuge the

wet cake in another reactor, charge water and HCL and charge wet cake, centrifuge the

mass and wash with water.

4. Charge stage 3 mass with caustic potash, water ,sodium Hydrosulphite and reflux for 8

hrs. Check TLC and then charge another 10 kg extra caustic flakes. cool to 25-30 OC

5. Charge Stage 4 mass, DM water, EDTA, Activated Carbon and IPA, heat to 80 OC till

dissolution, Check pH 10-13. Charge IPA, Carbon and stir for 30 mins and then filter and

centrifuge the mass with chilled wash of IPA.




Chemical Reaction:

STAGE-1

2,6DCP(C6H4Cl2O)

+ MMCA

TOLUENE

(C7H8)

STEP I

(2,6-DICHLORO

PHENYLAMINE)

2,6 Dichloro phenol

ANILINE (C6H5NH2)

SODIUM METHOXIDE

(CH3NaO)

STAGE-2

STEP I

(DIAMINE)

2,6-DICHLORO

PHENYLAMINE

+ CHLORO

ACETYL CHLORIDE

TOLUENE

SULPHURIC

ACID

STEP II

(

N-CHLOROACETYL, 2,6-

DICHLORO

PHENYLAMINE )

STEP II

(N-CHLOROACETYL,

2,6-DICHLORO

PHENYLAMINE)

+ ALLUMINIUM CHLORIDE

STEP III

(

(1-(2,6-

DICHLOROPHENYL) 2-

INDOLINONE))

STEP III

(

1-(2,6 -

DICHLOROPHENYL)

2-INDOLINONE)

+

SODIUM.H.SULPHITE

CAUSTIC FLAKES

WATER

STEP IV (DICLOFENAC

SODIUM

CRUDE)




STEP IV

(DICLOFENAC

SODIUM

CRUDE)

+

IPA

CARBON EDTA

DICLOFENAC SODIUM

PURE

Material Balance:

Input MT Output MT

2,6 DICHLORO PHENOL 0.75 ML TO ETP 2.65

TOLUENE 3.03 METHANOL 0.60

POTASSIUM

CARBONATE 0.40

DICLOFENAC

SODIUM 1.00

MONO METHYL CHLORO

ACETIC ACID 0.55

TOLUENE 2.88

ANILINE 0.42 TOLUENE LOSS 0.15

SODIUM METHOXIDE

SOLUTION 0.20

ALUMINIUM

HYDROXIDE

GEL/POWDER 0.50

WATER 2.36 SPENT CARBON 0.03

CHLORO ACETYL

CHLORIDE 0.32

EFFLUENT TO

SOLVENT STRIPPER 1.3

ALLUMINIUM CHLORIDE 0.50

HCL 0.09

CAUSTIC FLAKES 0.48

CARBON 0.03

9.14 9.14




3) ACECLOFENAC

Brief Process of ACECLOFENAC

1. Charge N Dimethyl Amine , Tertiary Butyl Alcohol stirr 1/2 Hrs & unload in clean drum,

again charge Chloro Acetyl Chloride in same reactor chill to 8-10OC.Add mix solution of

NNDMA + T Butanol at 8-10 O

C addition time 8-10hrs. Maintain 5 hrs at 8-10 O

C, slowly

raise Temp up to 35 O

C.

2. Charge water, stirr 1.0 Hr & settle, seperate organic layer from bottom aqueous layer

for NN DMA recovery, organic Layer charge in GLR add water, stirring & separate

bottom organic to give soda ash solution wash to make ph 8.5 to 9.5.

3. Stirr & separate in organic layer, charge sodium sulphate & filter through 5 Micron

cloth. Collect all organic in GLR and Distilled out product at 85 to 105 O

C under vacuum.

4. Charge Reaction mass from Step 2 with crude Diclofenac Sodium, heat the reaction

mass to 80-85 OC, maintain 5 Hrs and cool to 55 to 60

OC, charge formic acid heat to 48

to 55 O

C maintain 8 hrs check TLC, cool to 40 OC, charge water and Toluene stirring 2 Hrs

Centrifuge wash with water. centrifuge and Unload cake & Dry.




Chemical Reaction:

Stage 1:

+ +

Chloro Acetyl Chloride Tertiary Butyl Alcohol DMA Tert Buyl

Chloroacetate

Stage 2:

+ +

Tert Buyl Chloroacetate Diclofenac Sodium Formic Acid

Aceclofenac

Material Balance:

Input MT Output MT

CHLORO ACETYL

CHLORIDE 0.55 ML TO ETP 2.65

TERTIARY BUTYL

ALCOHOL 0.36 OUTPUT 1.00

DI METHYL ANILINE 0.65 REC NN DMA 0.63

SODA ASH 0.01

RECOVERED

TOLUENE 0.98

CAYSTIC LYE 48% 0.45 TOLUENE LOSS 0.05

DICLOFENAC SODIUM 1.03

FORMIC ACID 0.71

TOLUENE 1.03

WATER 0.52

5.31 5.31




4) NIMESULIDE


1. Charge PHENOL and KOH and then heat to 850C and charge ONCB maintain for 4 hrs,

charge water stir for 1 hrs and settle for 1 hr. separate organic layer from bottom for

next step and aqueous to ETP for KCL recovery.

2. Charge organic i.e. step 1 with water, Iron Powder and acetic acid and heat to 110 0C,

maintain for 4 hrs cool to 80 0

C filter all reaction mass through centrifuge collect all ML

to water evaporator. Distill out all water then distilled out step 2 to use in step 3.

3. Charge the NNDMA and step 2 then add Methane Sulphonyl Chloride and heat to 40 0C

maintain for 4 hrs then cool to 20 0

C.

4. Stir for 1 hrs. Centrifuge the material, unload cake for step 4and ML to NNDMA

recovery.

5. Charge the wet cake from step 3 and toluene add HNO3, maintain the temperature at

10 0C and then centrifuge the mass ML for Toluene recovery.

6. Charge the centrifuge mass from step4 and add methanol, carbon and heat to reflux till

clear solution then filter the mass through Sparkler, Collect all ML in another rector cool

to 15 0C, centrifuge the mass unload the wet cake for drying and ML for Methanol

recovery.




Chemical Reaction:

Step 1:

+

Phenol O-chloronitrobenzene O-Phenoxy Nitrobenzene

Step 2:

+H2 Raney-Ni

O-Phenoxy Nitrobenzene O-Phenoxy Aniline

Step 3:

CH3SO2CL

O-Phenoxy Methane

Sulphonide

Step 4:

HNO3

O-Phenoxy Methane Sulphonide Nimesulide




Material Balance:

Input MT Output MT

PHENOL 0.34 KCL RECOVERY OR ETP 0.06

KOH 0.27 SPENT IRON 0.24

ONCB 0.44 ML TO RECYCLE 2.30

WATER 3.54 DMA 0.42

ACETIC ACID 0.01 ML TO ETP 2.13

IRON POWDER 0.24

RESIDUE FROM

METAHNAOL

RECOVERY 0.04

METHANOL 2.21 TOLUENE LOSS 0.05

METHANE SULPHONYL

CHLORIDE 0.36

TOLUENE 0.95

NN DIMETHYL ANILINE 0.44 OUT PUT-Nimesulide 1.00

CARBON 0.02 METHANOL 2.10

CAUSTIC LYE 0.31 METHANOL LOSS 0.11

CONC HNO3 70 % 0.24 SPENT CARBON 0.02

TOLUENE 1.00

9.43 9.43

5. CHLORZOXAZONE





1. Charge Urea, Acetic acid and Hydrochloric acid with 4-Chloro-2- Amino Phenol In the

reactor and heat up to 95 0C and maintain for 1 hr. Check TLC then centrifuge crude

material at 30 0C, then wash with water till neutral pH.

2. Add Charcoal and heat to reflux for 2 hr at 55 0C Filter hot through Sparker, collect clear

filtrate in crystallizer.

3. Collect clear filtrate in crystallizer and keep temp 45 0C in crystallizer. Wash sparklers

carbon bed with Acetone and transfer it to crystallizer.

4. Add Hydrose with water then fast add DM Water 15 minutes at 70 0C. Slowly cool to 40

0C.

5. Apply chilling and chill the material up to 10 oC and maintain for 1 hrs.

6. Centrifuge the material at 10 0C and collect for Acetone Recovery.

7. Wash the cake with DM water till chloride free, unload material and dry at 90 0C, check

LOD and unload from dryer.

Chemical Reaction:

Flow Chart for Chlorzoxazone

4-Chloro-2-Amino

Phenol

+

Urea

+




Acetic acid

Hydrochloric Acid

Sodium hydroxide

Activated Carbon

Methanol

Hyflow

Sodium

Hydrosulphite

Acetone

→

Chlorzoxazone

CAS number :- 95-25-0

Formula :- C7H4ClNO2

Material Balance:

Input MT Output MT

4-CHLORO-2- AMINO

PHENOL (4CAP) 0.95

RECOVERED

METHANOL 2.85

UREA 0.95 METHANOL LOSS 0.15

HYDROCHLORIC ACID 2.04

ML to ETP

(SPENT ACID) 2.5

METHANOL 3.00 CHLORZOXAZONE 1.00

ACTIVATED CARBON 0.11

EFFLUENT TO SOLVENT

STRIPPER 1.2

SULPHURIC ACID 0.10

ACETIC ACID 0.50

SODIUM

HYDROSULPHITE 0.05

7.70 7.70




6. MEFENAMIC ACID


STEP 1

In SS reactor Charge 310 Litres of toluene at room temperature start addition of 2,3-Xylidine

heat to 75-80 o

C & settle for 30 minutes, separate water from bottom, heat to reflux and reflux

for 1 hr & separate water from distillation, Cool to room temperature & give sample to QC for

Xylidine content. Charge 100 OCBA. Make slurry of 44 kg K2CO3 in 18.5 ltr water. Fill water in

jacket charge the K2CO3 slurry slowly to R1, Flush the slurry bucket with 5 ltrs water & add it to

reactor charge 4 kg sodium hydrosulfite charge 44 kg K2CO3 to reactor. Stir for 30 minutes at

RT, Start heating & heat to reflux, Reflux & Separate water by azotropic distillation, Confirm

complete removal of water by one hr. more distillation xylidine content of toluene, cool to 50

to 55 oC, Charge fresh Xylidine start N2 Gas purging charge 10 kg DMF stop N2 gas purging heat

to reflux, Reflux for 12 hrs and remove water by azotropic distillation, confirm complete water

removal by one more hr. distillation start toluene and xylidine distillation and complete it.

charge water to make up volume up to 400 ltrs heat to 90 -95 oC transfer the hot mass to

reactor through sparkler filter with 2 kg Hyflow bed. Pass about 30ltrs water from reactor

through sparkler check ph of filtrate and adjust it to 9.5 with K2co3 if required, charge 155 ltr

toluene to reactor stir for 15 minutes settle for 20 minutes , separate toluene layer from top -A,

Charge 125 ltr Toluene to reactor to reactor stir for 15 minutes , settle for 20 minutes , separate

Toluene Layer from Top -B, charge 95 Ltrs toluene stir for 20 minutes , separate Toluene layer

from Top -D, Total Toluene layer = A+B+C+D, Charge Total Layer to reactor & wash with 30 Ltrs

water. Add this Toluene washed to aqueous layer heat & remove Toluene traces from reaction

mass toluene removed, distilout water such that the volume of R.M is about 370 Ltrs, Cool the

mass to 35 to 40 oC , Chill the mass to 10

oC , stir at 10

oC for 1 hr, Centrifuge in 2 lots, Spin dry

to remove all M.L. wash each lot with 30 ltrs Toluene. Spin dry to remove all Toluene & collect

all Toluene M.L

Step :- II

Check the reactor cleanliness charge 1000 ltr Dm water charge wet 61 kg M.A.K salt, stirr for 20

minutes Add 50 gms EDTA , heat to 75 to 80 o

C , Add 1 ltr Ammonia solution (20%) check clarity




of solution, Charge 3.3 kg Act carbon, Stir for 30 minutes at 75 -80 oC , recycle hot through

Sparkler & Check Clarity of Filtrate , Charge the clear filtrate to clean reactor & cool to RT

Adjust ph to 3 with HCL ( C.P Grade ) at RT ,Chill to 10 oC , Centrifuge & spin dry to remove all

M.l, wash with the water till neutral to PH & free from Chloride spin well & unload.

Chemical Reaction

Chemical Name :- 2,3

Xylidine CAS

Number 87-59-2

+

2-Chloro benzoic acid

cas number :-118-91-2

+

Toluene

Sodium carbonate

Copper acetate

Di methyl formamide

HCI Cp grade

Methanol

Sodium Hydro Sulphite

(Hydrose)

→

Chemical Name:-Mefenamic acid

CAS No.: 61-68-7

Molecular Formula:- C15H15NO2

MATERIAL BALANCE

Input MT Output MT




2-CHLORO BENZOIC

AID 0.48 CRUDE OUTPUT 1.00

2,3-XYLIDINE 0.31 TOLUENE RECOVERED 0.028

TOLUENE 0.03 EFFLUENT 0.52

K2CO3 0.23 PROCESS WASTE 0.10

CUPROUS CHLORIDE 0.00 TOLUENE LOSS 0.002

DMF 0.05

CARBON 0.02

WATER 0.52

HYFLOW 0.01

1.65 1.65




7. MESALMINE

BRIEF MANUFACTURING PROCESS

STEP 1

Preparation of 2-Hydroxy-5-Nitro Benzoic Acid

With Nitration of Ortho Chloro Toluene receive the Ortho Chloro Benzoic Acid again the

nitration of the Ortho Chloro Benzoic Acid we will receive the 2-chloro-5- nitro benzoic acid.

To a stirred solution of potassium hydroxide (70 kg, 1250 mol) and water (250 l) was added 2-

chloro-5- nitro benzoic acid (50 kg ,248 mol) over a period of 20 minutes between 25 to 30 0C in

an autoclave. The reaction mixture was heated to 125-130oC , stirred At the same temperature

for 5 hours under 2.5 kg /cm2. The reaction mass was cooled to 25 oC and acidify to PH 1.0-2.0

using hydrochloric acid (85 L) , stirred for 1 hour. The precipitated solid was filtered and washed

with water (150 L) , and the cake slurried in water (300 L) at 30 Oc for 1 hour, filtered, washed

with water ( 150 L) and dried at 65 oC for 10 hours to afford product 43.5 kg

yield :- 43.5 kg (96 % ) purity :- 99.87 %

1H NMR ( 400 MHZ, DMSO): DELTA 11.2 (s,1H), 8.5 (m,2H), 7.3 ( s ,1H),5.2 (s,1H).MS m/z 183;

Anal Calcd.for C7H5NO5

STEP 2

Preparation of 5-amino-2-hydroxy benzoic acid

2-Hydroxy-5-Nitro Benzoic Acid (40 kg,218 mol) was added slowly to a stirred mixture of water

(320 L ) and sodium carbonate (16.3 kg, 153 mol) . stirred for 30 minutes and the mass ph

maintained between 8.0 and 9.5 . 10 % Raney Nickel (8 L) along with water (80 L) was added to

the above solution. The resultant mixture( 130 L) was added to the mass at 25oC , Stirred for 30

minutes . The catalyst was filtered through celite , and washed with water (80L) . the solution was

acidified to Ph 2.5-3.0 with hydrochloric acid (33L) and stirred for 1 hour. The obtained compound

was filtered , washed with water (40 L ). To the solution of wet cake and water (560 l ) and

hydrochloric acid (41 L) . active charcoal (2.8 kg) was added, and the contents were heated to 70

oC , maintained at the same temperature for 2 hours. Filtered the total solution through celite,

washed with water (28 L) . Active charcoal (2.8 kg) was added to the filtrate, stirred at a

temperature of 70 oC for 2 hours, filtered through celite and washed with water (28L) . to the




obtained filtrate, Ph was adjusted to 3.0-3.5 with aq.sodium bicarbonate solution (15 L ) , stirred

for 1 hour, filtered the solid and washed with water (42 L), dried the solid at 80 OC for 9 hours to

give the product as off white colored powder.

Yield :- 27.5 kg (82 % ) Purity : -(99.9%)

CHEMICAL REACTION

2-chloro-5- nitro

benzoic acid

+

KOH

+

HYDROCHLORIC

ACID

→

2-Hydroxy-5-Nitro Benzoic

Acid

2-Hydroxy-5-Nitro

Benzoic Acid

+

Sodium carbonate+

Raney nickel +

Sodium hydroxide +

Hydrochloric acid +

Charcoal +

sodium bicarbonate

→

MESALAMINE

CAS number :- 89-57-6

Formula :- C7H7NO3

(5-amino-2-hydroxy benzoic

acid)

MATERIAL BALANCE




Input MT Output MT

POTASSIUM

HYDROXIDE

0.52

ML TO ETP 2.02

2-CHLORO-5- NITRO

BENZOIC ACID

0.24

HCL 1.00

HYDROCHLORIC ACID 3.12 PROCESS WASTE 0.10

WATER 1.45 SODIUM CARBONATE 0.25

SODIUM CARBONATE 0.25 RANEY NICKEL 0.29

RANEY NICKEL 0.29 SODIUM HYDROXIDE 0.16

SODIUM HYDROXIDE 0.18 MESALAMINE CRUDE 1.00

HYDROCHLORIC ACID

0.00

EFFLUENT TO SOLVENT

STRIPPER 1.6

CHARCOAL 0.19

SODIUM BICARBONATE 0.18

6.42 6.42

8. ALBENDAZOLE





1. Charge Methanol, Ortho nitro aniline , Ammonium Thiocynate and cool to 0oC.Add

Chlorine marinating temp between 0-5 oC ,then charge water and stirr for 1 hrs,

centrifuge at R.T and wash with water to PH neutral.

2. Charge water , N-propanol ,charge STEP-1.Start addition of caustic lye slowly below 40 oC and heat to 50

oC . Maintain temp between 40-50

oC for 1/2 hrs and charge n- Propyl

Bromide maintain the temperature at 50 o

C . Maintain 4 Hrs at 62-65 oC .Distilled water

Heat to 90 oC . Charge NACL while stirring. Settle & separate organic layer (TOP)

3. Charge STEP-2 with methanol stirring 15 minutes and heat to 50 oC . Start addition of

NAHS slowly lot wise. Temp rises from 50 to 70 oC. Complete addition of NAHS from 60 -

65 o

C . Reflux 6-8 Hrs at 80-85 oC .

4. Start methanol recovery at temp 90 oC . Charge water and heat upto 85-90

oC . Settle

RM for 1 Hrs. Separate RM for 1 hrs , Separate Aqueous layer from bottom .Collect the

top organic layer in Drums. Distilled out organic layer under vacuum I st cut removed

upto temp 100 oC then distilled out product at temp upto 210

oC out product at temp

upto 210 oC .

5. Charge water and cool to 8-10 o

C . Charge Hydrogen Cynamide solution. Start

simultaneous addition of MCF and Caustic lye slowly below 20 o

C and PH should be 6-8 .

Complete the addition below 20 o

C. Stirring 1/2 Hrs. Check the absence of unreacted

Hydrogen Cynamide.

6. Charge water , HCL , PART A, ,acetone and start addition of PART B. Heat to 65 o

C .

continue to reflux RM at 80-85 o

C for 1HRs. Check PH of RM .It should be 4.00 to 6.0.

Centrifuge Reaction mass at 80-85oC . Wash cake with Hot Water , Then wash with

Methanol and again wash with Acetone to get the pure Albendazole.




Chemical Reaction:

Chemical reaction ofALBENDAZOLE

STEP-1

NH4SCN Chlorine Gas

Methanol

NH4CL+HCL

Ortho Nitro Aniline

MOL WT :- 138.12

Ammonium

Thiocynate

MOL WT :-

76.122

5-THIOCYNO-2-

NITRO

ANILINEMOL WT :-

195.1985

Step-2

NAOH

CH3CH2CH2Br

Methanol

+ NABR

+NACN

5-THIOCYNO-2-

NITRO ANILINEMOL

WT :- 195.1985

INTERMIDIATE 2-NITRO 4

PROPYL THIO

ANILINE

STEP -3 & 4

3,4

DIAMINOPROPYL

THIO ANILINE (A)

NAHS MEOH

STEP-2 Caustic Soda,

Sodium

Hydrosulphide,

TOLUENE,

Carbon,

EDTA, SODIUM

META

BISULPHITE,

Acetone

METHANOL

HCL 30%

1,2-DIAMINE-

5-PROPYL

THIO

BENZENE

STEP -5 PART (B)

(CYANAMIDE

COMPLEX WITH

CYANAMIDE

SOLUTION)




CH2N2

NAOH

NC-NH-COOCH3 +HCL+ NAOH

CYANAMIDESOLUTI

ON (L-500)

METHYL

CHLORO

FORMAT

CAUSTIC SODA METHYL CYNO

ESTER ( CYNO

COMPOUND )

STEP-6

NC-NH-COOCH3

1,2-DIAMINE-5-

PROPYL THIO

BENZENE

METHYL CYNO

ESTER (CYNO

COMPOUND)

CONDENSATION

(A+B)=C

METHANOL

ACETONE

ALBENDAZOLE




MATERIAL BALANCE

Input MT Output MT

ORTHO NITRO ANILINE 0.85 HCL 0.94

AMMONIUM

THIOCYNATE

0.21

NH4CL

0.14

METHANOL 8.70 METHANOL LOSS 0.19

CHLORINE GAS 0.53 ML TO ETP 2.73

WATER 1.91 OUTPUT QTY ABZ 1.00

CAUSTIC SODA 0.32 NaBr 0.17

N- PROPANOL 0.43 LOSS TOLUENE 0.05

N-PROPYL BROMIDE 0.85

RECOVERED

METHANOL 8.51

TOLUENE 2.98 LOSS 0.19

METHANOL 0.00 RECOVERED TOLUENE 2.93

SODIUM

HYDROSULPHIDE

DILUTED

0.53

RECOVERD ACETONE

2.49

CYAANAMIDE

SOLUTION (L-500)

0.25

LOSS ACETONE

0.19

CAUSTIC SODA 0.79 RESIDUE 0.07

METHYL CHLORO

FORMAT

0.07

EFFLUENT TO SOLVENT

S TRIIPPER 1.7

ACETONE 2.68

21.11 21.11




9. FEBENDAZOLE

MANUFACTURING PROCESS

1. Charge 5-Chloro 2 Nitro Aniline ,IPA and heat to 60oC.ChargeCynamide solution 50%

maintaining temperature at 60 to 70oC.Stirr the reaction mas and maintain for 3 hrs.

2. Charge EDTA and raise temperature to 60oC,add caustic lye solution maintain for 3 hrs

under stirring at temperature 60oC.Cool to RT.

3. Add salt to the above mixture resulting in formation of two layers,separate the organic

layer and transfer the reaction mass to another reactor.

4. Charge methyl chloro formate to the reaction mass in step 3 and heat to 80oC,add ferric

chloride and maintain the reaction mass at 80oC.Cool to RT.

5. Charge hydrazine hydrate at RT maintain temperature between 50 to 55oC,maintain

under stirring for 3 hrs.

6. Charge Thiophenol ,heat the reaction mass to 90oC and add Aluminium Oxide ,maintan

temperature at 90oC for 1 hrs and then cool to RT and maintain temperature at RT for 3

hrs.

7. Chill the material to 5oC and centrifuge the material with chilled methanol wash,collect

ML for methanol recovery and 2nd

crop of material present in traces in methanol.

8. Unload the wet cake and dry in tray dryer and unload the material.




Chemical reaction

Step1:

+ CN2H2 + +

5 Chloro 2 Nitroaniline Cynamide Methyl Chloroformate Thiophenol

Fenbendazole




Material Balance:

INPUT MT Output MT

5 CHLORO 2 NITRO

ANILINE

0.79

FEBENDAZOLE 1.00

METHANOL 3.03

RECOVERED

METHANOL 2.88

THIOPHENOL 0.54 LOSS METAHNOL 0.15

RANEY NICKEL 0.06

RECOVERED RANEY

NICKEL 0.06

CYANAMIDE

SOLN(50%)

0.39

ML TO ETP 2.66

METHYL CHLORO

FORMATE

0.46

RESIDUE 0.07

CAUSTIC FLAKES 0.41

BUTYL ACETATE 0.41


WATER 0.50

6.81 6.81




10. MEBENDAZOLE

Mebendazole

Process Description

1. In SSR charge DABP. Methyl Chloro Formate ,5 Methyl Thiourea. Methanol, Di Methyl

Sulphate ,at RT.

2. Heat to 80oC and add EDTA.Maintain temperature of 60

oC under stirring for 4 hrs.

3. After stirring cool the batch to 20oC and after stirring centrifuge it.

4. Collect the ML for 2nd

crop and unload the wet cake from centrifuge and send to tray

dryer for drying and packing,for Mebendazole in dry powder form.

Chemical Reaction

NAOH

(3,4-

Diaminobenzophen

one) DABP

(C6H5COC6H3(NH2)2 )

+

Thioure

a

(CH4N2S

)+

DMS (C2H6O4S)

+

METHYL

CHLORO

FORMATE

(ClCOOCH3 ) +

Acetic Acid

(C2H4O2 ) +

Caustic

lye +

EDTA (C10H16N2O8 )

→ MEBENDAZOLE (C16H13N3O3)




Material Balance:

Input MT Output MT

PCBA 0.26 SO2 0.23

HNO3 55% 0.21 ML TO ETP 2.5

H2SO4 1.08 RECOVERED BENZENE 1.36

WATER 3.50 LOSS BENZENE 0.21

BENZENE 1.57 Cl2 0.32

THIONYL CHLORIDE 0.13

AL. HYDROXIDE BY

PRODUCT 0.57

ALUMINIUM CHLORIDE 0.07

RECOVERED

METHANOL 2.75

ACETIC ACID 0.08 SPENT CARBON 0.04

LIQ AMMONIA 0.12 LOSS METHANOL 0.30

METHANOL 3.06 MEBANDAZOLE 1.00

NAOH LYE 0.00

METHANOL

RECOVERED 0.00

SULPHUR 0.22 LOSS METHANOL 0.00


EFFLUENT TO


THIOUREA 0.15

DIMETHYL SULPHATE 0.12

METHYL CHLORO

FORMATE 0.13

CAUSTIC SODA LYE 0.04

10.78 10.78




11) METRONIDAZOLE

PROCEES OF METRONIDAZOLE

In a SS304 reactor add. 2 Methyl 5 Nitro Imidazole (2MNI) is treated with Acetic Acid,

ETHYLENE OXIDE , SULPHURIC ACID, LIQ NH3, ACTIVATED CARBON at R.T. The mixture is

treated with Naohto get ph of 2.1 to separate crude Metronidazole which is washed on

centrifuge ,Thus obtained crude product is crystallized with water produce Pharmaceutical

grade Metronidazole in powder form.

Chemical Reaction:

2 Methyl 5 Nitro

Imidazole

(2MNI)

+

ETHYLENE OXIDE

C2H4O

SULPHURIC

ACID

H2SO4

LIQ NH3

NH3

ACTIVATED CARBON

+

Acetic Acid

Medium

C2H4O2

METRONIDAZOLE




Material Balance:

Input MT Output MT

2 METHYL 5 NITRO

IMIDAZOLE (2MNI)

1.20 2 METHYL 5 NITRO

IMIDAZOLE (2MNI)

RECOVERED

0.43

GL A .ACID 0.78 EFFLUENT TO SOLVENT

STRIPPER

1.00

ACETIC ANHYDRIDE 0.08 WATER RECYCLE NEXT

BATCH

4.40

ETHYLENE OXIDE 0.96 ML TO ETP 1.30

SULPHURIC ACID 1.15 METRONIDAZOLE

PURE

1.00

LIQ NH3 1.12 SPENT CARBON 0.04

WATER 2.80

CARBON 0.08

8.18 8.18

12) METRONIDAZOLE BENZOATE




1. In a clean and dry GLR charge Benzene ,Metronidazole 10 kgs under stirring. Add beta

Picoline .Under stirring start the addition of Benzoyl chloride slowly (ice cooling)

maintaining the temp below 40Oc . After complete addition of Benzoyl chloride, the

colour of the reaction mixture will be slightly pale.

2. Stir the reaction mixture for 1/2 hrs. Then start heating to attain reflux temp. i.e. 83-

86oc . Maintain reflux for 5 hrs. then start the distillation of Benzene ( under vacuum) .

keeping the temp below 90oc .

3. After distillation quench the brown colour residue in chilled water or ice water during

quenching the temp. must not increase more, the temp must be below 15oc , and

stirring must be fast during quenching .

4. Stir the quenched mass for about 45 min. then start filtration .Filter and collect the solid

mass i.e. , crude MBO,white to slight pink in colour . Give chilled water wash in

centrifuge till the colourless ML.

5. Take the crude MBO in water, stir and start the addition of liq. ammonia to adjust the

ph 7.5 - 8.0. At this ph stir for 1/2 hrs to 1 hr then Centrifuge . Give chilled water wash

upto neutral Ph . Suck dry the cake in centrifuge . remove the cake from centrifuge . i.e.

Crude MBO -II.

6. Dissolve the crude by heating temp 50-55oC . After dissolution add charcoal, stir for 1/2

hr. filter off the charcoal.

7. Collect ML containing MBO. Chill the ML to 5oc . Centrifuge , give Chilled (methanol +

water ) wash to the cake.Unload and dry the material in tray dryer.

CHEMICAL REACTION

Metronidazole

+

BENZOYL CHLORIDE

BENZENE

BETA PICOLINE

LIQUOR AMMONIA 25%

METHANOL

CHARCOAL

Metronidazole Benzoate




MATERIAL BALANCE:

Input MT Output MT

METRONIDAZOLE 0.71 RECOVERED BENZENE 1.71

BENZENE 1.79

RECOVERED

METHANOL 2.36

BETA PICOLINE 0.54 LOSS BENZENE 0.07

BENZOYL CHLOIRDE 0.71 ML TO ETP 1.10

LIQUOR AMMONIA

25%

0.14

SPENT CARBON 0.04

METHANOL 2.50 LOSS METHANOL 0.14

CHARCOAL 0.04

OUTPUT

METRONIDAZOLE

BENZOATE 1.00

6.43 6.43

13) TINIDAZOLE

Tinidazole

Process Description

1. In a Glass line reactor add. Acetic acid glacial, 2 MNI , ETHYL THIOETHANOL, SULPHURIC

ACID below 600 Degree , heat the batch upto 85

0 C at the end of stirring cool the batch

to 200C add NH3 solution and adjust the ph to 6.5.




2. Separate the layers and add Methylene Chloride to viscous layer and after stirring

centrifuge it, collect the filtrate in glass line reactor and wash with HCL and water .

3. The reaction mass is then charge to another reaction with already charged hydrogen

peroxide and benzene cool the mixture to 200 C degree then allow the reaction to settle

down.

4. Take the peroxide layer for precipitation add ammonia to maintaining 7.5 ph and you

get is crude Trinidazole.

5. This is then recrystallised at the 800 degree temperature and giving charcoal treatment

and filtering in a ss reactor and cooling to batch to 150 degree centrifuge later in. The

batch of dried to 600 degree to get pure Trinidazole in powder form.

I ST STAGE

Charge 2 ETE in clean SS reactor then charge 500 LTR MCB , then charge 2 MNI in 1 then add

sulphuric acid 98% in 50 to 60 oC in 3.0 hrs. then raise slowly up to 80 to 85 oc maintain at 9.0

Hr, then cool to 70 oC add ETE and DM water cool to 40 to 45

oC make ph 6.5 to 7.0 by Liq.

Ammonia 25 % centrifuge reaction mass in ss centrifuge in 2 lots. wash cake with 330 Ltrs MCB

( i.e 115 ltr of I st and 215 in II lot) collect all ML adding with washing MCB in different conical

vessel having steering system with the sight glass settle for 1 hrs separate aqueous layer.

EXTRACTION II NS STEP

FIRST EXTRACTION

Charge 300 litres water in another syntex container and charge 300 lts HCL 30 % above dil HCL

charge in conical pp fr . vessel stir for 1/2 hrs . Then settle for 1.0 to 1 1/2 hr separate bottom

aqueous layer collect in GLR.

Second Extraction

Same as FIRST Extraction with 175 Litres water + 75 Litres HCL in it.

Third Extraction

Same as SECOND Extraction with 175 Litres water + 75 Litres HCL in it.

(Note :- In this extraction see proper weather aqueous layer separate in bottom or Top side.)

All Extracted layer i.e separated compound charge in GLR add Tungstic Acid as a catalyst. (

Tungestic acid solution prepared with 1 litres Liquor Ammonia & 2 Lit Water )

OXIDATION III RD STAGE

in a GLR having extracted material with catalyst add sulphuric acid 50% slowly with maintaining

temperature 40 to 48 oC . in time cycle 18 to 24 hrs. It cooling sufficient . It may reduce 6 to 8

hrs only. After addition completed maintain for 5 hrs at same temperature then filter oxidation

mass through separate pp/frp filter collect all filtrate ML in other GLR . Then add slowly liq.

ammonia 25% 200 to 220 ltrs .Then charge 2.5 kg HYFLOW 5.0 KG EDTA AND 5.0 KG Charcoal at

RT or 40 oC filter through same basket filter in PP/ FRP vessel or precipitation having inner

chilling coil add liq ammonia at 40 to 45 o

C . in 2 to 3.0 hrs . Stir for 1.0 Hr. Then centrifuge




reaction mass and ML to ETP each lot wash 100 Litres DM water spin dry & unload it, Wet cake

-800 Kgs

In SS REACTOR charge DM water 3300 Litres charge crude & Charge 8.0 kg charcoal then Heat

upto 85 oC after clear solution filter in SS leaf filter in 1/2 hr. collect all filtrate ML in another SS

reactor cool & chill to 15 oC container and wash with DM water output :- 560 to 580 kgs

CHEMICAL REACTION

2 methyl 5

nitroimidazole(2MNI)

+

ETHYL THIO

ETHANOL

C2H5SCH2CH2OH →

SULPHIDE COMPOUND

+ HYDEROGEN PEROXIDE

( 2H2O2 )

→

TINIDAZOLE




Material Balance:

Input MT Output MT

2 METHYL 5

NITROMIDAZOLE

(2MNI) 1.42

RECOVER 2MNI 0.72

BENZENE 1.13 ML TO ETP 2.73

ETHYL THIO ETHANOL 1.13 RECOVER BENZENE 1.07

SULPHURIC ACID 0.71 PURE TINIDAZOLE DRY 1.00

LIQ AMMONIA 2.08 BENZENE LOSS 0.06

H2O2 50 % 0.92 METHANOL LOSS 0.04

METHANOL 0.85

RECOVERED

METHANOL 0.80


CHARCOAL 0.03

RECYCLE FOR NEXT

BATCH 3.36

EFFLUENT TO SOLVENT

SRIPPER 1.57

11.40 11.40




14. ORNIDAZOLE

Ornidazole

Process Description

1. Charge MDC ,Formic acid,2 MNI,stir for 30 mins at RT and slowly add sulphuric acid in 2-

3 hrs time at RT,start addition of Epichlorohydrin maintaining temperature 30-32oC.

2. Add 400 litr DM water to reaction mass at 30-32oC ,stir for 20 mins and add liq.ammonia

to adjust pH 6 to 6.5 at RT and stir for 30 mins.

3. Centrifuge the cake,collect ML(product in ML),wash cake with MDC,DM water &

centrifuge.

4. Collect M.L. MDC washings & water washings & charge in Reactor – (for work up).Adjust

PH 7 by liq. Ammonia (PH critical).Stir for 15 minutes & keep for settling.

5. Collect oil separately,charge all MDC layer in reactor & charge previously separated

main oil layer also, stir for 10 minutes & filter through sparkler filter.

6. Collect filtered MDC layer & transfer to reactor (keep diluted sulfuric acid ready 25 kg

sulfuric acid + 10L water in a container).Add dilute-sulfuric acid (20L) (stir & settle)

7. Separate oil layer-MDC layer to be collected for MDC Recovery. Repeat 2nd

extraction

with of MDC with 5L of diluted sulfuric acid.Do Layer separation. MDC Layer will go for

distillation of MDC.

8. Collect oil layer & charge in Reactor.Heat to 60 c & keep for 2 hrs at 60 c ,filter through–

(MDC to be removed completely from oil)

9. Charge 400L DM water & cool to RT,adjust PH 6.5 to 7 with Liq. Ammonia.Stir for 8 hrs

at RT ( Check complete crystallization water should be free from oil)

10. Centrifuge the product & give 2 DM water washings – 100L & 50L DM water spin dry &

unload)- Wet cake is Crude Material- (Check 2MNI content should be NMT 3% by

(HPLC).

11. Charge crude cake,heat to 50C till clear solution,Charge 3 kg activated charcoal,stir for

30 min ,filter through sparkler and wash with methanol.

12. Centrifuge the product & spin dry,wash cake with DM water.Spin dry and unload.




CHEMICAL REACTION FOR ORNIDAZOLE

Chemical Name:- Ornidazole

CAS No.: 16773-42-5

HCL H2SO4

2 methyl 5 Nitro

Imidazole

C4H5N3O2 +

Epichloro

Hydrine

C3H5ClO+

Formic Acid

CH2O2

+

Ethyl

Acetate

C4H8O2

+

Hydro

Chloric

Acid

HCL +

Sulphuric

Acid

H2SO4 +

→

Methylene Chloride

CH2Cl2

+

Toluene

C7H8 +

Acetone

C3H6O +

→ Ornidazole

CAS No.: 16773-42-5

Molecular Formula:-

C7H10ClN3O3

Molecular Formula:- C7H10ClN3O3




Material Balance:

Input MT Output MT

2 METHYL 5 NITRO

IMIDAZOLE 1.92

RECOVERE 2 MNI 0.92

FORMIC ACID 85% 1.15 RECOVERED MDC 6.60

METHYLENE CHLORIDE 3.33

RECOVERED

METHANOL 1.65

EPICHLORO HYDRINE 0.38 ORNIDIZOLE PURE 1.00

LIQ AMMONIA 3.98 ML TO ETP 2.73

SULPHURIC ACID 70% 1.63 LOSS MDC 1.15


ACTIVATED CARBON 0.06 SPENT CARBON 0.04

14.20 14.20




15. OXYCLOZANIDE

Process Description

1. Charge Mono Chloro Benzene, 3,5,6-Trichloro Salicylic Acidand Thionyl dichloride into

the reactor and Heat to 60OC in 2 hrs than heat 80

O C in 2 hrs.

2. Distill out excess Thionyl dichloride. Transfer the material in to another reactor contain

mixture of 2, 4, Di chloro-6-Amino Phenol and Mono Chloro Benzene,HCl scrub through

crubber.Reflux the material for 3 hrs .Cool the reaction mass and filter it.

3. Dry the wet cake in Dryer. Unload the product as CrudeOxyclozanide

4. Charge Acetone, Crude Oxyclozanide and Activated Carboninto the reactor. Heat the

reaction mass to 60~65°C.

5. Stirr &reflux the reaction mass at 60~65°C. Stir the reaction massfor 1.0 hour.

6. Transfer this reaction mass to another reactorthrough filter which is previously ready

with hyflow bed toremove charcoal. Chill the reaction mass Stir the reactionmass and

filter it.

7. Wash the wet cake with Chilled Acetone.Dry the wet cake in Dryer. Unload the product

as OXYCLOZANIDE.

Chemical reaction of OXYCLOZANIDE

STEP 1

+

HCL

+

SO2

2,3,5-TRICHLORO-6-

HYDROXYBENZOIC

ACID

CAS No. 40932-60-3

Thionyl Chloride METHYL 2,3,5-

TRICHLOR-6-

HYDROXYBENZOATE

STEP 2

130OC

+

HCL

METHYL 2,3,5-

TRICHLOR-6-

2-AMINO -4,6-

DICHLOROPHENOL

OXYCLOZANIDE




HYDROXYBENZOATE

Material Balance:

Input MT Output MT

3, 5, 6 TRI CHLORO

SALICYLIC ACID 0.61

MONO CHLORO

BENZENE (RECOVERED) 3.92

THIONYL CHLORIDE 0.30 SO2 GAS 0.16

2, 4 -DI CHLORO - 6-

AMINO PHENOL 0.45

HCL GAS 0.19

MONO CHLORO

BENZENE (FRESH) 0.18

DISTILLATION RESIDUE 0.02

MONO CHLORO

BENZENE (RECOVERED) 3.92

DISTILLATION LOSS 0.08

ACETONE (FRESH) 0.39 DRYING LOSS 0.08

ACETONE (RECOVERED) 2.78 OXYCLOZANIDE 1.00


ACETONE

(RECOVERED) 2.79

SPENT CARBON 0.03

DISTILLATION RESIDUE 0.02

DISTILLATION LOSS 0.12

DRYING (SOLVENT)

LOSS 0.26

8.674 8.674

16. ROXARSONE





1. Charge H2O2, Arsenic Trioxide, Potassium iodide , water in SS reactor, Heat upto 46-

50oc and keep under stirring for 16 hrs,after reaction is complete process the material

through filterto GLR and distill out all water under vacuum.

2. Add material from step 1 in GLR,charge arsenic acid,ONA,per chloro ethylene and heat

reflux.Transfer the material to SS reactor,add water.

3. Centrifuge the material and give water wash,separate the wet cake and collect the

mother liquor on GLR and distill out water.

4. Add wet cake from step 3 , \caustic lye 48% and water and heat to 90oC,maintain for 2

hrs and make pH9.0 ,maintain for 2.0 hrs.Centrifuge material and collect ML in MS

reactor.

5. Charge caustic lye 48% , heat to 90oC and maintain for 18 hrs,cool to RT,add dil. HCL

mainain pH 2.0 & cool to RT.

6. Centrifuge material , add water for purification in water, wet cake obtained from

centrifuge ,add methanol ,activated carbon and heat upto 100oC.

7. Transfer the material to filter & then to a SSR where it heat to be crystallised & chill to15

oc.The pure ROXARSONE obtained , is to be dried in Tray dryer & dispatched.

CHEMICAL REACTION FOR ROXARSONE:

H3ASO4+ ONA

C4CL2

.




16 ROXARSONE

Material Balance:

Input MT Output MT

SODA ASH 0.29 SPENT carbon 0.04

ARSENIC TRIOXIDE 0.31 OUTPUT 1.00

PARA CHLORO ANILINE 0.37 ML TO ETP 1.67

Dil. HCL 1.00 PROCESS WASTE 0.10

SODIUM NITRITE 0.42

SULPHURIC ACID 0.45

COPPER SULPHATE 0.15

NITRIC ACID 98% 0.40

CAUSTIC LYE 48% 0.21

CARBON 0.04

WATER 0.5

2.80 2.80




17 CHLORPHENIRAMINE MALEATE


Initially4-Chlorobenzyl cyanide compound is reacted with sodium amide and Pchloropyridine to

give bromophenylpyridyl acetonitrile. This is then reacted with sodium amide then dimethyl

amino ethyl chloride to give 4bromophenyldimethylaminoethyl-pyridyl acetonitrile. This

intermediate is then hydrolyzed and decarboxylated to bromphenirame using 80% H2S04 at

14Oo-15O0C for 24 hours. followed by recrystallization .

Chemical reaction

NaNH2

4-chlorobenzylcyanide 2-chloropyridine 4-CHLOROPHENYL-(2-

PYRIDYL)ACETONITRILE

NaNH2

H2SO4

CHLORPHENIRAMINE

MALEATE




MATERIAL BALANCE

Input MT Output MT

4 CHLROBENZYL

CYANIDE 0.95

SODIUM SULPHATE 0.375

SODIUM AMIDE 0.8 ML TO ETP 2.675

PARA CHLORO

PYRIDINE 0.4

CP MALEATE 1

DIMETHYL AMINO

ETHYL CHLORIDE 0.7

SULPHURIC ACID 0.2

WATER 1

4.05 4.05




18 BROMHEXINE HCL

Process Description .

1. In a clean and dry GLR charge MCB, DBH, AIBN, ONT at RT,stir and heat to 43oC.Due to

exothermic reaction temperature increases to 64-70oC ,maintain temperature at 64

oC

by cooling.

2. Raise temperature 80-85oC and maintain next 2 hrs,check reaction mixture for ONT

conversion into ONBB,cool to 70oC and add Sodium Bicarbonate Solution.

3. Start slowly addition NMCHA lot wise. Maintain temp. 50 – 60 0C. for 8 hrs ,separate

organic layer and adjust pH 1.8-2.0 ,after complete precipitation stir next 2 hrs to 30oC

then centrifuge material .

4. Charge Methanol,Nitro solution with HCL and maintain under reflux,filter through

Neutch filter ,wash Iron powder ,methanol and hot water.

5. Collect fitrate in GLR ,start addition of liq.Bromine maintain temp between 35-

40oC.After reaction is complete add water and centrifuge the material,wash wetcake

with water.

6. Charge material from step 5(previous stage) with Ethyl Acetate,soda ash,102eth

continue for 30 minutes,stop stirring ,settle 1 hrs.Separate ethyl acetate layer to

another reactor .

7. Add activated charcoal in reactor and continue 60 to 90 min at 45-50oC,filter through

sparkler filter.

8. Add HCl and adjust pH 2.0 to 1.8. and maintain under reflux at 50-60oC,maintain reflux

for 1 hrs ,cool to 40oC,chill to between 5-10

oC,centrifuge the material and unload and

dry in tray dryer.




Chemical Reaction:

ROUTE OF SYNTHESIS FOR BROMHEXINE HYDROCHLORIDE

CH2

NO2

CH3

NO2

DDH / MCB / HN

CH3

N

CH3

NH2

CH3

CH2

N

O-Nitro Toluene

2-Nitro-N-cyclohexyl-N-methyl

benzene methanamine

2-Amino-N-cyclohexyl-N-methyl benzene

Raney/Ni

H2

methanamine

MeoH/Br2

NH2

Br

CH3

CH2

NBr

Na2CO3/Toluene

EtOH/HCl

NH2

Br

CH3

CH2

NBr

HCl

HBr

2-Amino-3,5-dibromobenzyl cyclohexyl methylamine

hydrochloride

2-Amino-3,5-dibromobenzyl cyclohexyl methylamine

hydrobromide




Material Balance:

Input MT Output MT

MONO CHLORO BENZENE 3.93 RECOVERED MCB 3.74

ORTHO NITRO TOLUENE 0.86 LOSS MCB 0.19

DIBROMO DIMETHYL

HYDANTOIN

0.39

ML TO ETP

2.61

AZOBISISOBUTYRONITRILE 0.07

RECOVERED

METHANOL

7.46

SODIUM BIO-CARBONATE

SOLN.

0.79

LOSS METHANOL

0.39

N-METHYL

CYCLOHEXYLAMINE

0.96

SPENT IRON

0.25

WATER 3.30 DISTILLED WATER 1.86

HYDROCHLORIC ACID

(30%)

1.25

RECOVERED ETHYL

ACETATE

5.43

METHANOL 7.02 LOSS ETHYL ACETATE 0.29

ACT.CARBON 0.04 SPENT CARBON 0.03

IRON POWDER 0.36 PRODUCT FOR SALE 1.00

LIQ . BROMINE 0.14

EFFLUENT TO

SOLVENT STRIPER

1.59

ETHYL ACETATE 5.71

SODIUM HYDRO SULPHITE 0.03

24.84 24.84

19 AMBROXOL HCL




Ambroxol HCl


1. In a clean dry GLR charge Methanol,Methyl Anthranilate, cool to 15 to 20 OC. Add

Bromine maintaining temp at 15-20 OC , maintain for 2 hrs at 15-20

OC . Add H2O2 -50%

maintaining temp 15 -20 OCand then for 3.0 Hrs at 15 -20

OC , charge water , make PH

by Liq. Ammonia 25% to 7.0 to 7.50.

2. In a clean dry SSR Charge THF , Step I and acetic acid , add slowly sodium Borohydride at

15 -20 OC within 4-5 hrs, raise temperature to RT ,

3. Maintain 4 hrs at RT, distill out THF under vacuum max at 70 OC , After distillation

completed charge water , cool to Rt , Start Centrifuge And give methanol wash for each

lot, Spin dry unload & dry in tray dryer.

4. Charge reaction mass from step 3 & Manganese dioxide at RT .Charge EDC, Activated

Carbon, Hyflow , Stirr for 1.0 Hrs and raise temperature to 95 OC to 110

OC .

5. Start filtration & collect all ML to another SSR, big filtration require, after filtration

complete give cake wash tolune , in another SSR , Collect all ML distillate , Toluene

under vacuum at 80 O

C. Cooltro RT , Chill to 15 OC , Maintain 5.0 Hr at 15

OC , Centrifuge ,

Give methanol wash to material , spin dry , Unload cake and dry in FBD.

6. In clean dry SSR charge Toluene,step 5 under stirring. Charge Trans4-Amino

Cyclohexanol, reflux at 110 OC. Remove water through distillation, After removing water

distill out Toluene atmospherically .Cool to RT . Chill to 10 OC . Centrifuge the mass &

wash with Toluene& Spin Dry , unload cake.

7. In Cool dry SS Reactor charge methanol. Charge Step 6 on dry basis .Chill to 10 OC and

add Sodium Borohydride at 10 -15 OC within 4 Hrs. Raise Temperature to RT for 1.0Hr.

Check TLC. If Complies , Raise Temperature Refux 70- 80 OC , Maintain for 2.0 Hr. Cool to

RT, Chill to 10 OC. Start centrifuge , Spin dry unload cake..

8. In clean dry SS reactor charge Iso propyl Alcohol. Charge Ambroxol Base (Step 5) on dry

basis .Heat and reflux. Check clear solution , If ok charge Act. Carbon .Filter Through

Sparkler having Hyflow Bed & collect all Ml in GLR. In GLR collect all Ml cool to 5 O

C .

Add HCL -30 % make PH 3.0 to 4.0 . After PH Heat to 70 OC & maintain for 1.0 Hr at 70

OC . Cool to Rt Chill to 10

OC . Start centrifuge in SS centrifuge . Spin dry unload cake dry

in FBD.




Chemical Reaction:

STEP-1

Br2

+

NH3

+

H2O2

⇒

METHANOL METHYL

ANTHRANILATE

STEP-1 YEILD

STEP-2

STEP-

1

TETRA

HYDROFURAN

SODIUM BORO

HYDRIDE

ACETIC

ACID

METHANOL 2-AMINO-3,5-

DIBROMOBENZALDEHYDE

STEP-3

STE

P-2

HCL

+

NH3

C6H14O3

MNO2

⇒

ACETO

NE

TRANS-4-AMINO

CYCLOHEXOL

AMBROXOL




Material Balance:

Input MT Output MT

METHANOL 3.41

RECOVERED

METHNAOL 3.24

METHYL

ANTHRANILATE 0.48

ML TO ETP 2.41

BROMINE 0.09 LOSS METHANOL 0.17

LIQ. AMMONIA 0.07 RECOVERED THF 1.66

HYDROGEN PEROXIDE 0.09 LOSS THF 0.12

WATER 1.62 RECOVERED TOLUENE 4.95

THF 1.77 LOSS TOLUENE 0.26

SODIUM BORO

HYDRIDE 0.12

SPENT CARBON 0.04

ACETIC ACID 0.02

SOLID WASTE OF

MNO2 0.40

TOLUENE 5.21 RECOVERED TOLUENE 2.39

CHARCOAL 0.04 LOS TOLUENE 0.13

MANGANESE DIOXIDE 1.01 PROCESS WASTE 0.06

TOLUENE 2.51 RECOVERED IPA 3.07

SODIUM

BOROHYDRIDE 0.10

LOSS IPA 0.16

TRANS 4-AMINO

CYCLOHEXANOL 0.11

SPENT CARBON 0.01

IPA 3.23 PRODUCT 1.00

ACT CARBON 0.01 RESIDUE 0.07

HCL 0.24

20.14 20.14




20 PHENYLPHERINE

Brief process of PHENYLPHERINE HCL

STEP 1: Charge Meta Hydroxyl aetophenone at RT.Charge Ethyl acetate Lot-1 at RT.

Cool to 0 to 2 OC. Charge aluminium chloride at 0 to 2OC.

(note: after aluminium chloride addition material is not dissolved & after addition of bromine

60 to 70% reaction mass clear solution.)

Slowly add bromine solution (bromine is mixed with ethyl acetate LOT-II) at 0 to 25 OC DURING

2 HRS. (NOTE :therxn mass solution clear and dark brown colour.)

Maintain for 1hr at 0 to 2 OC. Add toluene LOT-I at 10 to 15 OC. Add D M Water LOT –I at 10 to

15 OC. Stir for 30 min. separate toluene layer and kept aside . take aq. Layer and charge toluene

LOT-II at RT.Stir for 30min .separate toluene and mix with main layer. Take toluene in to reactor

add 2%sodium bicarbonate solution.

(note: the toluene layer colour changes to dark brown to greenish colour .)

Stir for 30 min.settle for 30 min.separate toluene layer and charge D M Water LOT-II at RT. Stir

for 30 min. settle for 30 min. separate toluene layer and charge D M Water LOT-III at same

temp. stir for 30min at same temp. Settle for 30 min at same temp. Separate toluene layer and

cool to 0 to 2 OC .Slowly add 2 Methyl benzyl amine at 0 TO 2 OC during 2 hrs.

(note: at the addition starting of n methyl benzyl amine rxn mass changes from greenish to

light (yellowish) . addition continues then reaction continues then mass colour changes slowly

to dark brown.)

Maintain for 2Hrs at 0 to 2 OC. Filter the rxn mass and wash with toluene LOT-II. Take clear

toluene layer and add Iso Propyl Alcohol HCL solution up to PH comes to 1.0 to 1.5 at 30 to 35

OC.(NOTE: at the time of PH adjustment to IPA HCL material moves like a layer and after PH it

forms gummy nature (material struck in walls) . then at the time of maintenance material

separate freely.)

Stir for 30min at 30 to 35 OC .slowly heat to 50 to 55 OC. Centrifuge and wash with chilled

Toluene 100lts .spin dry the material . Unload and dry the material at 50to 55 OC. Finally dry

the material at 100 to 105 OC during 30 to 4 hrs for removing of excess HCL gas for

smoothreduction

.Out put:

Wet wt: 400 to 410 kg

Dry wet:350 to 360 kg

Description: off white to greenish

Melting point:185to 190 OC

STAGE 2:charge methanol at RT. CHARGE STAGE –I at RT. Heat to 60 to 65 OC. Check clear

solution .charge carbon at 60 to 65 OC. Stir for 30 min at60 to 65 OC. Filter the methanol layer

through leaf filter and collect filtrate in to a clean and dry autoclave. Wash with methanol LOT-II

through leaf filter.

(Take Pd/C and dehydrate with methanol and use in rxn.)

Charge Pd/C under nitrogen atmosphere and close manhole. Pass nitrogen gas up to 2 kg

pressure and stir for 30 min and degas nitrogen slowly up to 0Kg pressure.again pass nitrogen




gas up to 2 Kg pressure and stir for 30 min and degas nitrogen slowly up to 0Kg pressure. Pass

hydrogen gas upto 1 kg pressure and stir for 30 min and degas hydrogen slowly up to 0Kg

pressure. Pass hydrogen gas 4.0 Kg pressure at RT. Heat to 50 to 55 OC. Maintain the pressure

4.0 to 6.0 Kg at 50 to 55 OC for 15 to 16hrs.

(note: first 2 hrs consumption is over and maintain the pressure for another rxn because hear

two rxn takes place first debenzylation and then further maintenance ketone reduction.)

(note: at the rxn forwarding the rxn mass is changes to dark brown to pale yellow and material

formation in methanol that is the indication of middle stage then you must proceed under

hydrogen pressure up to rxnmasscolor blackish green color . whenever you stop the middle

stages you work out the rxn mass you got the material dark brown and it looks like tamber

material)

Check TLC, if rxn completed.

(note: in TLC first spot moves to upper to middle and then moves to lower. First you check

absence of stage –I and further check absence of middle pot. Whenever absence of two spots

we can terminate hydrogen gas.)

Cool to RT. Degas the hydrogen pressure up to 0 Kg pressure slowly. Pass nitrogen gas up to

2Kg pressure and stir for 30 min and degas nitrogen slowly up to 0 Kg pressure. Again pass

nitrogen gas up to 2 Kg pressure and stir for 30min and degas nitrogen slowly up to 0Kg

pressure .filter the Pd/C through leaf filter and collect filtrate in to clean and dry reactor. Wash

with 100Lts methanol to leaf filter. Collect filtrate and distilled of methanol completely under

vacuum at below 60 OC up to thick and degas for 2 to 3Hrs.

(note: if methanol is present in residue you must loss yield and separation of material is takes

time)

residue wt:- 155 to 160 kg. coll to 40 OC . charge D M Water-I at 35 to 40 OC. Stir for 20 min at

RT. Check clear solution. PH adjusted to 9.0 to 9.5 with liquor ammonia solution at RT. Stir for

1HR at RT. Cool to 10 to 15 OC.Centrifuge and wash with D M Water LOT_II.spin dry the

material. Unload the material and dry the material at 50 to 55 OC.

Out put:

Wet wt: 120 to 140 kg

Dry wt: 80 to 85 kg

Description: brown color solid

Melting range : 140 to 145 OC.

STAGE-III

Charge Iso propyl alcohol at RT. Charge stage –II at RT. Charge L(+) tartaric acid at RT. Charge D

M Water LOT-I at RT. Heat to 60 to 65 OC .check clear solution . stir for 30 min at 60 to 65

OC.slowly cool to 30 to 35 OC 1 Hr. stir for 5 Hrs at 30 to 35 OC .

(note: charge seeding of(+) salt, otherwise salt forms more time (it tales 2 or 3 days)

Centrifuge and wash with 15% moisture iso propyl alcohol solution. Inload the salt.

Wet wt:- 75 kg (PED(+) salt)

Description: - off white powder.




Take filtrate MI’s and PH adjusted to 9.0 to 9.5 with liquor ammonia solution. Stir for 30 min at

RT. Cool to 10 to 15 OC. Centrifuge and wash with IPA LOT-II and D M Water LOT-II solution.

Take D M Water LOT-III at RT. Charge above wet cake at RT .heat to 65 to 710 OC. Cool to 25 to

30 OC .stir for 1 Hr to 25 to 30 OC. Cool to 10 to 15 OC.stir for 1 Hr at 10 to 15OC. Centrifuge

the material and wash with D M Water LOT-IV .spin dry the material .Unload the material and

dry the material at 55 to 60OC.

Output:

Wet wt:50 to 55 KG

Dry wt:35 to 38 Kg

Description: off white crystalline powder

Melting range:169 to 172 OC.

Optical rotation: - -50 O

STAGE –III RECOVERY

RECOVERY FROM PED(+) SALT:

Charge PED (+) salt at RT. Charge D M Water LOT-I at RT. Heat to 60 to 65 OC .clear solution

observed. PH adjusted to 9.0 to 9.5 liquor ammonia solution at RT. Stir for 1Hr at RT. Centrifuge

and wash with D M Water LOT-II. Unload the material and dry the material at 50 to 55 OC.

Dry wt:- 45 to 47 Kg , SOR (+) 49 O , MR : 140 to 145 OC. Take acetic anhydride at RT. Charge

above material at RT during 1 Hr slowly. Slowly add sulphuric acid at 25 to 35 Oc during 2 Hrs.

heat to 100 to 105 OC. Stir for 1 Hr at 100 to 105 OC. Cool to 80 to 85 OC. Slowly add D M

Water LOT-III at RT. Slowly heat to 85 OC . stir for 3 hrs at 80 to 85 OC. Cool to 40 to 45 OC.

Slowly add liquor ammonia 7 Lts at 45 OC. Heat to 75 to 80 OC. Distilled of water completely

under vacuum at below 80 OC .cool to 40 to 45 OC. Slowly add D M Water LOT-IV at RT.slowly

heat to 85 OC .stir for 3 Hrs at 80 to 85 OC cool to 40 to 45OC. Slowly add liquor ammonia

13Lts at 45 OC .heat to 75 to 80 OC . distilled of water completely under vacuum at below 80

OC. Cool to 50 to 50 OC. Slowly add D M Water LOT-IV at RT. Slowly heat to 85 OC. Stir for 3 Hrs

at 80 to 85 OC. Cool to 40 to 45OC.slowly add liquor ammonia LOT-IV up to PH comes 9.0 to 9.5

Lts at 45 OC. Stir for 30 min at rt. Centrifuge the material and wash with D M Water LOT-V at

RT. Spin dry the material. Dry the material at 50 to 55 OC.

Dry wt: 35 to 38 KG ,SOR (-) 45 o, MR : 169 TO 171 oc. Take 10 % MC iso propyl alcohol LOT-I at

RT. Charge above dry material at RT. Heat to reflux.cool to 25 to 30 OC.centrifuge and wash

with 10 % iso propyl alcohol LOT-I at RT.charge above dry material at RT. Heat to reflux . Stir for

1 Hr at reflux. Cool to 25 to30 OC. Centrifuge and wash with 10 %IPA LOT-II. Spin dry the

material .dry the material at 50 to 55 OC.




CHEMICAL REACTION

HOC6H4COCH3

BR2

+

Meta hydroxyl

acetophenone

Bromine

2 methyl benzyl

amine

IPA HCL+

TOLUENE

(C9H14ClNO2)

PD/C

METHANOL

COCH2N(CH3)2C6H5

OH

DL-PHENYL

EPHERINE

HCL

METHANOL

PHENYLPHERINE

HCL

COCH2BR

-

OH




MATERIAL BALANCE

Input MT Output MT

3 HYDROXY

ACETOPHENONE

1.33

PALLADIUM CHARCOAL

CATALYST

0.28

ETHYL ACETATE 0.78 AMMONIA GAS 11.11

BROMINE 0.78 ML TO ETP 1.21

TOLUENE 12.56 METHANOL 7.78

SODIUM BI

CARBONATE SOLUTION

0.18

TOLUENE 12.33

2-METHYL BENZYL

AMINE

0.92

PHENYLPHERINE

CRUDE

1.00

IPA HCL 1.44 RECOVERED ACETONE 0.25

METHANOL 8.00 LOSS ACETONE 0.02

PALLADIUM CHARCOAL

CATALYST

0.28

CARBON 0.05

LIQ.AMONIA 1.67

IPA 1.20

L(+)TARTARIC ACID 1.11

ACETIC ANHYDRIDE 1.31

SULPHURIC ACID 0.37

IPA HCL 20% 0.80

CARBON 0.04

ACETONE 0.27

DM WATER 1.11

34.18 34.18




21) DEXOMETHERPHAN

Manufacturing process

STEP 1

200 g of anhydrous methanesulfonic acid were placed under an inert gas atmosphere in a 750

ml four-necked flask provided with a thermometer and paddle stirrer and treated with 2 ml of

water. 30.40 g (100 mmol) of molten (heated to about 85° C.) I- or (S)-1- 1-(4-methoxybenzyl)-

1,2,3,4,5,6,7,8-octahydro-isoquinolin-2-yl!etha none (content: about 98%) were added to this

solution in 4 portions within 30 minutes at a temperature of about 10-15°.

The reaction mixture was stirred in a water bath. The I- or (S)-1- 1-(4-methoxybenzyl)-

1,2,3,4,5,6,7,8-octahydro-isoquinolin-2-yl!etha none had dissolved completely after about 3

hours. The brown solution was stirred at 10-21° C. for 6 days.

The course of the reaction was checked by gas chromatography.

STEP 2

400 ml of toluene and in one portion a mixture of 150 g of ice and 330 ml of water were added

to the brown solution from Example 1. After stirring for 5 minutes the mixture was extracted

with 2×100 ml of toluene. The toluene phases were washed in succession with 2×100 ml of

water.

The aqueous phases were combined and the methanesulfonic acid was recovered therefrom.

The toluene phases were combined and evaporated in a water-jet vacuum. There were

obtained 30.25 g (92%) of crude (9α,13α,14α-1-(3-methoxymorphinan-17-yl)ethanone, content

according to GC: 91%.

STEP 3

600 ml of water were added dropwise at 60° while stirring within about 1 hour to the brown

solution from Example 1. The crystal suspension obtained was cooled to room temperature.

The solid was filtered of under suction, pressed out well and rinsed with 100 ml of water. The

filter cake was dried at 35° in a water-jet vacuum for 18 hours. There were thus obtained 27.81

g (88%) of (9α,13α,14α)-1-(3-methoxymorphinan-17-yl)ethanone, content according to GC:

95%.




CHEMICAL REACTION

+

3-HYDROXY-N-METHYLMORPHINAN PHENYLTRIMETHYL AMMONIUM CHLORIDE

CH3OH;CH3Ona

(D/L)-3-METHOXY-N-MATHYLMORPHINAN

1. D-tartaric acid

2. Resolution

DEXOMETHORPHAN




MATERIAL BALANCE

Input MT Output MT

CYCLO HEXNYL ETHYL

AMINE 0.4

SODIUM BROMO

HYDRIDE 1

4 METHOXY PHENYL

ACETIC ACID 0.25


PHOSPHOROUS OXY

CHLORIDE 0.4

DEXO METHER PHAN

HBR 1

SODIUM BROMO

HYDRIDE 0.14

TOLUENE 3.50

ORTHO XYLENE 0.5 HBR 1

CAUSTIC SODA LYE 0.35 SALT 0.5

TOLUENE 3.59

METHANESULPHONIC

ACID 0.45

SODIUM SALT 0.5

EFFLUENT TO


D MANDALIC ACID 0.4 TOLUENE LOSS 0.09

SMO 0.4

METHYL FORMATE 0.51

PHOSPHORIC ACID 0.31

PHOSPHOROUS

PENTOXIDE 0.3

METHANOL 0.5

FORMALDEHYDE 0.48

FORMIC ACID 0.36


ACETONE 0.5

HYDROBROMIC ACID 0.4

10.41 10.41

22) SALBUTAMOL SULPHATE


SALBUTAMOL

STEP 1 PREAPARATION OF ACETYL METHYL SALICYLATE

ADD METHYL SALICYLATE ethylene chloride ,AL2CL3, sodiu7m carbonate and add citric acid

slowly add citric acid stir it gently , cool the reactor mixture.

STEP 2 FORMATION OF BENZYL METHYL SALICYLATE

Add step 1, acetone , potassium carbonate, KI, Benzyl chloride. The ppt that form wash it with

methanol to form benyl methyl salicylate.

STEP 3 BROMINATION OF BENZYL METHYL SALICYLATE




Treat the step 2 product in presence of bromine and methanol to form bromo benzyl methyl

salicylate.

STEP 4 FORMATION OF O-BENZYL SALBUTAMOL

Add step 3 and t-butyl amine , diglyme , to form o-benzyl salbutamol crude

STEP 5 SALBUTAMOL SULPHATE FORMATION

Treat step 4 with methanol and act.carbon for purification process wash it dry it and check

assay.

CHEMICAL RXN

Step 1:

Yield : 70-75%

Step 2 + 3:

2 Steps: Total Yield 70%

Step 4:




Step 5: protected arylethanolamine ester:

Yield 72%

(+)-DBTA Resolution: Harteley, et al16




MATERIAL BALANCE

Input MT Output MT

METHYL SALICYLATE 0.33 ETHYLENE CHLORIDE 3.28

ETHYLENE CHLORIDE 3.50 ALUMINIUM CHLORIDE 0.14

ALUMINIUM CHLORIDE 1.21 PROCESS WASTE 0.05

ACETYL CHLORIDE 0.27 SODIUM CARBONATE 0.03

SODIUM CARBONATE 0.03 ACETONE 5.33

CITRIC ACID 0.01

SALBUTAMOL

SULPHATE

1.00

ICE 0.53 METHANOL 4.53

ACETONE 1.00 ETHYL ACETATE 2.60

POT CARBONATE 1.00 ML TO ETP 2.15

POTASSIUM IODIDE 0.04 PD/C 10 % 0.04

BENZYL CHLORIDE 0.40

EFFLUENT TO SOLVENT

STRIPPER

1.35

METHANOL 5.00

TBAB 0.05

SULPHURIC ACID 1.07

BROMINE 0.87

DIGLYME 0.33

T-BUYL AMINE 0.84

TBAB 0.01

SODIUM

BOROHYDRIDE

0.29

PD/C 10 % 0.04

ETHYL ACETATE 2.73

A CHARCOAL 1.00

20.56 20.56




23) THEOPHYLLINE


1. Add water ,industrial salt & Dimethyl urea and heat to make molten slurry.

2. The above slurry undergoes Methylation MMA gas releasing ammonia as by product.

3. The mixture undergoes dilution by acetic acid resulting in formation of Dimethyl Urea +

Acetic Acid.

4. The Dimethyl Urea salt reacts with Cyanoacetic Acid and Acetic Anhydride to form

Cyano Acetyl Dimethyl urea + Acetic Acid.

5. Cyanoacetyl Dimethyl Urea undergoes cyclization with caustic Lye 48%

6. The material after cyclization reacts with Sodium Nitrite ,HCL & Sulphuric Acid 40%

resulting in formation of Nitroso Compound.

7. In a seprate reactor add water ,Iron Powder ,HCl, Nitroso Compound ,Na Hydrosulphite

& Sodium Carbonate for reduction.

8. The organic mass then undergoes formylation with formic acid ,cyclization with caustic

lye 48% undergoes and crystallization with process salt to form sodium salt of

Theophylline.

CHEMICAL REACTION FOR THE THEOPHYLLIN

STEP :- I

PREPERATION OF DIMETHYL UREA

H2NCONH2 + CH3NH2 H2NCONHCH3 + NH3

UREA MONOMETHYLAMINE MONOMETHYL UREA AMMONIA

H2NCONHCH3 + CH3NH2 H3CNHCONHCH3 + NH3

MONOMETHYL

UREA

MONOMETHYLAMINE DIMETHYL UREA AMMONIA




ClCH2COOH + NaOH ClCH2COONa H2O

ClCH2COONa + NaCN NCCH2COONa + NaCl

2 NCCH2COONa + H2SO42 NCCH2COOH + Na2SO4

+

STEP-II

Preparation of Cyanoacetic acid

Monochloroacetic acid

Sodiummonochloro acetate

Sodium Cyanide Sodiumcyano acetate




MATERIAL BALANCE

Input MT Output MT

UREA 0.50 SODIUM SULPHATE 0.38

MMA GAS 0.39

EFFLUENT TO SOLVENT

STRIPPER 1.485

CAA AQUEOUS 0.80 CL2 GAS 1.60

MIBK 0.10 SPENT IRON 0.25

ACETIC ANHYDRIDE 0.60 THEOPHYLLINE 1.00

SODIUM NITRITE 0.73 ML TO ETP 2.515

CAUSTIC LYE 48 % 0.99

SULPHURIC ACID (98%) 0.70

IRON POWDER 0.27


HYDROSO 0.01

FORMIC ACID 0.63

PROCESS SALT 0.50

HYFLO 0.01

DMS 0.00

CHLOROFORM 0.00

HYDROSO 0.01

A.CARBON 0.20

7.23 7.23

24) CAFFEIN

Manufacturing Process:




1. Add water ,industrial salt & Dimethyl urea and heat to make molten slurry.

2. The above slurry undergoes Methylation MMA gas releasing ammonia as by product.

3. The mixture undergoes dilution by acetic acid resulting in formation of Dimethyl Urea

+ Acetic Acid.

4. The Dimethyl Urea salt reacts with Cyanoacetic Acid and Acetic Anhydride to form

Cyano Acetyl Dimethyl urea + Acetic Acid.

5. Cyanoacetyl Dimethyl Urea undergoes cyclization with caustic Lye 48%

6. The material after cyclization reacts with Sodium Nitrite ,HCL & Sulphuric Acid 40%

resulting in formation of Nitroso Compound.

7. In a seprate reactor add water ,Iron Powder ,HCl, Nitroso Compound ,Na

Hydrosulphite & Sodium Carbonate for reduction.

8. The organic mass then undergoes formylation with formic acid ,cyclization with

caustic lye 48% undergoes and crystallization with process salt to form sodium salt of

Theophylline.

9. The sodium salt of Theophylline on methylation with water, HCL, DMS , NaOH ,

Activated Carbon undergoes filtration ,Crystallisation then filtration wash with chilled water

and activated carbon to form Pure Caffeine.




Preparation of sodium salt of Theophylline

N

N

NH2

O

O

CH3

CH3

NO

Fe / HCl

HCOOH

NaOH

N

N

O

CH3

CH3

N

N-

Na-O

Step - IV

+ 2H2O

Nitroso Soda sada salt

Step - V

Preparation of Caffeine

N

N

O

O

CH3

CH3

N

N-

Na-

(CH3O)2SO2

NaOH

N

N

O

O

CH3

CH3

N

N

CH3

+ (CH3O)(ONa)SO2

Soda salt Caffeine Methylsodium sulphate

MATERIAL BALANCE




Input MT Output MT

UREA 0.58

METHYL SODIUM

SULPHATE 0.64

MMA GAS 0.58 FINISH PRODUCT 1.00

CAA AQUEOUS 0.43

CHLOROFORM

RECOVERED 0.22

SULPHURIC ACID 98% 0.62 MIBK RECOVERED 0.21

MIBK 0.09 SPENT IRON 0.25

ACETIC ANHYDRIDE 0.66 CL2 GAS 0.58

SODIUM NITRITE 0.60 ML TO ETP 2.3

CAUSTIC LYE 48 % 0.44

EFFLUENT TO SOLVENT

STRIPPER 1.7

IRON POWDER 0.26


HYDROSO 0.01

FORMIC ACID 0.55

PROCESS SALT 0.76

HYFLO 0.01

DMS 0.72

HCL 0.02

CHLOROFORM 0.25

HYDROSO 0.01

A.CARBON 0.30

6.90 6.90




25. THEOBROMINE


Preparation of Theobromine includes the following steps.

STAGE — I: PREPARATION OF MONOMETHYLUREA

Monomethylamine gas is purged in to the molten urea at 90-120°C followed by crystallized with

solvent, chloroform to get Monomethylurea which is sufficiently pure as an intermediate for

Theobromine.

REACTION SEQUENCE

+H2NCONH2 CH3NH2H2NCONHCH3 + NH3

M.W =60 M.W=31 M.W=74 M.W=17

90 - 120°C

UreaMonomethylamine Monomethylurea Ammonia

For this purpose:

1. Arranged 2.0 litre 4- necked cylindrical round bottom flask with thermometer pocket, gas

purging probe on centre neck having fine sparging and heat exchange condenser on side

neck.

2. Charged 1.6 kg & 0.2 kg water in to the cylindrical round bottom flask at RT.

3. The mixture is heated to 90 -110°C and added urea slowly such that urea should dissolve

completely at temperature 90 to 110°C.

4. Monomethyl amine gas is purged though fine sparging probe at between 90 to 120°C over

a period of 14 to 15 hrs and reaction is completed with continue monitoring of reaction by

HPLC & setting point of molten mixture ,MMU content : 75 to 80% ; DMU content:15 to

20% & urea :less than 1.0% & setting point : 85 to 89°C.

5. Arranged the 5.0 litre 4- necked round bottom flask with thermometer pocket, electric

stirrer on centre neck, heat exchange condenser and addition funnel on side neck. Added

the molten mixture in to the above flask at 45 to 55°C containing chloroform.




6. The mixture is stirred for 30 minutes at 50 to 55°C.

7. Slowly cooled the temperature to 30 to 35oC over a period of 30 Minutes.

8. Filtered the mixture on buckner funnel under vacuum followed by washing with

chloroform and suck the mother liquor completely under vacuum.

9. Dried the material under vacuum at 45-50°C till constant weight.

STAGE — II: PREPARATION OF CYANO ACETYLMONOMETHYLUREA

Monomethylurea is reacted with Cyanoacetic acid in the presence of acetic anhydride at 90°C

followed by filtration to yield Cyano Acetylmethylurea as a white crystalline solid.

REACTION SEQUENCE

NCCH2COOH + NH2CONHCH3CH3COOH+ 2

NH

NH

O

CH3

CNO

(CH3CO)2O

Cyanoacetic acid Monomethylurea

M.W=85 M.W=74

Acetic anhydride

M.W=85

Cyanoacetylmethyluracil

M.W=141

Acetic acid

M.W=60

90°C

For this purpose:

1. 217.0 Gms Cyanoacetic acid is charged in to the 4- necked round bottom flask arranged

with thermometer pocket, electric stirrer on centre neck, and heat exchange condenser

and addition funnel on side neck.

2. Heated to 60 to 65°C and added acetic anhydride, 63.8 gms x4times, through addition

funnel, Monomethylurea in four equal lots, 43 gmsx4 times, at 60 to 65°C under stirring

with interval time of 10 to 15 minutes.

3. Heated the mixture 85 to 90°C and stirred for 60 minutes at 85 to 90°C and added

second lot of acetic anhydride,45 gms, and Monomethylurea,26 gms, at 85 to 90°C and

stirred for 30 minutes at 85 to 90°C.




4. Cooled the mixture 25 to 30°C and filtered on Buckner funnel under vacuum and suck the

mother liquor completely under vacuum and slurry washed with 500 ml water at 30°C and

filtered on buckner funnel under vacuum.

STAGE — III: PREPARATION OF 4-AMINO 3-METHYLURACIL

Cyano Acetylmethylurea is added in to the caustic solution at 40-50°C followed by neutralized

with sulphuric acid to get 4-Amino 3-Methyluracil as a white amorphous solid.

REACTION SEQUENCE

N

NH

NH2

O

CH3

ONaOH

H2SO4

4-Amino 3-Methyluracil

CNNH

NH

O

CH3

O

Cyano acetylmethyluracil

M.W=141 M.W=141

+ Na2SO4+ H2O

For this purpose:

1. 390 gms of charged caustic lye (48%) & 600 ml water in to the 3- necked round bottom

flask arranged with thermometer pocket, electric stirrer on centre neck and addition

funnel on side neck.

2. 370 – 390 gms of wet cyano acetylmethylurea is added in to the above mixture at 40 to

50°C for 30 minutes by controlling the mass temperature.

3. Heated the mixture 50 to 55°C.

4. Stirred for 30 minutes at 55 to 55°C.

5. Cooled the mixture 40°C and neutralized with 40% sulphuric acid, 500 gms at 40 to 50°C

by controlling the mass temperature.




6. Cooled the mixture 40°C and filtered on centrifuge and remove the mother liquor

completely followed by slurry washed with 1000 ml water at 30°C and filtered on

centrifuge and remove the mother liquor completelywith washing of 200 ml water.

STAGE — III: PREPARATION OF 4-AMINO 5-NITROSO 3-METHYLURACIL

4-Amino 3-Methyluracil is reacted with sodium nitrite at 90°C in the presence of acetic acid to

yield 4-Amino 5-Nitroso 3- Methyluracil as a Purple coloured crystalline powder.

REACTION SEQUENCE

N

NH

NH2

O

O

CH3

NaNO2/CH3COOHN

NH

NH2

O

O

CH3

NO

+ CH3COONa

4-Amino 3-methyluracil

4-Amino 5-nitroso 3-methyluracil

M.W=141 M.W=170

Sodium acetate

M.W=82

For this purpose:

1. Charged 360 – 370 gms of wet 4-Amino 3-methyluracil & 800 ml water in to the 4-

necked round bottom flask arranged with thermometer pocket, electric stirrer on centre

neck, and heat exchange condenser and addition funnel on side neck.

2. Heated the mixture 85 to 90°C.

3. Charged 150 gms of acetic acid at 85 to 90°C

4. Added 290-300 gms of sodium nitrite solution (38%) drop by drop at 85 to 90°C for 60

minutes up to getting blue spot on starch iodide paper.





6. Cooled the mixture 25-30°C and filtered on centrifuge and suck the mother liquor

completelyfollowed by slurry washed with 1250 ml water (Ph 4.5 to 5.0) at 30°C and

filtered on centrifuge and remove the mother liquor completelywith washing of 500 ml

water of ph 5 to 5.5.

STAGE — IV: PREPARATION OF 3-METHYLXANTHINE

4-Amino 5-Nitroso 3-Methyluracil is subjected to reduction with palladium catalyst in the

presence of formic acid at 90°C followed by cyclization with alkali and sulphuric acid to get 3-

Methyl Xanthine as a Pale cream to light brown crystalline powder

REACTION SEQUENCE

N

NH

NH2

O

O

CH3

NO

N

NH

NH2

O

O

CH3

NH

OH

NaOH

N

NH

O

CH3

N

NH

O

+

H2O

Pd/3HCOOH2H2O

4-Amino 5-Nitroso 3-Methyluracil

M.W=170

4-Amino 5-formamino 3-Methyluracil

Palladium/Formic acid

M.W=184

90°C

H2SO4

+

3 - Methylxanthine

M.W= 166

90°C

+2CO2

For this purpose:




1. Charged 350- 360 gms of wet 4-Amino 5- Nitroso 3-methyluracil, water, 760 gms & 12.0

gms of 5% palladium on carbon in to the 4- necked round bottom flask arranged with

thermometer pocket, electric stirrer on centre neck, and heat exchange condenser and

addition funnel on side neck.

2. Warmed the mixture 40°C and added 314 gms of formic acid (85%) at 40 to 50°C for 120

minutes by controlling of frothing & mass temperature.


4. Heated the mixture slowly 85 to 90°C.


6. Charged 950 ml of water at 85 to 90°C

7. Added 250 – 260 gms of caustic solution (48%) drop by drop at 85 to 90°C for 30

minutes up to ph 11.3 to 11.50.


9. Filtered the clear mass through on buckner funnel under vacuum and washed with 100 ml

hot water having ph of 10 – 10.5.

10. Taken filtrate in to the 4- necked round bottom flask arranged with thermometer

pocket, electric stirrer on centre neck, and heat exchange condenser and addition

funnel on side neck.

11. Added 290 – 300 gms of 40% sulphuric acid drop by drop at 85 to 90°C for 60 minutes

up to ph 5 to 5.5.

12. Cooled the mixture 40°C and filtered on centrifuge followed by washing with 250 ml

water having ph of 5 to 5.5.




13. Thus obtained material is reslurry with water (ph 5 to 5.5) and filtered on centrifuge

followed by washing with 250 ml water having ph of 5 to 5.5.

STEP-V: PREPARATION OF 3, 7 –DIMETHYLXANTHINE (DMX PURE)

3-Methyl Xanthine is methylated with dimethyl sulphate and caustic to get 3, 7-Dimethyl

Xanthine as a crude and thus obtained crude is further purified by dissolving in water with

caustic followed by Charcoalisation, filtration and reprecipitating with sulphuric acid to get pure

3, 7-Dimethyl Xanthine as a white crystalline solid.

REACTION SEQUENCE

N

NH

O

O

CH3

N

NH

(CH3O)2SO2

NaOH

+ (CH3O)(ONa)SO 2

3-Methylxanthine

M.W = 166

N

NH

O

O

CH3

N

N

CH3

3,7-Dimethylxanthine

M.W= 180

Methylsodium sulphate

M.W = 134

Dimethylsulphate

M.W = 126

For this purpose:

1. Charged 1350 ml of water in to the 3- necked round bottom flask arranged with

thermometer pocket, electric stirrer on centre neck and addition funnel on side neck.

2. Charged 290 – 320 gms of wet 3-Methylxanthine in the above round bottom flask.

3. Heated the mixture 65-70°C and added caustic solution (30%) up to dissolution of 3-

Methylxanthine at 65 to 70°C.




4. Charged 34.0 gms of dry activated carbon and stirred for 30 minutes at 65 to 70°C and

filtered through hyflow bed followed by washed with hot water, 200 ml having ph 10 –

10.5.

5. Taken the filtrate in to the clean 3- necked round bottom flask arranged with


6. Cooled the mass 55 to 60°C.

7. Adjust the mass ph 10 to 10.5 at 55 to 60°C by 40% sulphuric acid.

8. Added 165 gms of dimethyl sulphate drop by drop for 120 minutes at 50 to 55°C up to

mass ph reaches 7.5 and then added 30% caustic solution and dimethyl sulphate(*)

simultaneously at mass ph 7.5 to 8.0 and stabilized the mass ph to 7.5 to 8.0 and

reaction is monitored by HPLC for completion of reaction.

9. Charged 2000 ml water in to the 3- necked round bottom flask arranged with


10. Charged 350 – 370 wet 3, 7-dimethylxanthine in the above round bottom flask

containing 2000 gms of water at RT.

11. Heated the mixture 70-75°C and added 140 – 150 gms of caustic solution (30%) up to

dissolution of 3, 7-dimethylxanthine at 70 to 75°C.

12. Charged 67.0 of wet activated carbon (washed 50% wet) and stirred for 30 minutes at

70 to 75°C and filtered through hyflow bed followed by washed with hot water, 200 ml

having ph 10 – 10.5.

13. Cooled the mass 60 to 65°C.

14. Added 140 – 150 gms of 40% sulphuric acid drop by drop at 60 to 65°C for 60 minutes

up to ph 5 to 5.5.




15. Cooled the mixture 25 to 30°C.

16. The material is filtered on centrifuge followed by washing with water, 500 ml having ph

5 to 5.5.

17. Dried the material at 100°C up to the constant weight.

MATERIAL BALANCE

Input MT Output MT

CYNOACETIC ACID

(CAA)

0.33

ACETIC ACID

RECOVERED

1.33

Monomethylurea 0.89 ML TO ETP 1.03

Acetic anhydride 0.50 THIO PURE 0.64


CAUSTIC FLAKES 0.71

MMA SOLUTION BI

PRODUCT

0.13

HCL 0.67 DRYING LOSS 1.00

MMA GAS 0.22

EFFLUENT TO

SOLVENT STRIPPER

2.065

BROMINE 0.09

H2O2 0.20

FORMIC ACID 0.22

C S LYE 48% 0.11

CARBON 0.03

6.25 6.25




26) CIPROFLOXACIN

MANUFACTURING PROCESS:

STAGE -1

In a glass lined reactor , water ,3-4 HCL and NaNO2 was charged and stir it for around 3 hrs at

the same time chilled bine was circulated through the jacket to maintain the temp. the reactant

mass is then extracted in a PP/FRP extractor where HCL & copper chloride is added .the

aqueous layer is recycled for further purification and organic layer is recycled for further

purification and organic layer is fed to next extractor for further purification .the organic layer

from this extractor is collected in a 5000 ltr capacity holding tank, which is then distilled

&collected in a200 ltr H.D.F.E

STAGE -2

the rxn mixture from 1st

stage is charged in a 2500 lit .glass lined reactor .acetyl chloride , EDCM

aluminium chloride ,HCL, we were also charged steam is circulated through jacket for proper

temp. extractor ,where HCL& lye are added .the organic layer is fed to into next reactor for the

distillation of EDC.

Stage-3

whatever obtained from 2nd

STAGE is charges in a SS316 reactor which is already charged with

Benzene, acetic acid ,sodium hydride etc. in a reactor temp is maintained in between 8 to 10 oc

. by hot oil (kerosene) circulation system I proper stiming. The total reactor is of 9.00 hrs .the

reactant mass from above reactor is then washed with chilled water & filtered Nutch filter

STAGE-4

The filtrate is again charged in SS 316 reactor where aluminium anhydride benzene & chloro

Propyl amine is added in to reactor is carried out in presence of catalyst and at the temp of 150

OC benzene is recovered in next condensation unit

& remaining reactant is centrifuged.

STAGE 5

benzene ,sodium hydride &acetic acid is charged in a SS316 reactor also the cake obtain from

4th

stage is added in it the rxn later place at 70 to 80 OC temp then it is fed to a next reactor

where HCL & methanol added in it. The rxn temp is and 125 OC which is then cool down to 40

OC by chilled brine circulation .the reacted mass to then centrifuge & dried.

Stage -6in the last stage carbon treatment is given to the crude ciprofloxacin &then it is again

centrifuge & dried in a tray dryer .




CHEMICAL REACTION

condensation

Hydrolysis

decarboxyla

tion

2,4-dichloro-5-

fluorobenzoyl

chloride

diethyl 2,4-

dichloro-5-

fluorobenzoylmalo

nate

ethyl 2,4-dichloro-

5-

fluorobenzoylaceta

te

cyclization

7-chloro-1-

cyclopropyl-6-

fluoro-1,4-

dihydro-4-

oxoquinoline-3-

carboxylic acid

ethyl 2-(2,4-

dichloro-5-

fluorobenzoyl)-3-

cyclopropylaminoa

crylate

ethyl 2-(2,4-

dichloro-5-

fluorobenzoyl)-3-

ethoxyacrylate

condensation

PIPERAZINE IN

DMSO

CIPROFLOXACIN




MATERIAL BALANCE

Input MT Output MT

3 CHLORO 4 FLUORO

ANILINE 0.2

ML TO ETP 2.1

CYCLOPROPYLAMINE 0.22

RECOVERED


TRIETHYL ORTHO

FORMATE 0.25

SPENT CARBON 0.04

PIPERAZINE 0.13

RECOVERED

METHANOL 4.9

SODIUM METHOXIDE 0.3 ETHER 0.5

DIMETHYL CARBONATE 0.24 CIPROFLOXACIN 1

DIMETHYL SULPHOXIDE 0.3 METHANOL LOSS 0.05

PYRIDINE 0.2

ACETYL CHLORIDE 0.3


POT. HYDROXIDE 0.2

SODIUM NITRITE 0.24

CUPROUS CHLORIDE 0.2

SODIUM CHLORIDE 0.44


SODIUM SULPHATE 0.2


ACETIC ACID 0.2

HYDROCHLORIC ACID 3


ACIVATED CARBON 0.09

HYFLOSUPERCEL 0.1

AMMONIA 0.15

EDTA 0.04

HYDROCHLORIC ACID 0

CAUSTIC SODA FLAKES 0.2

BENZENE 0.5

METHANOL 2

EDC 0.18

11.51 11.51




27. OFLOXACIN

Process Description

Stage –I

In clean dry SSR charge OQ ACID METHANOL N-METHYL PIPERAZINE DI METHYL SULPHOXIDE

METHANOL, heat to reflux 117 o

C to 125 oC maintain for 12-13 hrs check TLC if complies, Distil

out N-Butanol completely at last apply vacuum to remove all traces of , charge methanol 100

ltrs & distil out methanol to remove 138ethan of n-butanol, gain charge methanol 500 ltrs stir

for ½ hrs at 50 -58 oc , cool & chill to o oC centrifuge the mass & cake give methanol wash. Spin

dry & unload cake, Ml for II nd crop recovery.

Stage —II

In clean SSR charge 1000 ltrs DM water charge wet crude, Stir & make ph by acetic acid 4.2 to

4.50, check for dissolution , if clear charge act carbon, heat to 60 oC , Stirr for 1 hr then filter

sparkler filter all ML collect in next SSR, In a filtrate Ml make PH 6.60 to 6.60 by KOH and

methanol solution chill to 10 oC , centrifuge it , Cake wash with chill methanol spin dry and

unload

Chemical Reaction for OFLAXACIN

STAGE 1

METHANOL

SODIUM

HYDROXIDE

FLAKES

OFLOXACIN

CRUDE IP

OFLOXACIN Q ACID

+

N-METHYL

PIPERAZINE +

DI METHYL

SULPHOXIDE

STAGE 2

OFLOXACIN CRUDE

IP

ACETIC ACID LIQ. AMMONIA+

ACTVATED

CARBON+METHAN

OL +D.M.WATER

OFLOXACIN

MATERIAL BALANCE




Input MT Output MT

OFLOXACIN Q ACID 0.81

RECOVERED

METHANOL 0.58


N-METHYL PIPERAZINE 0.35

N BUTANOL

RECOVERED 0.47

N-BUTANOL 0.49 LOSS N BUTANOL 0.01

D.M. WATER 1.43 RESIDUAL 0.07


EFFLUENT TO SOLVENT

STRIPPER 0.7

ACETIC ACID 0.29 ML TO ETP 1.38

LIQUOR AMMONIA 0.28 SPENT CARBON 0.03

PRODUCT 1.00

4.50 4.50




28) ENROFLOXACIN

MANUFACTURING PROCESS:

STAGE -1

In a glass lined reactor , water ,3-4 HCL and NaNO2 was charged and stir it for around 3 hrs at

the same time chilled bine was circulated through the jacket to maintain the temp. the reactant

mass is then extracted in a PP/FRP extractor where HCL & copper chloride is added .the

aqueous layer is recycled for further purification and organic layer is recycled for further

purification and organic layer is fed to next extractor for further purification .the organic layer

from this extractor is collected in a 5000 ltr capacity holding tank, which is then distilled

&collected in a200 ltr H.D.F.E

STAGE -2

the rxn mixture from 1st

stage is charged in a 2500 lit .glass lined reactor .acetyl chloride , EDCM

aluminium chloride ,HCL, we were also charged steam is circulated through jacket for proper

temp. extractor ,where HCL& lye are added .the organic layer is fed to into next reactor for the

distillation of EDC.

STAGE-3

whatever obtained from 2nd

STAGE is charges in a SS316 reactor which is already charged with

Benzene, acetic acid ,sodium hydride etc. in a reactor temp is maintained in between 8 to 10 0c

. by hot oil (kerosene) circulation system I proper stiming. The total reactor is of 9.00 hrs .the

reactant mass from above reactor is then washed with chilled water & filtered Nutch filter

STAGE-4

The filtrate is again charged in SS 316 reactor where aluminium anhydride benzene & chloro

Propyl amine is added in to reactor is carried out in presence of catalyst and at the temp of 150 0c benzene is recovered in next condensation unit & remaining reactant is centrifuged.

STAGE 5

benzene ,sodium hydride &acetic acid is charged in a SS316 reactor also the cake obtain from

4th

stage is added in it the rxn later place at 70 to 80 0c temp then it is fed to a next reactor

where HCL & methanol added in it. The rxn temp is and 1250cwhich is then cool down to 40

0cby chilled brine circulation .the reacted mass to then centrifuge & dried.

Stage -6in the last stage carbon treatment is given to the crude enrofloxacin &then it is again

centrifuge & dried in a tray dryer .




CHEMICAL REACTION FOR ENROFLOXACIN

condensation

Hydrolysis

decarboxyla

tion

2,4-dichloro-5-

fluorobenzoyl

chloride

diethyl 2,4-

dichloro-5-

fluorobenzoylmalo

nate

ethyl 2,4-dichloro-

5-

fluorobenzoylaceta

te

cyclization

7-chloro-1-

cyclopropyl-6-

fluoro-1,4-

dihydro-4-

oxoquinoline-3-

carboxylic acid

ethyl 2-(2,4-

dichloro-5-

fluorobenzoyl)-3-

cyclopropylaminoa

crylate

ethyl 2-(2,4-

dichloro-5-

fluorobenzoyl)-3-

ethoxyacrylate

condensation

C6H10N2

enrofloxacin

MATERIAL BALANCE




Input MT Output MT

3 CHLORO 4 FLUORO

ANILINE 0.12

RECOVERED


CYCLOPROPYLAMINE 0.17 SPENT CARBON 0.1

TRIETHYL ORTHO

FORMATE 0.15

RECOVERED

METHANOL 1

PIPERAZINE 0.25

EFFLUENT TO SOLVENT

STRIPPER 1.2

SODIUM METHOXIDE 0.28 ML TO ETP 2.2

DIMETHYL CARBONATE 0.15 ETHER 0.25

DIMETHYL SULPHOXIDE 0.2 ENROFLOXACIN 1

PYRIDINE 0.16

ACETYL CHLORIDE 0.27


POT. HYDROXIDE 0.18

SODIUM NITRITE 0.25

CUPROUS CHLORIDE 0.18

SODIUM CHLORIDE 0.12


SODIUM SULPHATE 0.15


ACETIC ACID 0.02



ACIVATED CARBON 0.15

HYFLOSUPERCEL 0.1

AMMONIA 0.25

EDTA 0.04

CAUSTIC SODA FLAKES 0.2

BENZENE 0.13

METHANOL 0.59

EDC 0.25

6.55 6.55




29. SILDINAFIL CITRATE

Sildinafil Citrate

Process Description

1. In clean SSR charge Sodium Methoxide(SMO) under Nitrogen atmosphere, charge 2-

Pentanone ,maintain temperature between 30-35oC ,maintain 5 hrs then cool to 28-

30oC.

2. Charge water,hydrazine hydrate ,HCL ,Step 1 material heat to 35oC,maintain 4 hrs at

RT.Quinch the above mass and heat the material to 65oC and maintain for 1 hrs,cool to

20-25oC and filter through nutch filter.

3. Charge water,EDC ,material from step 2 ,heat to 55oC,maintain for 5 hrs.Cool the

reaction mass to 20-25oC ,make pH2.0-1.8.Settle for 15 min at 20-25oC.Separate the

organic layer and transfer to other reactor.

4. Charge material from Step 3, Ethyl Acetate ,Dil. H2SO4,raise the temperature to

45oC.Charge iron powder ,the reaction is exothermic maintain temperature 75oC.Cool

to 45oC.Charge water heat to 85oC,cool to 50oC .Make pH with soda ash .Separate the

organic layer and cool to 20oc centrifuge the material.

5. Charge Chloro Sulphonic Acid at RT,add stage 2 in 60-90 min under nitrogen

atmosphere.Quench the reaction mass into cool water and MDC below 20oC

• clean and dry the GLR. Charge chloro sulphonic acid at RT .add stage II in 60-90 min

under nitrogen atmosphere . maintainance 4 hrs U/N2 atm . check TLC .Quench the rxn

into cool water and MDC below 20 oC. Stir for 15 min .extract with MDC .stir for 10 min

and settle for 30 min. separate the bottom MDC LAYER and kept aside . giveII&III MDC

extraction to aq. Layer . stir for 15 mins settle for 30 mins. Separate the bottom MDC

layers ,check aq. Layer TLC . take total MDC layers and wash with water stir for 15 mts

settle for 15mts . separate the bottom MDC layer cool to 10oC . take aq layer is clear

drain it. Take MDC layer and cool . add NMP + soda ash =water mixture at 10-15 oC in 1

hr PH should be 7.5-8.0 raise the temp at RT maintainance for 60-90 min check the TLC

if TLC complies settle for 30 mins separate bottom MDC layer . take aq. Layer and check

TLCFOR MATERIAL ABSENT . IF material present wash with MDC take total MDC layer

into the reactor distil out MDC completely with normally .finally apply vacuum . charge

water and remove MDC traces under vacuum . charge water cool to 25 oC and stir for

30-60 mins . centrifuge the material wash with chilled methanol . spin dry for 30-60

mins and unload the material. Total wet et --- dry the material 50-50o?C




STAGE 4

• Clean and dry the SSR charge water charge stage III dry at RT. Stir for 10 min raise the

temp 90-95oC stir for 1 hr. add slowly citric acid at 90-95 oC stir for 30 mts at 90-95 oC

check dissolution charge carbon .stir for 1 hr . filter through leaf filter to another reactor

at 90-95 oC (leaf jacket also arranges steam . cool to RT stir for 1 hr at 30-35 oC

centrifuge the mass wash with filterd acetone . spin dry 2 hrs unload the material dry

the material at 90-95 oC

STAGE -5

Clean and dry the GLR charge 2- ethoxy benzoic acid charge DMF at RT SSTIR FOR 10 MIN add

TC at 30oC raise the temp 70-750oC . maintainance 3 hrs at 70-75 oC check TLC if it is complies

Distil out TC completely at 75-80oCfinally apply vacuum. Nitrogen gas passing with bubbling ½

hr then check the ASSAY free acid (HCL content) gas passing at 75oC then cool to RT unload

into dry carboy’s

CHEMICAL REACTION

Sildnafil Citrate

Reaction sequence for sildnafil Citrate

STAGE —IA

2- Pentanone on condensation with diethyl oxalate in presence of sodium methoxide powder in

methanol gives

stage —IA

CH3COCH2CH2CH3 COOC2H5

COOC2H5

CH3ONA CO COOC2H5

CH2COCH2CH2CH3

2-PENTANONE +

DIETHYL OXALATE STAGE-IA

STAGE —IA

On cyclisation with hydrazine hydride in methanol media in presence of con. Sulphuric acid

gives stage-IB




CO COOC2H5

CH2COCH2CH2CH3

(H2N-NH2) H20

STAGE-IA +

H2SO4

STAGE —IB on Methylation with Dimethyl sulphate gives stage —Ic




MATERIAL BALANCE

Input MT Output MT

2- PENTANONE 0.05 THIONYL CHLORIDE 0.8

SMO LIQUOR 0.06 NITRIC ACID 0.91

HYDRAZINE HYDRATE

80% 0.07

ETHYLE ACETATE 1.3

Dil .SULPHURIC ACID 1.11 ML TO ETP 2.42

METHANOL 0.38 SPENT IRON 0.25

DI ETHYL OXALATE 0.3 NH3 Gas 0.8611

METHYLENE CHLORIDE 0.2

SPENT SULPHURIC

ACID 0.8

C.S FLAKES 0.25 RECOVERED TOLUENE 0.47

DMS 0.58 LOSS TOLUENE 0.03

HCL 0.58 SPENT CARBON 0.04

T.C 0.43 HYFOLW 0.01

DMF 0.04 RECOVERED EDC 0.94

HNO3 98% 0.92 SODA ASH 0.5

ETHYL ACETATE 0.5 SIDENAFIL CITRATE 1

IRON POWDER 100

MESH 0.75 LOSS EDC 0.01

AMMONIA GAS 0.35

TOLUENE 0.5

SODA ASH 0.7

2-ETHAOXY BENZOIC

ACID 0.43

CHLOROSULPHONIC

ACID 0.4

N- METHYL PIPERAZINE

(NMP) 0.2

EDC 0.94

CITRIC ACID

MONOHYDRIDE 0.25

ACETONE 0.32


HYFLOW SUPER CELL 0.01

10.36 10.36




30) TRAMADOL


1. Charge Water , DMA HCl and Paraformaldehyde along with HCL and stir for 30 mins and

add Cyclohexanone, maintain temperature at 60oC for 5 hrs and check sample for G.C

2. Separate organic layer from top in another reactor and distill out Cyclohexanone.

3. Charge Magnesium Turning, MCA, THF and maintain for 2 hrs at 80oC.Quench reaction

mass and separate mass, add magnesium hexahydrate to aqueous layer, centrifuge and

give water wash. Unload Tramadol Crude and proceed for purification.

4. Charge Methanol ,wet cake stir and cool to 10oC and centrifuge with chill methanol,

charge water, toluene and tramadol wet cake ,147eth for 1 hrs ,settle and separate

toluene layer

5. Aqueous layer wash with Toluene and add NaOH solution at 40oC.Separate at 40

oC

.Separate at 40oC and I toluene Layer. Distill out under vacuum at 70-75

oC

6. Add IPA and carbon Heat upto 50oC for 2 hrs, collect the filtrate ,add IPA HCL at 25

oC

,stir well and cool to 10oC

7. Cake wash with IPA and centrifuge material and sent material for drying.




Chemical Reaction :

Route Of Synthesis

STAGE —I

+

(CH3)2 NH

HCL

+ →

CYCLOHEXANONE DMA- HCL PARAFORMALDEHY

DE

TRAMADOL

MANNICH

HYDROCHLORIDE

STAGE-II

→

TRAMADOL MANNICH

HYDROCHLORIDE

CAUSTIC LYE MANNICH BASE

STAGE —III

+

→

MANNICH BASE M-CHLORO ANISOLE THF/MG TRAMADOL




Material balance

Input MT Output MT

CYCLOHEXANONE 1.00 RECOVERED TOLUENE 2.16

DIMETHYL AMINE HCL 0.63 LOSS TOLUENE 0.11

PARAFORMALDEHYDE 0.23 ML TO ETP 2.73

ACETIC ACID 0.02 RECOVERED THF 2.13

C.S FLAKES 0.36

MAGNESIUM TURNING

RECYCLE 0.07

TOLUENE 1.93 RECOVERED TOLUENE 2.59

D.M.WATER 0.44 LOSS TOLUENE 0.14

THF 0.50 SPENT CARBON 0.02

MG. TURNING 0.13 RECOVERED IPA 1.00

MCA 0.91 LOSS IPA 0.13

HCL 30% 0.68 TRAMADOL OUTPUT 1.00

TOLUENE 2.73 RESIDUE 0.04

D. M .WATER 0.00

C S FLAKES 0.23

REAGENT 0.82

AMMONIA 25% 1.02

IPA 1.14


IPA HCL 0.70

13.48 13.48




31) LUMEFANTRINE


1. Charged methanol, Sodium Hydroxide flakes in reactor at 30oC under cooling stir for 2

hrs for complete dissolution of caustic flakes & insure the caustic flakes should

completely dissolve, Apply chilling and cool to 25oC.

2. Charge2,7-Dichloro-alpha-[(dibutylamino)methyl]-9H-fluorene-4-methanol (LF3) in one

lot in reactor at 25oC. stir for 4 hrs at 5

oC mean while prepare a solution of Para chloro

Benzaldehyde in 150ethanol and filter it

3. Add Para Chloro Benzaldehyde solution in reactor with 40 min at temperature 25oC and

flush the addition receiver by methanol .Stir for 65oC hrs at 25

oC.

4. Maintain 25oC for 3 hrs centrifuge the products in centrifuge machine at 25

oC

5. Unload the wet cake & Load in Tray Dryer & after drying Check the material && forward

to Packaging dept.

Chemical Reaction:

Chemical Name :- 2,7-Dichloro-alpha-

[(dibutylamino)methyl]-9H-fluorene-4-

methanol

Molecular FormulaC23H29Cl2NO

CAS No:- 69759-61-1

+

Chemical Name:- 4-

CHLOROBENZALDEHYDE

Molecular Formula C7H5ClO

CAS No.: 104-88-1

→




Chemical Name :-LUMEFANTRINE

Molecular Formula C30H32Cl3NO

CAS number :- 82186-77-4

Material balance:

Input MT Output MT

2,7 DI CHLORO 9-H

FLUORENE 0.45

RECOVERED MDC 8.77

MDC 10.20 LOSS DC 1.55


METHANOL

RECOVERED 3.77

CHLORO ACETYL

CHLORIDE 0.42

LOSS METHANOL 0.20

METHANOL 3.97

EFFLUENT TO SOLVENT

STRIPPER 0.28

SODIUM BI

CARBONATE 0.16

Al(OH)3 BY PRODUCT 0.57

WATER 0.70 ML TO ETP 1.42

SODIUM BORO

HYDRIDE 0.05

N BUTANOL

RECOVERED 3.62

DI BUTYL AMINE 0.41 LOSS N BUTANOL 0.19

N BUTANOL

RECOVERED 2.11

N BUTANOL 3.81 LOSS N BUTANOL 0.11

PARA CHLORO

BENZALDEHYDE 0.34

MDC RECOVERED 2.16

N BUTANOL 2.22

OUTPUT

LUMIFANTRINE 1.00

CAUSTIC SODA FLAKES 0.06 LOSS MDC 0.37

MDC 2.54

26.00 26.00




32) ALUMINIUM HYDROXIDE GEL/POWDER


1. In SS reactor Charge Aluminium Chloride mother Liquor at R.T start addition of Caustic

lye slowly under stirring at R.T.

2. Adjust pH and add activated Carbon.

3. Check & Filter the Material.

4. Add Soda ash Solution, Filter the Material and send to Dryer.

5. Check the material, unload and send to Packing.

Chemical Reaction:

AlCl3 + 3H2O Al(OH)3 + 3HCl

MATERIAL BALANCE

Input MT Output MT


ALUMINIUM

HYDROXIDE

1.00

WATER 0.70 ML TO ETP 1.27

C S LYE 0.13 PROCESS LOSS 0.03

SOD ASH 0.01

CARBON 0.01

2.29 2.29

33 ) AMPICILLIN TRIHYDRATE

AMPICILLIN TRIHYDRATE




Charge methylene chloride, 6-A.P.A, acetamide and trimethylamine and cool the contents

between 5-100c and add dimethyl dichlorosilane (DMDCS) in three lots slowly . precaution

should be taken that temp does no go beyond 250c . after the addition is over continue stirring

for 2 hrs between 200c-25

0c

Reaction is complete in this period.

Stage-1 SILYL ESTER FORMATION

Charge methylene chloride in SSR add , 6-A.P.A , acetamide , H.M.D.S, wash the funnel with

methylene chloride . start heating and stirring for contents. Reflux ½ hr, check for clarity of soln.

distill out methylene chloride

Stage -2 CONDENSATION

Transfer above mix to GLR and wash with methylene chloride cool to -120c to -14

0c with brine .

add possibly in two lots P.G.C.H maintaining temp below -50c stir for 2 hrs at -5

0c and

condensation completes within this period.

Stage 3 HYDROLYSIS AND BASIFICATION

Take water in SSR cool the water up to 3-50c transfer above mix into cooled water add 10%

caustic solution .stir 10 min .allow it to settle , separate the lower layer (methylene chloride)

and move it for recovery. Upper aq. Layer is basified with 10%caustic soln by slow addition

maintain temp 50c separate starts at 3-3.5 pH by slow addition of caustic adjust pH to 5.2.

Stir for 2 hrs between 0-50c . centrifuge the material and cake is washed with DM WATER , IPA

Or ethanol. Cake is dried in dryer below 550c.

CHEMICAL RXN

H2N

S

26 N

COOH

CH3 CL

+ Si

CH3

CL

+ N(C2H5)3

CH3CONH2

MCL FRESH

6-APA

(6-AMINO PENICILLANIC

ACID)

DMDCS

(DIMETHYL DI

CHLORIDE

SILICON)




(CH3)2HN

S

+

o N 0 CH(NH2)-

COCL

COOSi(CH3)3

3H2O

AMPICILIN TRIHYDRATE

MATERIAL BALANCE

Input MT Output MT

6-AMINO PENICILLANIC ACID(6-APA) 1.4

METHYLENE CHLORIDE 8.4 LOSS IPA 0.4

ACETAMIDE 0.7 LOSS MDC 0.7

DIMETHYLDICHLOROSILANE(DMDCS) 1 RECOVERED IPA 2

ISO PROPYL ALCOHOL 2.4 RECOVERED MDC 12.3

TRIMETHYL AMINE 1.6 ML TO ETP 1.75

CAUSTIC SOLUTION 0.6 PROCESS LOSS 3.9

ACETONE 4.3

EFFLUENT TO


DM WATER 1 OUTPUT 1

PGCH 1.4

22.8 22.8

34) AMOXICILLIN TRIHYDRATE




BRIEF MANUFACTURING PROCESS

STAGE 1-REDUCTION

TEA -6-A.P.A FORMATION:

Charge DM WATER and 6-a.b.a and cool to 50c.

Add TEA slowly in 10 minutes. Add acetone and cool it. After 10 min soln becomes water like

clear.

Final temp should be -20 to -250c.

Mixed anhydride:

Charge acetone and PHGS and cooling is started with brine. After getting -50c start liq N2

cooling to get -350c

Add NMM catalyst and ECF. Flush the walls of reactor with acetone thoroughly . terminate N2

Cooling after getting -28 to -350c and continue brine cooling. After 45 min remove brine from

jacket and start liq N2 Cooling to get -40 to 450c.

STAGE 2 CONDENSATION AND HYDROLYSIS:

Add TEA -6 –A.P.A In one lot to mixed anhydride , while liq N2 Cooling continued. Get the temp

-40 by liq N2.

Stir for 1 hr without cooling note the temp should be -35 to -300c start brine circulation in

jacket and continue for ½ hr. add cold water (+50c) to the condensed mass and continue

stirring for 15 min solun becomes clear (-200c).add 9.5 HCL + 10 LT water ) , temp should be -5

to 100c and ph 1.5.

Stir for ½ hr and add 120 ltr CH2Cl2 and stir for 15 min. put under setting for 20 min and start

layer separation. Take upper aqueous layer for basification.

STAGE-3 BASIFICATION

Take above aqueous layer in third reactor. Basify with 10% caustic solution , separation starts at

2 to 2.5

Ph , adjust 5.2 ph maintain 0-50c continue stirring for 2 hrs. centrifuge the material. Wash with

DMWater IPA

Or ALCOHOL and acetone all three washings have to be done by making good slurry. Dry the

cake at 50-550c. followed by pulverizing and final product specification




CHEMICAL REACTION:

STAGE 1

H2N

S

26 N

COOH

TEA

ACETONE

/WATER

H2N

S

o N

COON+H(Et)3

6-APA

(6-AMINO PENICILLANIC ACID) 6-APA-TEA SALT

STAGE-2

HO---- O CH-COOK

NH

H3 C-C=CH-C00CH3

ACETONE

NMM

ECF

HO---- O CH-COON+H(Et)3

NH

H3 C-C=CH-C00CH3

DANE SALT MIXED ANHYDRIDE

6-APA-TEA SALT

.3H2O

HCL

HYDROLYSIS

BASIFICATION

HO---- O CH-COONH-6-APA-TEA

SALT

NH

H3 C-C=CH-C00CH3




MATERIAL BALANCE

Input MT Output MT

METHYLENE CHLORIDE 3.21 PROCESS LOSS 0.67

DANE SALT 0.90 NH3 Gas 5.95

NN DIMETHYL ACETAMIDE 0.29 ML TO ETP 1.19

2,6 LUTIDINE 0.03 ACETONE 0.95

PIVALOYL CHLORIDE 0.36

METHYLENE

CHLORIDE

3.07

2 ETHYL HEXANOIC ACID 0.03

AMOXICILLINE

TRIHYDRATE

1.00

6 APA 0.60

IPA 0.71

WATER 0.75

TEA 0.29

HCL 0.48

LIQ NH3 0.24

ACETONE 1.00

LIQ NITROGEN 3.95

12.83 12.83

35) CLOXACILLIN


STEP 1




Charge DM Water and chill to 0-20c. charge 6-APA 0-2

0c add 10% caustic soln

In 1 ½ hr at 0-20c ph should be 7.5 to 7.6. add ethyl acetate 2-4

0c add CIMC-Cl

Stir for 45 min5-80c raise temp in 30 min 17 to 18

0c stir for 30 min chill to 0

0c and add NaCl soln

. stir for 5 min ph 1.2 to 1.6 settle for 20 min (0-20c) separate layer discard aq. Layer .

STEP 2

charge NaCl soln in org layer stir for 5 min (0-20c) settle for 20 min separate aq layer and discard

add sodium sulphate in org layer stir for 10 min and stop stirrer . filter through sparkler and

transfer in another reactor flush 100 E.A raise temp of org layer to 140c.

Dump cloxa alkali without stirring add cloxa-Na as a seeding. Give 2-3jerks of stirrer stop stirring

leave as settling for 1 hr. stir for 10 min chill to 100c and centrifuge .flush E.A to centrifuge. Spin

for 4 hr. prepare slurry in E.A spin for 3 hr flush acetone .spin 1 hr unload. Dry for 8 hr at 45-

500c

Cloxa-alkali:

Charge MIBK charge cat-002 chill to 100c charge caustic flakes . heat to reflux and do azeotropic

distillation . Separate water and discard. Distill MIBK

With vacuum up to thick slurry cool to 500c stir for 30 min check % of alkali color index .

Chemical reaction

H2N

S

+ NH3+C2H5-NH2+ CH3 (CH2)3 –CH2-COONA +

o N

COOH

6-APA SODIUM HEXONATE

(6-AMINO PENICILLANIC ACID)

VC-MIC CHLORIDE




CLOXACILLIN

MATERIAL BALANCE

Input MT Output MT

6-APA 0.49 PROCESS LOSS 0.23

AMMONIA SOLUTION 0.32

RECOVERED ETHYL

ACETATE 4.45

CMIC 0.61 ML TO ETP 2.05

ETHYL ACETATE 4.68 CLOXACILLIN 1.00

NACL 0.66

SODIUM HEXONATE 0.98

7.73 7.73




36. CEPHALEXIN

MANUFACTURING PROCESS OF CEPHALEXIN

STEP 1

of 7-desacetoxycephalosporanic acid (7-ADCA) was slurried in of dry methylene chloride (MeCl

2) to which of 1,1,1,3,3-hexamethyl-disilazane (HMDS) was added and the reaction mixture was

refluxed for 20 hours. A clear, yellow-orange solution was obtained. Nitrogen gas purging was

used during the reflux period to purge NH3 gas. The reaction was cooled to 10° C. and 10.0 ml.

of dimethylaniline hydrochloride (DMA. HCl) in MeCl 2 (30% w/v) was added followed by.

dimethylaniline (DMA). The reaction was chilled to 0° C. and blanketed with dry N2. G. of D—(-)-

phenylglycyl chloride hydrochloride was added in 10 increments over a period of about one

hour. The temperature during the addition was held at 0°-2° C. The reaction was held at about

3° C. for 1 more hour. The reaction was then allowed to rise slowly over a period of four hours

to 20° C. During this time the slurry of D-(-)-phenylglycine chloride hydrochloride reacted and a

slight turbidity was noted. The reaction was held at 20° C. for 11/2 hours and a complete

solution was obtained. TLC (thin layer chromatography) on a sample of the reaction mixture at

this time showed the major cephalexin zone and did not show any unreacted 7-ADCA. The

reaction was placed in a refrigerator and held overnight for work-up the next day.

STEP 2

The reaction was stirred and of dry methanol was added. The reaction was stirred and brought

to 20°-25° C. and held for 20 minutes. Deionized water was added to the reaction and the two

phases were stirred for 15 minutes. The pH was 1.3. The pH was adjusted to 2.3 with of TEA. A

small amount of brown solids was noted at the interface; they were removed in the next step,

dried, and were discarded. The reaction mixture was polish filtered with a filter paper on top

and the cake was washed with of MeCl 2 and then deionized water for a complete transfer. The

aqueous phase was separated and was stirred with of new MeCl 2 and then separated. This

aqueous phase was stirred and of decolorizing charcoal was added and the slurry was stirred

for 15 min. The pH of the slurry was 1.9. The slurry was filtered and the cake was washed with

of deionized water. The filtrate and wash was concentrated under vacuum volume. pH = 1.9.

200 ml. of n-butanol (BuOH) was added to the aqueous concentrate and the two phases were

stirred while of triethylamine (TEA) was added and of seed cephalexin monohydrate (insoluble

form) was added to the crystallization mix. The temperature was 23° C. The pH was adjusted

slowly over a period of 21/2 hours to pH 4.6 with TEA. The total amount of TEA used was The

resulting slurry was stirred for 2 hours at 20°-23° C. and filtered. The cake was washed with n-

butanol followed by cold (0°-5° C.) deionized water. The cake was then washed with n-butanol

followed by a wash of isopropanol (IPA). The cake was dried at 55°-60° C. and of cephalexin

monohydrate was obtained. The yield was 27.2 g. cephalexin monohydrate (insoluble form;

yield corrected for 1.0 g. seed crystals added). The water content was a bit low because the

drying temperature should not have exceeded 50° C. The product (30 mgm.) did not dissolve in

1 ml. H2 O but did dissolve completely in 3 ml. H2 O.

Followed by recrystalization




Chemical reaction




MATERIAL BALANCE

Input MT Output MT

MECL2 7.24 ML TO ETP 2.70

ACETAMIDE 0.64 MECL2 9.2

HMDS 0.8

RECOVERED

METHANOL 2.2

7 ADCA 1 SPENT CARBON 0.04

D(ALPHA) PGCH 1.16 CEPHALEXIN 1

TEA 1.12

EFFLUENT TO


METHANOL 2.24


ACETONE 2.2

16.44 16.44




2.3 RAW MATERIAL STORAGE AND HANDLING

The raw materials shall be received in M.S. tank, HDPE/fibre drums, Carboys and cylinders as

well as through tankers. All the storage tanks of hazardous flammable substances shall be

located within premises in separate storage area i.e. Tank farm area shall be stored in MS/SS

tank with all precautionary process instrumentation and safety appliances. Large area is

covered by well-designed warehouse, which shall be containing store office, raw material store,

finished product store, etc. The personnel protective equipments like hand gloves, safety shoes,

goggles, helmet, clothing, etc. shall be provided to those handling hazardous chemicals as per

requirement. All the motors and electrical connections are flame proof. List of raw materials

are given in Table-2.1.

TABLE – 2.1

LIST OF RAW MATERIALS

SR. NO.

LIST OF RAW MATERIALS

QUANTITY MT/MT

(1) IBUPROFEN

1 MCA 0.25

2 IPA 0.91

3 SULPHURIC ACID 0.27

4 SODA ASH 0.10

5 ISO BUTYL BENZENE 0.23

6 ALUMINIUM CHLORIDE 0.20

7 EDC 1.30

8 AMMONIA SOLUTION 0.12

9 HCL 0.21

10 ACETYL CHLORIDE 0.11

11 SODIUM METAL 0.17

12 C.S.LYE 0.50

13 SODIUM DICHROMATE 0.19

14 ACETONE 1.48

15 N-HEXANE 1.26

(2) DICLOFENAC SODIUM

1 2,6 DICHLORO PHENOL 0.75

2 TOLUENE 3.03




3 POTASSIUM CARBONATE 0.40

4 MONO METHYL CHLORO ACETIC ACID 0.55

5 ANILINE 0.42

6 SODIUM METHOXIDE SOLUTION 0.20

7 CHLORO ACETYL CHLORIDE 0.32

8 ALLUMINIUM CHLORIDE 0.50

9 HCL 0.09

10 CAUSTIC FLAKES 0.48

11 CARBON 0.03

(3) ACECLOFENAC


2 TERTIARY BUTYL ALCOHOL 0.36

3 DI METHYL ANILINE 0.65

4 SODA ASH 0.01

5 CAYSTIC LYE 48% 0.45

6 DICLOFENAC SODIUM 1.03

7 FORMIC ACID 0.71

8 TOLUENE 1.03

(4) NIMESULIDE

1 PHENOL 0.34

2 KOH 0.27

3 ONCB 0.44

4 ACETIC ACID 0.01

5 IRON POWDER 0.24

6 METHANOL 2.21

7 METHANE SULPHONYL CHLORIDE 0.36

8 NN DIMETHYL ANILINE 0.44

9 CARBON 0.02

10 CAUSTIC LYE 0.31

11 CONC HNO3 70 % 0.24

12 TOLUENE 1.00

13 PHENOL 0.34

(5) CHLORZOXAZONE

1 4-CHLORO-2- AMINO PHENOL (4CAP) 0.95

2 UREA 0.95

3 HYDROCHLORIC ACID 3.13

4 METHANOL 1.91

5 ACTIVATED CARBON 0.11





7 ACETIC ACID 0.50

8 SODIUM HYDROSULPHITE 0.05

(6) MEFENAMIC ACID

1 2-CHLORO BENZOIC AID 0.48

2 2,3-XYLIDINE 0.31

3 TOLUENE 0.03

3 K2CO3 0.23

4 DMF 0.05

5 CARBON 0.02

6 HYFLOW 0.01

(7) MESALAMINE

1 POTASSIUM HYDROXIDE 0.52

2 2-chloro-5- nitro benzoic acid 0.24


4 SODIUM CARBONATE 0.25

5 RANEY NICKEL 0.29

6 SODIUM HYDROXIDE 0.18

7 CHARCOAL 0.19

8 SODIUM BICARBONATE 0.18

(8) ALBENDAZOLE

1 ORTHO NITRO ANILINE 0.85

2 AMMONIUM THIOCYNATE 0.21

3 METHANOL 8.70

4 CHLORINE GAS 0.53

5 CAUSTIC SODA 0.32

6 N- PROPANOL 0.43

7 N-PROPYL BROMIDE 0.85

8 TOLUENE 2.98

9 SODIUM HYDROSULPHIDE DILUTED 0.53

10 CYAANAMIDE SOLUTION (L-500) 0.25

11 CAUSTIC SODA 0.79

12 METHYL CHLORO FORMAT 0.07

13 ACETONE 2.68

(9) FEBENDAZOLE

1 5 CHLORO 2 NITRO ANILINE 0.79

2 METHANOL 3.03

3 THIOPHENOL 0.54

4 RANEY NICKEL 0.06




5 CYANAMIDE SOLN(50%) 0.39

6 METHYL CHLORO FORMATE 0.46


8 BUTYL ACETATE 0.41


(10) MEBENDAZOLE

1 PCBA 0.26

2 HNO3 55% 0.21

3 H2SO4 1.08

4 BENZENE 1.57

5 THIONYL CHLORIDE 0.13


7 ACETIC ACID 0.08

8 LIQ AMMONIA 0.12

9 METHANOL 3.06

10 SULPHUR 0.22


12 THIOUREA 0.15

13 DIMETHYL SULPHATE 0.12

14 METHYL CHLORO FORMATE 0.13

15 CAUSTIC SODA LYE 0.04

(11) METRONIDAZOLE

1 2 METHYL 5 NITRO IMIDAZOLE (2MNI) 1.20

2 GL A .ACID 0.78

3 ACETIC ANHYDRIDE 0.08

4 ETHYLENE OXIDE 0.96

5 SULPHURIC ACID 70% 1.15

6 LIQ NH3 1.12

7 CARBON 0.08

(12) METRONIDAZOLE BENZOATE

1 METRONIDAZOLE 0.71

2 BENZENE 1.79

3 BETA PICOLINE 0.54

4 BENZOYL CHLOIRDE 0.71

5 LIQUOR AMMONIA 25% 0.14

6 METHANOL 2.50

7 CHARCOAL 0.04

(13) TINIDAZOLE

1 2 METHYL 5 NITROMIDAZOLE (2MNI) 1.42

2 BENZENE 1.13




3 ETHYL THIO ETHANOL 1.13


5 LIQ AMMONIA 2.08

6 H2O2 50 % 0.92

7 METHANOL 0.85

8 CHARCOAL 0.03

(14) ORNIDAZOLE

1 2 METHYL 5 NITRO IMIDAZOLE 1.92

2 FORMIC ACID 85% 1.15

3 METHYLENE CHLORIDE 3.33

4 EPICHLORO HYDRINE 1.73

5 LIQ AMMONIA 3.98


7 METHANOL 1.73


(15) OXYCLOZANIDE

1 3, 5, 6 TRI CHLORO SALICYLIC ACID 0.61

2 THIONYL CHLORIDE 0.30

3 2, 4 -DI CHLORO - 6- AMINO PHENOL 0.45

4 MONO CHLORO BENZENE (FRESH) 0.18

5 MONO CHLORO BENZENE (RECOVERED) 3.92

6 ACETONE (FRESH) 0.39

7 ACETONE (RECOVERED) 2.78


(16) ROXARSONE

1 SODA ASH 0.29

2 ARSENIC TRIOXIDE 0.31

3 PARA CHLORO ANILINE 0.37

4 HCL 32 % 1.00

5 SODIUM NITRITE 0.42


7 COPPER SULPHATE 0.15

8 NITRIC ACID 98% 0.40

9 CAUSTIC LYE 48% 0.21

10 CARBON 0.04

(17) CHLORPHENIRAMINE MALEATE (C.P. MALEATE)

1 4 CHLROBENZYL CYANIDE 0.95

2 SODIUM AMIDE 0.80

3 PARA CHLORO PYRIDINE 0.4




4 DIMETHYL AMINO ETHYL CHLORIDE 0.70


(18) BROMHEXINE HCL

1 MONO CHLORO BENZENE 3.93

2 ORTHO NITRO TOLUENE 0.86

3 DIBROMO DIMETHYL HYDANTOIN 0.39

4 AZOBISISOBUTYRONITRILE 0.07

5 SODIUM BIO-CARBONATE SOLN. 0.79

6 N-METHYL CYCLOHEXYLAMINE 0.96

7 HYDROCHLORIC ACID (30%) 1.25

8 METHANOL 7.02

9 ACT.CARBON 0.04

10 IRON POWDER 0.36

11 LIQ . BROMINE 0.14

12 ETHYL ACETATE 5.71

13 SODIUM HYDRO SULPHITE 0.03

(19) AMBROXOL HCL

1 METHANOL 3.41

2 METHYL ANTHRANILATE 0.48

3 BROMINE 0.09

4 LIQ. AMMONIA 0.07

5 HYDROGEN PEROXIDE 0.09

6 THF 1.77

7 SODIUM BORO HYDRIDE 0.12

8 ACETIC ACID 0.02

9 TOLUENE 5.21

10 CHARCOAL 0.04

11 MANGANESE DIOXIDE 1.01

12 TOLUENE 2.51

13 SODIUM BOROHYDRIDE 0.10

14 TRANS 4-AMINO CYCLOHEXANOL 0.11

15 IPA 3.23

16 ACT CARBON 0.01

17 HCL 0.24

(20) PHENYLPHERINE HCL

1 3 HYDROXY ACETOPHENONE 1.33


3 BROMINE 0.78

4 TOLUENE 12.56




5 SODIUM BI CARBONATE SOLUTION 0.18

6 2-METHYL BENZYL AMINE 0.92

7 IPA HCL 1.44

8 METHANOL 8.00

9 PALLADIUM CHARCOAL CATALYST 0.28

10 CARBON 0.05

11 LIQ.AMONIA 1.67

12 IPA 1.20

13 L(+)TARTARIC ACID 1.11



16 IPA HCL 20% 0.80

17 CARBON 0.04

18 ACETONE 0.27

(21) DEXOMETHERPHAN

1 CYCLO HEXNYL ETHYL AMINE 0.4

2 4 METHOXY PHENYL ACETIC ACID 0.25

3 PHOSPHOROUS OXY CHLORIDE 0.4

4 SODIUM BROMO HYDRIDE 0.14

5 ORTHO XYLENE 0.5

6 CAUSTIC SODA LYE 0.35

7 TOLUENE 3.59

8 SODIUM SALT 0.5

9 D MANDALIC ACID 0.4

10 SMO 0.4

11 METHYL FORMATE 0.51

12 PHOSPHORIC ACID 0.31

13 PHOSPHOROUS PENTOXIDE 0.3

14 METHANOL 0.5

15 FORMALDEHYDE 0.48

16 FORMIC ACID 0.36


18 ACETONE 0.5

19 HYDROBROMIC ACID 0.4

(22) SALBUTAMOL SULPHATE

1 METHYL SALICYLATE 0.33

2 ETHYLENE CHLORIDE 3.50






5 SODIUM CARBONATE 0.03

6 CITRIC ACID 0.01

7 ICE 0.53

8 ACETONE 1.00

9 POT CARBONATE 1.00

10 POTASSIUM IODIDE 0.04

11 BENZYL CHLORIDE 0.40

12 METHANOL 5.00

13 TBAB 0.05


15 BROMINE 0.87

16 DIGLYME 0.33

18 T-BUYL AMINE 0.84

19 TBAB 0.01

20 SODIUM BOROHYDRIDE 0.29

21 PD/C 10 % 0.04


23 A CHARCOAL 1.00

(23) THEOPHYLLINE

1 UREA 0.50

2 MMA GAS 0.39

3 CAA AQUEOUS 0.80

4 MIBK 0.10



7 CAUSTIC LYE 48 % 0.99

8 SULPHURIC ACID (98%) 0.70

9 IRON POWDER 0.27


11 HYDROSO 0.01

12 FORMIC ACID 0.63

13 PROCESS SALT 0.50

14 HYFLO 0.01

15 DMS 0.00

16 CHLOROFORM 0.00

17 HYDROSO 0.01

18 A.CARBON 0.20

(24) CAFFEIN




1 UREA 0.58

2 MMA GAS 0.58

3 CAA AQUEOUS 0.43


5 MIBK 0.09



8 CAUSTIC LYE 48 % 0.44

9 IRON POWDER 0.26


11 HYDROSO 0.01

12 FORMIC ACID 0.55

13 PROCESS SALT 0.76

14 HYFLO 0.01

15 DMS 0.72

16 HCL 0.02

17 CHLOROFORM 0.25

18 HYDROSO 0.01

19 A.CARBON 0.30

(25) THEOBROMINE

1 CYNOACETIC ACID (CAA) 0.33

2 MONOMETHYLUREA 0.89



5 HCL 0.67

6 MMA GAS 0.22

7 BROMINE 0.09

8 H2O2 0.20

9 FORMIC ACID 0.22

10 C S LYE 48% 0.11

11 CARBON 0.03

(26) CIPROFLOXACIN

1 3 CHLORO 4 FLUORO ANILINE 0.2

2 CYCLOPROPYLAMINE 0.22

3 TRIETHYL ORTHO FORMATE 0.25

4 PIPERAZINE 0.13

5 SODIUM METHOXIDE 0.3

6 DIMETHYL CARBONATE 0.24

7 DIMETHYL SULPHOXIDE 0.31




8 PYRIDINE 0.2



11 POT. HYDROXIDE 0.2


13 CUPROUS CHLORIDE 0.2

14 SODIUM CHLORIDE 0.44


16 SODIUM SULPHATE 0.2


18 ACETIC ACID 0.2

19 HYDROCHLORIC ACID 3


21 ACIVATED CARBON 0.15

22 HYFLOSUPERCEL 0.10

23 AMMONIA 0.15

24 EDTA 0.04

26 CAUSTIC SODA FLAKES 0.25

27 BENZENE 1.0

28 METHANOL 4.95

29 EDC 0.18

(27) OFLAXACIN

1 OFLOXACIN Q ACID 0.81

2 METHANOL 0.83

3 N-METHYL PIPERAZINE 0.35

4 N-BUTANOL 0.49


6 ACETIC ACID 0.29

7 LIQUOR AMMONIA 0.28

(28) ENROFLOXACIN

1 3 CHLORO 4 FLUORO ANILINE 0.12

2 CYCLOPROPYLAMINE 0.17

3 TRIETHYL ORTHO FORMATE 0.15

4 PIPERAZINE 0.25

5 SODIUM METHOXIDE 0.28

6 DIMETHYL CARBONATE 0.15

7 DIMETHYL SULPHOXIDE 0.20

8 PYRIDINE 0.16






11 POT. HYDROXIDE 0.18


13 CUPROUS CHLORIDE 0.18

14 SODIUM CHLORIDE 0.12


16 SODIUM SULPHATE 0.15


18 ACETIC ACID 0.02



21 ACIVATED CARBON 0.15

22 HYFLOSUPERCEL 0.1

23 AMMONIA 0.25

24 EDTA 0.04


26 BENZENE 0.13

27 METHANOL 0.59

28 EDC 0.5

(29) SILDINAFIL CITRATE

1 2- PENTANONE 0.05

2 SMO LIQUOR 0.06

3 HYDRAZINE HYDRATE 80% 0.07


5 METHANOL 0.38

6 DI ETHYL OXALATE 0.3


8 C.S FLAKES 0.25

9 DMS 0.58

10 HCL 0.58

11 T.C 0.43

12 DMF 0.04

13 HNO3 98% 0.92


15 IRON POWDER 100 MESH 0.75

16 AMMONIA GAS 0.35

17 TOLUENE 0.50

18 SODA ASH 0.70

19 2-ETHAOXY BENZOIC ACID 0.43




20 CHLOROSULPHONIC ACID 0.4

21 N- METHYL PIPERAZINE (NMP) 0.20

22 EDC 0.94

23 CITRIC ACID MONOHYDRIDE 0.25

24 ACETONE 0.32


26 HYFLOW SUPER CELL 0.01

(30) TRAMADOL HCL

1 CYCLOHEXANONE 1.00

2 DIMETHYL AMINE HCL 0.63

3 PARAFORMALDEHYDE 0.23

4 ACETIC ACID 0.02

5 C.S FLAKES 0.36

6 TOLUENE 1.93

7 THF 0.50

8 MG. TURNING 0.13

9 MCA 0.91

10 HCL 30% 0.68

11 TOLUENE 2.73

12 C S FLAKES 0.23

13 REAGENT 0.82

14 AMMONIA 25% 1.02

15 IPA 1.14


17 IPA HCl 0.70

(31) LUMEFANTRINE

1 2,7 DI CHLORO 9-H FLUORENE 0.45

2 MDC 12.74



5 METHANOL 3.97

6 SODIUM BI CARBONATE 0.16

7 SODIUM BORO HYDRIDE 0.05

8 DI BUTYL AMINE 0.41

9 N BUTANOL 3.81

10 PARA CHLORO BENZALDEHYDE 0.34

11 N BUTANOL 2.22


(32) ALUMINIUM HYDROXIDE GEL/POWDER





2 C S LYE 0.13

3 SOD ASH 0.01

4 CARBON 0.01

(33) AMPCILLIN TRIHYDRATE

1 6-AMINO PENICILLANIC ACID(6-APA) 1.4


3 ACETAMIDE 0.7

4 DIMETHYLDICHLOROSILANE(DMDCS) 1

5 ISO PROPYL ALCOHOL 2.4

6 TRIMETHYL AMINE 1.6

7 CAUSTIC SOLUTION 0.6

8 ACETONE 4.3

9 PGCH 1.4

(34) AMOXICLLINE TRIHYDRATE


2 DANE SALT 0.90

3 NN DIMETHYL ACETAMIDE 0.29

4 2,6 LUTIDINE 0.03

5 PIVALOYL CHLORIDE 0.36

6 2 ETHYL HEXANOIC ACID 0.03

7 6 APA 0.60

8 IPA 0.71

9 TEA 0.29

10 HCL 0.48

11 LIQ NH3 0.24

12 ACETONE 1.00

13 LIQ NITROGEN 3.95

(35) CLOXACILLIN

1 6-APA 0.49

2 AMMONIA SOLUTION 0.32

3 CMIC 0.61


5 NACL 0.66

6 SODIUM HEXONATE 0.98

(36) CEPHALEXIN

1 MECL2 7.24

2 ACETAMIDE 0.64

3 HMDS 0.8

4 7 ADCA 1




5 D(ALPHA) PGCH 1.16

6 TEA 1.12

7 METHANOL 2.24


9 ACETONE 2.2




2.4 INFRASTRUCTURE FACILITIES

2.4.1 LAND

Total Plot Area is of 16,067.36 m2 out of which 5300.36 m

2 (i.e. 32.99 % approx.) of land shall be

utilized for the green belt area.

2.4.2 TRANSPORTATION FACILITIES

Transportation of all the raw material and products shall be primarily by road only.

2.4.3 WATER AND WASTEWATER

Water requirement = 154.0 KL/Day (Fresh: 57 KLD + Re use: 97 KLD) (Source: GIDC Water

Supply)

Wastewater Generation = 103.0 KL/Day

• Industrial = 82.0 KL/Day

• Domestic = 21.0 KL/Day

• High COD stream (27.0 m3/day) from process will be treated in MEE plant with solvent

stripper.

• Low COD stream from, Process, Boiler, Cooling, Washing/ & Domestic effluent (74

m3/day) will be sent to proposed ETP consists of primary, secondary & tertiary

treatments. To achieve the Zero Liquid Discharge, Treated effluent from ETP (74.0

m3/day) shall be treated in R.O. plant. Then R.O. permeate (53.0 m

3/day) shall be reused

in Boiler and Cooling while, R.O. reject (21 m3/day) shall be treated in MEE Plant & salt

will be sent to TSDF site for disposal. MEE Condensate 44.0 KLD will be reuse in

Industrial Purpose.

• Domestic wastewater will be added in biological treatment of ETP.

• Scrubbing media will be reuse in plant premises and sent to end users having Rule-9

permission.




TABLE - 2.2

WATER CONSUMPTION AND WASTEWATER GENERATION

SR.

NO.

CATEGORY WATER CONSUMPTION

(m3/day)

WASTE WATER

GENERATION (m3/day)

1. Domestic 21 21

2. Other (Gardening) 3 -

3. Industrial

Process 50 60

Boiler 40 7

Cooling 30 5

Washing 10 10

Total Industrial 130 82

Grand Total 154 103




WATER BALANCE DIAGRAM




2.4.3.1 SEGRIGATION OF WASTE STREAMS

• As shown in the diagram, effluent from the first stage of the process shall be

segregated as HIGH COD effluent & shall be treated in Solvent Stripper.

• Effluent from the second or other consecutive stages shall be segregated as LOW

COD effluent and it will be treated in ETP.




2.4.3.2 TREATMENT PROCESS

(1) ETP

M/s. Nutraplus India Ltd. shall have a ZLD Effluent treatment plant consisting of primary,

secondary tertiary and advanced treatment units. The details of ETP are as follows.

Stream I (74 KLD Low COD + RO Reject 21.0 KLD)

First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall pass

through Screen Chamber (SC) where floating material shall be removed with help of Screen (S-

01). Then effluent shall be passed through Oil & Grease Removal Tank (OGRT). Automatic

mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease from

the wastewater to Oil & Grease Collection Tank (OGCT). Then effluent shall be collected in

Collection cum Equalization tank (CET). Pipe grid is provided at bottom of the CET to keep all

suspended solids in suspension and to provide proper mixing. 2 nos. of Air Blowers (1 stand-by)

shall supply air through diffusers to pipe grid. Mother liquor Solvent Stripper shall be added in

CET.

Then after, equalized wastewater shall be pumped to Neutralization Tank (NT) where the

continuous addition and stirring of lime solution is done to maintain neutral pH of wastewater

from Caustic Dosing Tanks (CDT) as per requirement by gravity. Then after, neutralized

wastewater shall go to Flash Mixer (FM) by gravity. Alum and Polyelectrolyte shall be dosed

from Flocculants Dosing Tank (FLDT) and Polyelectrolyte Dosing Tank (PEDT) respectively by

gravity into FM-1 to carry out coagulation by using a Flash Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear

supernatant from PTS shall be passed in Aeration Tank (AT-1) Here, biodegradation of organic

matter of the wastewater shall be carried out by bacteria (suspended growth) in the AT-1 and

for that oxygen shall be supplied by 2 nos. of air blowers (B-02) through diffusers. Air blowers

also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Settling Tank-1 (SST-1) from AT. Here, the

suspended solids shall be settled. Sludge shall be removed from bottom of SST-1 and pumped to

AT-1 to maintain MLSS and excess activated sludge shall be sent to Sludge Sump (SS). Clear

supernatant from SST-1 shall go to Aeration Tank-2 (AT-2). Here biodegradation of left out

organic matter of the wastewater shall be carried out by bacteria (suspended growth) and for




that oxygen shall be supplied by two nos. of blowers (B-03) with help of diffusers. Then after,

wastewater shall go to Secondary Tube Settler-2 (SST-2) from AT-2. Here, the suspended solids

shall be settled. Activated sludge shall be removed from bottom of SST-2 and pumped to AT-2 to

maintain MLSS and remaining will be sent to SS. Nutrients will be added from NDTs to Aeration

Tank-2 for growth of Bacteria. Clear effluent is the collected in of Intermediate Sump (IS) by

gravity.

Thereafter, the wastewater shall be passed through Pressure Sand Filter (PSF) to remove left out

TSS and Activated Carbon Filter (ACF) for final effluent polishing. After tertiary treatment, Filter

water is collected to RO Feed Tank (RFT) and then pumped to RO Unit (large capacity) for further

treatment. Permeate water from RO will be reuse in process. RO reject will be sent to SD Feed

Tank (SDFT) for further treatment. Then effluent shall be sent to Spray Dryer (SD). Solid from Spray

Dryer shall be collected and stored in HWSA for ultimate disposal to TSDF.

Sludge settled in PTS-1 and excess sludge from SST-1 & 2 shall be collected in Sludge Sump

then sludge shall be pumped to Filter Press (FP) where, dewatering shall be carried out before

storage in HWSA and ultimate disposal to TSDF.

All high TDS streams of wastewater shall be collected in Solvent Feed Tank (SFT) then it will be

sent to Solvent Stripper (STR) where solvent shall be removed from effluent and collected in

Reactor (RE) before sent to Distillation Unit. Mother liquid from Solvent Stripper shall be sent in

CET for further treatment.

Stream II (27 KLD High COD )

All High COD streams of wastewater shall be collected in Collection cum Neutralization Tanks-2

(CNTs-02). Mixer is provided in Tank. where Lime shall be added from Lime Dosing tank. Then

after, effluent shall have sent to Flash Mixer-2 (FM-02) where Alum and poly shall be added

from ADT and PDT-01 respectively. Then after, coagulated wastewater shall be settled in

Primary Clarifier-1 (PCL-01).

Clear effluent from PCL-01 shall be collected in Holding Tank (HT-01) before pumped to

strippers (ST-01). Effluent from stripper collected in MEE Feed Tank (MFT-01) where RO reject

will be mixed with it. Then effluent shall be sent to Multiple Effect Evaporator (MEE-01) for

further treatment for solids dewatering. Condensate from MEE shall collect in Condensate

Storage Tank (CST-01) before reuse in plant. Solids from SD-01 shall be collected and stored in

HWSA for disposal in TSDF.




SIZE OF TANKS (Stream I and Stream II)

S.N. Name of unit Size (m x m x m)

L x B x (LD+FB) No. MOC/ Remark

Stream I (Low COD Stream) 74 KLD +21 KLD Ro Reject

1 Screen Chamber (SC-01) 1.5 m x 0.8 m

(0.05 m+0.7 FB)

1 RCC M25+A/A Bk.

Lining

2 Collection cum

Equalization Tank (CET-

01)

4.0 m x3.0 m x

(3.0 m+1.0 FB)

1 RCC M25+A/A Bk.

Lining

3 Neutralization Tank (NT-

01)

1.0 m x 1.0 m x

(2.5 m +0.5 FB)

1 RCC M25+A/A Bk.

Lining

4 Flash Mixer (FM-01) 1.0 m x 1.0 m x

(2.3 m +0.7 FB)

1 RCC M25

5 Primary Tube Settler (PTS-

01)

2.75 m x2.0 m x

(2.0 m + 0.5 HB+0.5 FB)

1 RCC M25

6 Aeration Tank-1 (AT-01) 8.0 m x 7.5 m x

(4.0 m+0.7 m)

1 RCC M25

7 Secondary Settling Tank-1

(SST-01)

3.0 m x 2.0 m x

(2.0 m + 0.5 HB+0.5 FB)

1 RCC M25

8 Aeration Tank-2 (AT-02) 7.5 m x 6.0 m x

(4.0 m+0.7 m)

1 RCC M25

9 Secondary Settling Tank-2

(SST-02)

2.5 m x 2.0 m x

(2.0 m + 0.5 HB+0.5 FB)

1 RCC M25

10 Intermediate Sump (IS-01) 2.0 m x 2.0 m x

(2.5 m+0.5)

1 RCC M25

11 Pressure Sand Filter (PSF-

01)

5 m3/hr 1 FRP

12 Activated Carbon Filter

(ACF-01)

5 m3/hr 1 FRP

13 RO Feed Tank (ROFT-01) 4.0 m x3.5 m x

(2.5 m+0.5 FB)

1 RCC M25

14 RO Unit 4.25 m3/hr 1 As per spec.

15 Sludge Sump(SS-01) 2.0 m x 2.0 m x

(2.5 m + 0.5)

1 RCC M25




16 Filter Press(FP-01) 7 m3

/ batch 1 PP

17 Drain Pit(DP-01) 1.0 m x1.0 m x

(2.0 m+0.3 FB)

1 RCC M25

Stream II (High COD stream) 27 KLD

18 Collection Cum Neutralization

Tank (CNT-01)

4.0 m x3.5 m x

(2.5 m+0.5 FB)

1 RCC M25+A/A Bk.

Lining

19 Flash Mixer-2 (FM-02) 30 m3/D 1 RCC M25

20 Primary Settling Tank (PST-01) 30 KLD 1 RCC M30

21 Holding Tank (HT-01) 50 KL 1 RCC M30

22 Stripper (ST-01) 30 KL 1 SS316

23 MEE Feed Tank (MFT-01) 50 KL 1 RCC M30

24 Multiple Effect Eveporator(MEE -

01)

200 M3/hr 1 SS316L

25 Solid Dryer (SD-01) 25 M3/Day 1 RCC M30/HDPE

26 Condensate Storage Tank (CST-01) 30 KL 1 RCC M30

• RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

• PCC = PLAIN CEMENT CONCRETE

• PP = POLYPROPELENE

• MSEP = MILD STEEL EPOXY PAINTED

• SS = STAINLESS STEEL

DETAILS OF SOLVENT STRIPPER

• All the solvents shall be directly distilled from high COD effluent with the help of Solvent

Stripper and Distillation.

• The solvent distillation system shall be designed so as to achieve minimum 92.0 %

recovery of solvent.

• Pure solvent, crude solvent and distilled (recovered) solvent shall be stored only in

storage tanks.

• Wherever required, the solvents shall be directly pumped into day tanks from the

storage tanks and shall be charged into the reactors without involving any manual

handling.

• All the pumps shall be mechanical seal type to avoid any leakage of solvent.




• All necessary fire fighting systems shall be provided with alarm system. Flame proof

wiring and flame proof electrical accessories shall be provided to avoid any mishap.

• All the storage tank and day tank shall be connected to a vent system through cooling

water and chilled brine condensers to prevent loss of solvents in the atmosphere.

• All the distillation column vents are also connected to cooling water/ chilled brine

condensers for maximum possible recovery of the solvents.

• All the vents will be connected to a common carbon Adsorber for removing traces of

solvent from vent gases.

• Residue generated from the distillation will be incinerated in-house or sent to BEIL

incinerator site.

• Coolant to be used

Primary Condensers Cooling Water

Secondary Condensers Chilled Brine up to -150C

Vent Condensers Chilled Brine up to -150C




CHB: CHILLED BRINE

CHW: CHILLED WATER

Solvent

Main

Storage

Tank

Addition

Tank

Reaction

Mass

With

Solvent

Receiver

Distilled

Solvent

Solvent

Distillation

System

Recycle

Organic

Layer/spent

solvent to recovery

System

FLOW DIAGRAM OF SPENT SOLVENT MANAGEMENT SYSTEM

CHW

in

CHB. In

C.W.

CHB. Out

CHB. Chilled Brine

CHW Chilled Water

Distillation

Column




FIG. SPENT SOLVENT MANAGEMENT SYSTEM

TECHNICAL DETAILS OF R.O.

FIG. R.O




TECHNICAL SPECIFICATION OF R.O

TECHNICAL SPECIFICATION ( CONTD..)




ETP DIAGRAM & STP (ADDED DOMESTIC WASTE WATER IN ETP UNIT AERATION TANK )




2.4.3.3 EXPECTED CHARACTERISTICS OF WASTEWATER

TREATABILITY STUDY REPORT

(CONDUCTED ON WASTE WATER)




1.0 LABORATORY TREATABILITY STUDIES

During manufacturing process high and low concentration effluent stream will be generated

from various operation. The effluent stream will be segregated such two streams …..

A. Concentrated effluent stream - 27 KL/Day

B. Dilute effluent stream - 85 KL/Day

A. FOR DILUTE EFFLUENT STREAM:

Dilute stream shall be generated from Process, Scrubber, Boiler, Cooling & Washing shall be

given primary, Secondary & Tertiary treatment followed by R.O. in Effluent Treatment Plant and

then treated waste water will be reused in Boiler & Cooling. Product wise characteristics of

effluent and characteristics of effluent after each stage is also listed here.

No

Parameter

Production

LOW COD STREAM

BOILER COOLING WASHING/

SCRUBBING

EFFLUENT

FROM

SOLVENT

STRIPPER

Quantity

KL/Day

6 5 10 10

1. pH 7.9 7.1 7.3 4.5

2 COD, mg/L 60 170 4000 3700

3 BOD3, mg/L <10 34 1100 900

4 TDS, mg/L 600 1350 2400 65000




No

.

Parameter

Production

IBUPROFE

N

DICLOFEN

AC

SODIUM

ACECLOFE

NAC

NIMESULIDE MEFENAMI

C ACID

MESALAMI

NE

Quantity

35.6 35.33 35.33 28.4 6.98 26.93

1. pH 5.2 4.9 6.1 6.0 6.8 4.8

2 COD, mg/L 3500 4125 3960 3147 4861 4221

3 BOD3, mg/L 1395 1544 1698 1517 1609 1608

4 TDS, mg/L 1685 1324 1755 1630 1800 1420




No

.

Parameter

Production

PROCESS EFFLUENT (LOW COD)

ALBENDA

ZOLE

FEBENDA

ZOLE

MEBENDA

ZOLE

METRONIDAZ

OLE

METRONID

AZOLE

BENZOATE

TINIDAZOL

E

Quantity

KL/Day

26.93 36.36 35.47 33.33 17.33 36.36

1. pH 6.8 5.9 4.9 6.3 8.3 5.2

2 COD, mg/L 3074 4108 4334 4839 5000 3500

3 BOD3, mg/L 1597 1563 1700 1527 1690 1647

4 TDS, mg/L 1638 1745 1736 1498 1441 1285




N

o.

Parameter

Production


ORNIDAZ

OLE

CHLORPH

ENIRAMI

NE

MALEATE

BROMHEXI

NE HCL

AMBROXOL

HCL

PHENYLEFF

RINE HCL

SALBUTEM

OL

SULPHATE

THEOPH

YLLIN

Quantity KL/Day

36.36 35.60 34.80 32.13 22.40 28.67 33.60

1. pH 5.0 6.8 5.8 6.2 5.1 5.7 7.2

2 COD, mg/L 3498 4210 3980 3405 5000 4813 3580

3 BOD3, mg/L 1544 1597 1620 1654 1810 1740 1652

4 TDS, mg/L 1727 1450 1585 1547 1694 1720 1532




No

.

Parameter

Production


CAFFEIN THEOBRO

MINE

CIPROFLOX

ACIN

OFLAXACIN ENROFLOX

ACIN

SILDINAFI

L CITRATE

Quantity

KL/Day

30.67 27.47 28.00 18.40 29.33 32.27

1. pH 6.8 6.4 4.7 5.9 6.1 4.6

2 COD, mg/L 4228 4628 3697 4484 5000 4920

3 BOD3, mg/L 1594 1632 1700 1547 1643 1741

4 TDS, mg/L 1698 1742 1796 1674 1729 1618




No

.

Parameter

Production


TRAMAD

OL HCL

ALUMINI

UM

HYDROXI

DE

GEL/POW

DER

AMPICILLIN CLOXACILLON CEPHALEXIN COMPOSITE

SAMPLE OF

LOW COD

Quantity

KL/Day

36.36 16.93 23.33 27.33 36.00 54.55

1. pH 6.6 8.1 7.6 7.9 6.5 4-8

2 COD, mg/L 4850 3852 4974 4558 3996 3957

3 BOD3, mg/L 1520 1682 1641 1579 1611 1489

4 TDS, mg/L 1750 1620 1684 1800 1795 3484




EXPECTED CHARACTERISTICS OF LOW COD EFFLUENT:

Parameter Untreated

(Dilute

Stream)

After

Primary

Treatment

After First

Stage

Aeration

After

Second Stage

Aeration

After

tertiary

Treatment

pH 4 - 8 6 - 7.5 6-7.5 6 - 7.5 6 - 7.5

COD (mg/L) 3957 <3600 <1350 <300 <250

BOD3

(mg/L) 1489 <1300 <400 <50 <30

TDS (mg/L) 3484 3680 3341 3100 2500




B. FOR HIGH COD EFFLUENT STREAM

No

.

Parameter

Production

PROCESS EFFLUENT (HIGH COD)

IBUPROFE

N

DICLOFEN

AC

SODIUM

CHLORZOX

ASONE

MESALA

MINE

ALBENDAZ

OLE

MEBENDA

ZOLE

TINIDAZO

LE

Quantity

KL/Day

20 17.33 16 21.33 22.73 20 20.93

1. pH 4.9 5.7 5.9 6.2 4.0 6.6 5.0

2 COD, mg/L 27832 23278 23410 22936 25281 20536 25378

3 BOD3, mg/L 9270 7764 7804 7645 8420 6845 8460

4 TDS, mg/L 21362 26120 29588 21423 23466 23316 27236

5 AMMONICAL

NITROGEN 52 62 54 57 40 48 45




No

.

Parameter

Production


ROXARSO

NE

BROMHEX

INE HCL

SALBUTEM

OL

SULPHATE

THEOPHY

LLIN

CAFFEIN THEOBRO

MINE

OFLAXACI

N

Quantity

KL/Day

22.27 21.20 18.00 19.80 22.73 20.93 22.27

1. pH 6.7 6.6 5.5 9 6.7 5.0 6.7

2 COD, mg/L 28215 23821 29130 27197 28794 25378 28215

3 BOD3, mg/L 9410 7940 9710 9054 9598 8446 9405

4 TDS, mg/L 21592 27411 20058 28541 23154 27236 21592

5 AMMONICAL

NITROGEN 58 66 62 30 35 36 34




No

.

Parameter

Production


LUMEFAN

TRINE

AMPICILLI

N

AMOXICILL

IN

CEPHALEXI

N

COMPOSITE

SAMPLE OF HIGH

COD

Quantity

KL/Day

21.20 18.00 19.80 17.33 22.73

1. pH 6.6 5.5 8.2 6.7 4-9

2 COD, mg/L 23821 29130 27197 28794 27130

3 BOD3, mg/L 7940 9710 9065 9598 9040

4 TDS, mg/L 27411 20058 28541 23154 28958

5 AMMONIACAL

NITROGEN 66 62 78 54 63




Characteristics of Effluent:

Product No. Boiler Cooling Washing

pH 7.9 7.1 7.3

COD (mg/L) 60 170 2300

BOD3 (mg/L) <10 34 700

TDS (mg/L) 600 1350 1400

Expected Characteristics Of Wastewater Before & After Treatment Low COD

Parameter Untreated

(Dilute

Stream)

After

Primary

Treatment

After First

Stage

Aeration

After

Second Stage

Aeration

After

tertiary

Treatment

R.O

Permeate

pH 4 - 8 6 - 7.5 6-7.5 6 - 7.5 6 - 7.5 6 - 7.5

COD

(mg/L)

3957 2690 1107 180 176 <10

BOD3

(mg/L)

1489 1042 560 48 25 <5

TDS

(mg/L)

3484 3208 3190 3180 2898 <150

Expected Characteristics Of Wastewater Before & After Treatment High COD

SR.

NO.

PARAMETER CHARACTERISTICS(MG/L)

Untreated After Solvent Stripper MEE Condensate

1 pH 4.5 7.5 7.5

2 TDS 28000 28000 <30

3 COD 27500 1500 <200

4 BOD3 7000 650 <50




2.4.4 AIR POLLUTION AND CONTROL SYSTEM

1) FLUE GAS STACK

Details Of Flue Gas Emission

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

1 Steam Boiler

6 TPH *2 Nos.

30. 0 M Coal/

Briquettes

of Bio-Coal

24 MT/Day

or

15 MT/Day

Pm<150

Mg/Nm3

So2< 100 ppm

Nox< 50 ppm

Multi -Cylcone

separator with

bag filter and

water

scrubber

2 Thermopack

Capacity

(4000 U)

30. 0 M Coal/

Briquettes

of Bio-Coal

24 MT/Day

or

15 MT/Day

PM<150

Mg/Nm3

So2< 100 ppm

Nox< 50 ppm

Multi -Cylcone

separator with

bag filter and

water

scrubber

3 D. G Set

1000 KVA

11. 0 M Diesel 2000

Lit/Day

PM<150

Mg/Nm3

So2< 100 ppm

Nox< 50 ppm

Adequate

Height

Provided.




2) PROCESS STACK

Details Of Process Gas Emission

Particulars Height Emission Norms APCM

Process Vent*-1

(Product :15 : Oxyclozanide)

(Product :10 : Mebendazole)

15 m HCl < 20 mg/Nm3

SO2 < 40 mg/Nm3

Two Stage

Scrubber

(Water +

Alkali)

Process Vent*-2

(Product :10 : Mebendazole) (Product :23 :

Theophylline) (Product :24 : Caffein)

15 m CL2< 9.0 mg/Nm3 Two Stage

Scrubber

(Water + Alkali)

Process Vent*-3 :

(Product :20 Phenylpherine) (Product :29

Sildinafil Citrate) (Product :34 Amoxicillin

Trihydrate)

15 m NH3< 175.0 mg/Nm3 Two Stage Acid

Scrubber

Process Vent*-4 :

(Product :21 Dexometherphan)

15 m HBR< 30.0 mg/Nm3 Two Stage

Alkali Scrubber

2.4.5 NOISE LEVEL AND CONTROL SYSTEM

Extensive oiling and lubrication and preventive maintenance shall 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.

2.4.6 HAZARDOUS WASTE GENERATIONS AND DISPOSAL SYSTEM

Hazardous waste generation quantity, physical characteristics and mode of disposal are given in

Table-2.3.




TABLE-2.3

DETAILS OF HAZARDOUS WASTE AND ITS MODE OF DISPOSAL

Sr.

no.

Type/Name of

Hazardous

waste

Specific Source of

generation

(Name of the Activity,

Product etc.)

Category

and

Schedule

as per HW

Rules.

Quantity

(MT/Annum)

Management of HW

1 ETP Sludge From ETP plant Sch-I/35.3 636

MT/Year

Collection, Storage,

Transportation & sent

for co-processing in

cement industries or

disposal at nearest

TSDF Site.

2 Discarded

Container/

Bags/Drums

From raw material Sch-

I/33.1

36.0

MT/Year


Transportation,

Decontamination &

Sell to authorized

vendors

3 HDPE Bags From raw material Sch-

I/33.1

12.0

MT/Year


Transportation,

Decontamination &

Sell to authorized

vendors

4 Distillation

Residue

From Solvent

Recovery plan

Sch-

I/33.1

360.0

MT/Year





disposal at common

incineration site

5 Spent Solvent From mfg. Process Sch-

I/36.1

12000.0

MT/Year


and in-house solvent

recovery plan &

Reuse in plant

premises.

6 Used Oil From plant

machinery

Sch-I/5.1 6.0

MT/Year


Transportation &

Reuse or sale to

registered re-

processors




7 Process

Waste

From plant

machinery

Sch-

I/28.1

480.0

MT/Year





disposal at common

incineration site

8 Spent Carbon From mfg. process

Product no.02,04,10-

16,18,19,21,25,26-

30,36

Sch-

I/28.3

192

MT/Year

9 Iron Sludge From mfg. process

Product

no.04,18,23,24,29

Sch-

I/28.1

1200

MT/Year




cement industries

10 Spent Catalyst From mfg. process

Product no.09,22

Sch-

I/28.2

24.0

MT/Year


Transportation &

return back to

supplier for re-

generation or Sent to

nearest common

Incineration Site.

11 MEE Salt From waste water

treatment MEE

Sch-

I/35.3

430

MT/Year





disposal at nearest

TSDF Site.

12 HCl (32%) From mfg. process

Product no.07,08 &

Scrubber

Sch-

I/28.1

4800.0

MT/Year


Transportation And

Reuse in Roxarsone

(Require Quantity of

HCL (32%)–5400

MT/Annum)

13 H2SO

4 (70%) From mfg. process

Product no.09,22

Sch-

I/28.1

3840.0

MT/Year


Transportation And

Reuse in Sildinafil

Citrate (Require

Quantity of H2SO4

(70%)–5328.0

MT/Annum).

14 Sodium

Sulphite

From mfg. process

Product no.15,10 &

Scrubber

Sch-

I/28.1

360.0

MT/Year


Transportation & sell

to end user having

Rule-9 Permission.




15 Sodium

hypochlorite

From mfg. process

Product no.15,10 &

Scrubber

Sch-

I/28.1

180.0

MT/Year



to end user having

Rule-9 Permission. 16 Ammonium

Chloride

From mfg. process

Product no.08,22

Sch-

I/28.1

672.0

MT/Year

17 Sodium

Sulphate

From mfg. process

Product no.17,23

Sch-

I/28.1

1800.0

MT/Year

18 Sodium

Bromide

From mfg. process

Product no.08 &

Scrubber

Sch-

I/28.1

816.0

MT/Year

19 KCl Salt From mfg. process

Product no.04

Sch-

I/28.1

288.0

MT/Year

20 Sodium

Carbonate

From mfg. process

Product no.07,22

Sch-

I/28.1

1200

MT/Year


Transportation And

Reuse in MESALMINE


Sodium Carbonate

(1200.0 MT/Annum)

or SALBUTAMOL

SULPHATE (Require

Quantity of Sodium

Carbonate (144.0

MT/Annum) Send to

End users having Rule

9 permission.

21 AlCl2 From mfg. process

Product no.22,26

Sch-

I/28.1

660.0

MT/Year


Transportation And

Send to End users

having Rule 9

permission.

22 Al(OH)3 From mfg. process

Product

no.01,02,10,32

Sch-

I/28.1

2760.0

MT/Year



to end user having

Rule-9 Permission.

23 NaOH From mfg. process

Product no.07

Sch-

I/28.1

768.0

MT/Year


Transportation And

Reuse in MESALMINE


Sodium Hydroxide

(864.0 MT/Annum) or

Send to End users




having Rule 9

permission.

24 MnO2 From mfg. process

Product no.19

Sch-

I/28.1

1920.0

MT/Year



to end user having

Rule-9 Permission. 25 Methane

Sulfonic Acid

From mfg. process

Product no.21

Sch-

I/28.1

2160.0

MT/Year

26 Methyl Sodium

Sulphate

From mfg. process

Product no.24

Sch-

I/28.1

3060.0

MT/Year

27 MMA Solution From mfg. process

Product no.25

Sch-

I/28.1

624.0

MT/Year

28 Ether From mfg. process

Product no.26

Sch-

I/28.1

2400.0

MT/Year

Non-Hazardous Waste

1. Fly Ash From APCM -- 360.0

MT/Year


Transportation and

sell to brick

manufacturer

2.5 DETAILS OF UTILITIES

Various utilities required for proper functioning of manufacturing plants. These utilities include

boiler, cooling plant, Cooling tower, DM water plant, Chilling Plant & Brine Unit, Air

compressor, High Vacuum System, etc.

2.6 ELECTRICITY & FUEL REQUIREMENT

Estimated power requirement is 1200 MW

Power will be taken from DGVCL.

1 No. of 1000 KVA Capacity of DG set will be kept for emergency power back up.

FUEL REQUIREMENT (MT)

SR.

NO.

FUEL REQUIREMENT

1 DIESEL 1000 Lit/ Day




2 COAL/AGRO WASTE 18 MT/Day

2.7 DETAILS OF GREEN BELT

Good greenery shall be maintained in and around the site by planting various types of trees

and maintaining lawns. About 5300.36 m2 of the open area will be utilized for tree

plantation / development of lawns. A green belt with width of min. 1 m shall be developed

within the site boundary.

GREEN BELT DEVELOPMENT PROGRAMME

YEAR NO. OF TREES / PLANTS TO BE PLANTED IN PLANT AREA

2016-2017 200

2017-2018 200

2018-2019 75

2019-2020 80

2020-2021 80

2.8 IMPLIMENTATION SCHEDULE

Phase wise project implementation schedule bar chart and time frame.

• 8 Blocks Of APIs

• Each Block : Within 6 To 9 Months

• Within 3 years entire project will be done.

M/S. NUTRAPLUS INDIA LTD. (UNIT-2)



CHAPTER – 3:

BASELINE ENVIRONMENTAL STATUS

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 Pre-Monsoon Season of 2017 (March, 2017 to May, 2017)

in a study area of 10 km radial distance from the project site.

3.1 MICRO METEOROLOGY OF THE AREA

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. Bharuch 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. (Courtesy:

Environmental Information Centre, New Delhi)




3.1.1 TEMPERATURE DETAILS

Minimum, Maximum and Average Temperatures for Vadodara Station of the year 2016 are

given in Table 3.1.

TABLE 3.1

TEMPERATURE DATA

MONTH

(2016)

MINIMUM

TEMPERATURE

(0C)

MAXIMUM

TEMPERATURE

(0C)

AVERAGE

TEMPERATURE

(0C)

January 12 30 22

February 11 36 24

March 17 41 29

April 24 42 31

May 27 44 36

June 26 42 31

July 23 26 30

August 25 35 29

September 21 38 30

October 17 39 29

November 15 36 28

December 10 34 21




3.1.2 RELATIVE HUMIDITY (RH)

Minimum, Maximum and Average Monthly Relative Humidity for Vadodara Station of the

year 2016 is given in Table 3.2.

TABLE 3.2

RELATIVE HUMIDITY DETAILS

MONTH

(2016)

MINIMUM R.H.% MAXIMUM R.H.% AVERAGE R.H.%

January 22 92 60

February 21 84 51

March 15 92 48

April 16 91 52

May 18 90 54

June 25 100 69

July 45 100 76

August 51 97 75

September 29 96 69

October 10 89 56

November 24 98 53

December 20 82 49

The Relative Humidity values for Vadodara station was recorded & Relative Humidity is

generally high during the period from June to September. The diurnal variations are least

during monsoon season. The diurnal variation is highest during summer period.




3.1.3 RAINFALL

Rainfall data for Bharuch Station of the year 2016 is presented in Table 3.3.

TABLE 3.3

RAINFALL DATA

MONTH

(2016)

MONTHLY TOTAL

(MM)

NUMBERS OF RAINY DAYS

January 0 0

February 0 0

March 0 0

April 0 0

May 0 0

June 25 7

July 159 25

August 118 17

September 94 12

October 100 3

November 0 0

December 0 0

Total 496 64

Total rainfall, during the monsoon period, has been recorded as 496 mm.




3.1.4 WIND SPEED

Wind speed for Vadodara Station of the year 2016 is given in Table 3.4.

TABLE 3.4

WIND SPEED DATA

SR. NO. MONTH

(2016)

AVERAGE WIND SPEED

(KMPH)

1. January 10

2. February 9

3. March 9

4. April 12

5. May 14

6. June 17

7. July 19

8. August 13

9. September 11

10. October 8

11. November 6

12. December 8

Average 11.33




Site-specific mean meteorological data is given in Table-3.5. A meteorological station was

installed at the project site to know temperature, relative humidity, hourly wind speed,

direction, and rainfall at the project site during the study period:

TABLE - 3.5

___________________________________________________________________________

SITE SPECIFIC METEOROLOGICAL DATA

(PERIOD: MARCH, 2017 TO MAY, 2017)

METEOROLOGICAL

PARAMETER

MONTH

MARCH,

2017

APRIL,

2017

MAY,

2017

Temperature (0C)

Min.

Max.

Avg.

21

44

31

20

44

34

24

47

35

Relative Humidity(%)

Min.

Max.

Avg.

11

76

41

14

72

58

15

74

60

Wind Speed (km/h)

Min.

Max.

Avg.

0

21

5.0

0

20

6.5

0

26

8.5

There was no rainfall during the study period. The wind direction is predominantly from SW

to NE. Diurnal shift in wind direction was not observed during study period. The wind rose

diagram prepared from data collected at site is shown in Figure 3.1A, while stability class

diagram is shown in Figure 3.1B




FIGURE-3.1A

WIND ROSE DIAGRAM

March, 2017 to May, 2017




2.2

69.6

16.2

10.1

1.90

10

20

30

40

50

60

70

80

%

Wind Class Frequency Distribution

Wind Class (m/s)Calms 0.5 - 2.1 2.1 - 3.6 3.6 - 5.7 5.7 - 8.8 8.8 - 11.1 >= 11.1

12.1

15.3

9.811.0

12.5

37.2

0

5

10

15

20

25

30

35

40

45

%

Stability Class Frequency Distribution

Stability ClassA B C D E F

FIGURE-3.1B

STABILITY CLASS DISTRIBUTION




3.2 AIR ENVIRONMENT

3.2.1 DESIGN OF NETWORK FOR AMBIENT AIR QUALITY MONITORING LOCATIONS

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 baseline studies for air environment include identification of specific air pollutants prior

to implementation of the project. The Environmental Impact Assessment (EIA) study

requires monitoring of baseline ambient air quality during one season. Accordingly, ambient

air quality monitoring was carried out in the pre-monsoon season from March 1, 2017 to

May 31, 2017. The main sources of air emissions in the study area are industrial operations,

vehicular emission, dust from paved and unpaved tracks, fuel burning for domestic purpose,

and wind blown dust from open land.

Nine Ambient Air Quality Monitoring (AAQM) locations were selected based on guidelines of

ambient air quality network siting criteria of CPCB. All AAQM locations were selected within

the study area of 10 km radial distance from the project site covering all zones i.e. industrial,

residential, rural & other area as per NAAQS and keeping in mind local topography and

meteorology of the area.




3.2.2 METHODOLOGY FOR AMBIENT AIR QUALITY MONITORING

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 ten locations during the study period. The locations of the different stations with

respect to its distance and direction from project site are shown in Table-3.6 and Figure-3.2

respectively.

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), Ozone (O3), Lead

(Pb), Carbon Monoxide (CO), Ammonia (NH3), Benzene (C6H6), Benzo (a) Pyrene (BaP),

Arsenic (AS), Nickel (Ni), Chlorine (Cl2), HCl, Br2 & VOCs 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 maximum concentration and percentile values. The existing 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), Ozone (O3), Lead (Pb), Carbon Monoxide (CO), Ammonia (NH3),

Benzene (C6H6), Benzo (a) Pyrene (BaP), Arsenic (AS), Nickel (Ni), Chlorine (Cl2) ), HCl, Br2 &

VOCs are expressed in terms of various statistical parameters as given in Tables-3.7 National

ambient air quality standards are enclosed as Annexure-1.




TABLE - 3.8

___________________________________________________________________________

DETAILS OF AMBIENT AIR QUALITY MONITORING LOCATIONS

SR.

NO.

NAME OF VILLAGE BEARING

W.R.T.

PROJECT

SITE

APPROXIMATE RADIAL

DISTANCE FROM PROJECT

SITE (KM)

TYPE

OF

AREA

1 Project-site (A1) --- --- Industrial

2 Saykha (A2) SW 0.51 Residential

3 Vagra (A3) NE 6.85 Residential

4 Juned (A4) NE 4.30 Residential

5 Bhersam (A5) SE 3.50 Residential

6 Kothia (A6) SW 3.40 Residential

7 Khojbal (A7) SW 8.9 Residential

8 Keshrol (A8) SW 9.25 Residential




FIGURE - 3.2

___________________________________________________________________________

LOCATION OF AMBIENT AIR QUALITY MONITORING STATIONS




TABLE 3.9

___________________________________________________________________________

AMBIENT AIR QUALITY STATUS (March, 2017 to May, 2017) Unit: µg/m3

SR.

NO.

SAMPLING

LOCATION

SPM PM10 PM2.5 SO2 NOx O3

AVERAGE

1 Project-site

(A1)

122.25 76.12 45.23 11.15 17.12 132.25

2 Saykha (A2) 124.16 81.56 44.12 12.15 16.14 144.16 3 Vagra (A3) 129.27 84.15 43.15 16.14 19.23 139.27 4 Juned (A4) 124.13 79.48 40.2 17.23 17.5 134.13 5 Bhersam (A5) 128.03 79.23 39.15 12.1 14.2 138.03 6 Kothia (A6) 121.55 75.45 38.14 11.01 14.3 131.55 7 Khojbal (A7) 129.13 70.87 38.98 15.45 16.2 129.13 8 Keshrol (A8) 119.04 67.88 41.12 13.15 15.98 119.04 Limit 500 100 60 80 80 100

TABLE 3.9 (CONTD.)

___________________________________________________________________________


SR.

NO.

SAMPLING

LOCATION

Pb NH3 CO

(mg/m3)

C6H6 BaP

(ng/m3)

As

(ng/m3)

Ni

(ng/m3)

AVERAGE

1 Project-site (A1) BDL BDL 1.15 BDL BDL BDL BDL

2 Saykha (A2) BDL BDL 1.12 BDL BDL BDL BDL

3 Vagra (A3) BDL BDL 1.13 BDL BDL BDL BDL

4 Juned (A4) BDL BDL 1.16 BDL BDL BDL BDL

5 Bhersam (A5) BDL BDL 1.11 BDL BDL BDL BDL

6 Kothia (A6) BDL BDL 1.12 BDL BDL BDL BDL

7 Khojbal (A7) BDL BDL 1.14 BDL BDL BDL BDL

8 Keshrol (A8) BDL BDL 1.17 BDL BDL BDL BDL

Limit 1 400 4 5 1 6 20

Note: BDL – Below Detectable Limit




TABLE 3.9 (CONTD.)

___________________________________________________________________________


SR.

NO.

SAMPLING

LOCATION

HCl Cl2 HBr HC

(ppm)

VOCs (Isobutylene

Equivalent)

(ppm)

AVERAGE

1 Project-site

(A1)

BDL BDL BDL 1.10 0.4

2 Saykha (A2) BDL BDL BDL 1.20 0.5

3 Vagra (A3) BDL BDL BDL 1.31 0.6

4 Juned (A4) BDL BDL BDL 1.61 0.2

5 Bhersam (A5) BDL BDL BDL 1.30 0.5

6 Kothia (A6) BDL BDL BDL 1.71 0.5

7 Khojbal (A7) BDL BDL BDL 1.41 0.5

8 Keshrol (A8) BDL BDL BDL 1.31 0.2

Note: BDL – Below Detectable Limit

PARAMETER TEST METHOD

Particulate Matter (PM10) IS 5182 (PART 23):2006 (Cyclonic Flow Technique) Gravimetric

Particulate Matter (PM2.5) Gravimetric

Sulphur Dioxide (SO2) IS 5182 (PART-2):2001

Nitrogen Dioxide (NO2) IS 5182 (PART-6):2006

Ozone (O3) IS 5182 (PART-9) :1974 **

Lead (Pb) AAS APHA 3030 E

Ammonia (NH3) Indophenol Blue Method *Carbon Monoxide (CO) Digital CO Analyzer

**Benzene (C6H6) Adsorption extraction followed by GC/GCMS

**Benzo (α) Pyrene (BaP) Solvent extraction followed by GC/GCMS

**Arsenic (As) AAS APHA 3114 B- C

**Nickel (Ni) AAS APHA 3030 E

**Hydro Carbon (HC) Digital Gas Analyzer

Hydrogen Sulphide (H2S)

IS 5182 (PART-7):1973 *Hydrochloric Acid(HCl) Titrametric Method

Chlorine (CL2) IS:5182:(PART-19):1982 *Hydrogen Fluoride (HF) IS:5182:(PART-13):1991

Carbon Disulphide (CS2) IS:5182:(PART-20):1982

VOC – Aeroqual Series 300 (Sensor 0 – 25 ppm)

Minimum Detectable Limit – 0.1 ppm

Minimum Detection Limit: **

Lead (as Pb) : 0.5 µg/m3

**Benzo (α) Pyrene (BaP) : 0.5 ng/m

3

Ammonia (NH3) : 1 µg/m3

**Arsenic (as As) : 2 ng/m

3

Carbon Monoxide(as CO) : 1.14 mg/m3

**Nickel (as Ni) : 10 ng/m

3

**Benzene (as C6H6) : 2 µg/m

3

**Hydrocarbon(HC) : 1 ppm

*Not in our NABL Scope,

**Analysed by Sub Contractor (Not in our NABL Scope)




TABLE 3.9 (CONTD.)

___________________________________________________________________________

AMBIENT AIR QUALITY STATUS- MINIMUM, MAXIMUM, 98TH

PERCENTILE VALUE &

AVERAGE (24 HRS.)

(MARCH, 2017 TO MAY, 2017) Unit: µg/m3

SR.

NO.

SAMPLING

LOCATION

LIMIT PROJECT

SITE

SAYKHA VAGRA JUNED BHERSAM KOTHIA KHOJBAL KESHROL

1 PM10 100

Average 76.12 81.56 84.15 79.48 79.23 75.45 70.87 67.88

Min – Max 71-82 75-86 80-89 73-85 73-85 71-80 65-74 60-70

98th

Percentile

82 86 89 85 85 80 74 70

2 PM2.5 60

Average 45.23 44.12 43.15 40.2 39.15 38.14 38.98 41.12

Min – Max 39-49 39-49 39-48 35-46 35-45 33-45 33-45 33-46

98th

Percentile

49 48 48 46 45 45 46 46

3 SO2 80

Average 11.15 12.15 16.14 17.23 12.1 11.01 15.45 13.15

Min – Max 6-16 8-19 9-22 9-22 8-19 6-16 9-22 8-21

98th

Percentile

16 18 22 22 18 16 22 20

4 NOx 80

Average 17.12 16.14 19.23 17.5 14.2 14.3 16.2 15.98

Min – Max 13-20 12-20 13-25 15-20 6-22 6-22 12-20 12-19

98th

Percentile

20 20 25 20 22 22 20 19

5 O3 100

Average 10.15 12.4 13.25 14.23 15.46 14.12 10.56 13.45

Min – Max 6-16 6-20 6-25 6-28 8-29 6-28 6-16 6-25

98th

Percentile

16 19 24 28 28 27 16 24




3.3 NOISE ENVIRONMENT

The objective of the noise pollution 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. The noise monitoring locations

are given in Table-3.8 and shown in Figure-3.3 while the results of noise monitoring are

given in Table 3.8B.

3.3.1 METHODOLOGY FOR NOISE MONITORING

The noise monitoring was carried out at ten locations in day time during (6 am to 9 pm) and

at night time (9 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 – 3. Hourly Equivalent noise levels Leq (day) and Leq (night) were measured at

each monitoring locations. One day monitoring on April 16, 2017 during day and night time

was carried out at all the locations. Besides, damage risk criteria for hearing loss given by

Occupational Safety & Health Administration (OSHA) are enclosed as Annexure - 2.

The noise level measured in study area at different locations is given in Table 3.9. The noise

sources identified around the site are vehicular traffic, industrial and commercial activities.

CPCB recommendation for community noise exposure in different category of area (i.e.

residential, commercial, industrial and silence zone) is enclosed as Annexure - 3 while

Damage risk criteria for hearing loss given by occupational safety & health administration

(OSHA) is enclosed as Annexure - 2. The noise levels were below the stipulated standards of

CPCB.

Noise levels due to transportation were also measured at three different locations. The

equivalent noise level Leq (60 min average) measured at a distance of 10 m and 20 m from

the edge of the road at each of the locations are presented in Table 3.10. The communities

close to the project site are not exposed to major noise sources. The commercial activities

and transport apart from natural sources contribute to community noise levels.




TABLE - 3.10

DETAILS OF AMBIENT NOISE QUALITY MONITORING LOCATIONS

SR.

NO.

NAME OF

VILLAGE

BEARING W.R.T.

PROJECT SITE

APPROXIMATE RADIAL

DISTANCE FROM PROJECT

SITE (KM)

1 Project-site (A1) --- ---

2 Saykha (A2) SW 0.51

3 Vagra (A3) NE 6.85

4 Juned (A4) NE 4.30

5 Bhersam (A5) SE 3.50

6 Kothia (A6) SW 3.40

7 Khojbal (A7) SW 8.9

8 Keshrol (A8) SW 9.25




FIGURE - 3.3

__________________________________________________________________________

LOCATION OF AMBIENT NOISE LEVEL MONITORING STATIONS




TABLE - 3.11

___________________________________________________________________________

BACKGROUND NOISE LEVELS

SR.

NO.

LOCATION NOISE LEVEL dB(A) CPCB LIMIT

dB(A)

DAY TIME NIGHT TIME DAY

TIME

NIGHT

TIME MIN. MAX. MIN. MAX.

1 Project-site (N1) 44.2 48.6 41.4 45.3 <55 <45

2 Saykha (N2) 46.2 51.2 41.7 46.1 <55 <45

3 Vagra (N3) 52.1 56.8 47.2 52.0 <55 <45

4 Juned (N4) 53.6 58.0 48.9 53.1 <55 <45

5 Bhersam (N5) 42.6 46.9 39.2 44.7 <55 <45

6 Kothia (N6) 45.8 49.2 41.5 46.2 <55 <45

7 Khojbal (N7) 49.7 54.2 44.1 49.3 <55 <45

8 Keshrol (N8) 48.2 53.0 43.6 48.2 <55 <45

TABLE - 3.12

___________________________________________________________________________

NOISE LEVELS DUE TO TRANSPORTATION

SR.

NO.

LOCATION NOISE LEVEL dB(A) CPCB LIMIT

dB(A)

DAY TIME NIGHT TIME DAY

TIME

NIGHT

TIME MIN. MAX. MIN. MAX.

1 Nr. Saykha By

Pass Road

49.5 54.2 44.2 48.9 <65 <55

2 Nr. Kothia By

Pass Road

48.8 53.1 45.2 49.2 <65 <55

3 Nr. Vagra By

Pass Road

52.5 56.9 48.3 52.9 <65 <55




3.4 WATER ENVIRONMENT

3.4.1 RECONNAISSANCE

The average annual rainfall in the region is about 496 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.

3.4.2 METHODOLOGY FOR WATER QUALITY MONITORING

Ten nos. of ground water and three 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 once, on April 16, 2017, during the study period and analyzed as per standard

methods of water and wastewater analysis (APHA). The Indian standard specification for

drinking water IS: 10500-1993 and CPCB water use criteria are enclosed as Annexure – 5 & 6

respectively. The details of surface and ground water sampling locations are given in Table

3.11. And sampling locations of water quality monitoring are shown in Figure 3.4. The Indian

standard specification for drinking water is enclosed as Annexure – 5. The physico- chemical

characteristics of the different water samples are presented in the Tables 3.12.




TABLE – 3.13

SAMPLING LOCATIONS FOR MONITORING SURFACE AND GROUND WATER QUALITY

SR.

NO.

SAMPLING

LOCATIONS

BEARING

W. R.T.

PROJECT

SITE

APPROXIMATE

RADIAL DISTANCE FROM

PROJECT SITE

(KM)

1 Project-site (GW1) --- ---

2 Saykha (GW2) SW 0.51

3 Vagra (GW3) NE 6.85

4 Juned (GW4) NE 4.30

5 Bhersam (GW5) SE 3.50

6 Kothia (GW6) SW 3.40

7 Khojbal (GW7) SW 8.9

8 Keshrol (GW8) SW 9.25

9 Vagra Pond (SW1) NE 0.51

10 Keshrol Pond (SW2) SW 6.85

GW= Ground water, SW= Surface water




FIGURE - 3.4

__________________________________________________________________________

LOCATIONS OF WATER SAMPLING STATIONS




TABLE - 3.14

WATER QUALITY- PHYSICAL PARAMETERS

SR.

NO.

SAMPLING

LOCATION

pH TEMPERATURE

(0C)

TURBIDITY

(NTU)

T.D.S.

(mg/L)

T.S.S.

(mg/L)

1 Project-site (GW1) 7.12 24.5 0.3 282.0 6.0

2 Saykha (GW2) 7.10 24.7 0.2 238.0 14.0

3 Vagra (GW3) 7.54 25.2 0.2 276.0 10.0

4 Juned (GW4) 7.65 25.3 0.3 220.0 8.0

5 Bhersam (GW5) 7.34 25.3 0.2 264.0 12.0

6 Kothia (GW6) 7.25 24.8 0.3 226.0 16.0

7 Khojbal (GW7) 7.30 24.6 0.2 232.0 2.0

8 Keshrol (GW8) 7.67 24.5 0.2 214.0 18.0

9 Vagra Pond (SW1) 7.46 25.0 0.1 372.0 8.0

10 Keshrol Pond (SW2) 7.03 25.1 0.2 802.0 14.0


TABLE - 3.12 (CONTD.)

WATER QUALITY - NUTRIENTS, OXYGEN DEMAND AND ORGANIC PARAMETERS

SR.

NO.

SAMPLING LOCATION NH3-N DO COD BOD327

OIL &

GREASE

(mg/L)

1 Project-site (GW1) BDL 7.52 2.59 BDL BDL

2 Saykha (GW2) BDL 7.28 4.08 BDL BDL

3 Vagra (GW3) BDL 6.94 3.12 BDL BDL

4 Juned (GW4) BDL 7.12 2.94 BDL BDL

5 Bhersam (GW5) BDL 6.86 BDL BDL BDL

6 Kothia (GW6) BDL 7.46 1.84 BDL BDL

7 Khojbal (GW7) BDL 6.98 BDL BDL BDL

8 Keshrol (GW8) BDL 7.62 2.26 BDL BDL

9 Vagra Pond (SW1) BDL 6.74 8.19 BDL BDL

10 Keshrol Pond (SW2) BDL 7.02 4.96 BDL BDL






WATER QUALITY - INORGANIC PARAMETERS


T.H. =Total Hardness, C.H. =Calcium Hardness, BDL= Below Detectable Limit


WATER QUALITY - HEAVY METALS

SR.

NO.

SAMPLING

LOCATION

Na T-Cr+3

Cu Pb Fe Zn K Ni S-2

(mg / L)

1 Project-site (GW1) 32.28 BDL BDL 0.010 BDL 0.125 2.10 BDL BDL

2 Saykha (GW2) 38.09 BDL BDL 0.005 0.16 BDL 1.94 BDL BDL

3 Vagra (GW3) 38.03 BDL BDL 0.010 0.79 0.079 1.90 BDL BDL

4 Juned (GW4) 38.06 BDL BDL 0.013 0.46 0.068 1.89 BDL BDL

5 Bhersam (GW5) 19.26 BDL BDL 0.015 0.21 BDL 12.54 BDL BDL

6 Kothia (GW6) 21.68 BDL BDL 0.009 0.95 BDL 3.24 BDL BDL

7 Khojbal (GW7) 16.52 BDL BDL 0.006 0.36 0.132 1.72 BDL BDL

8 Keshrol (GW8) 22.06 BDL BDL 0.010 0.19 0.19 1.64 BDL BDL

9 Vagra Pond (SW1) 84.12 BDL BDL 0.006 0.13 0.087 10.76 BDL BDL

10 Keshrol Pond (SW2) 267.4 BDL BDL 0.008 0.49 0.29 41.8 BDL 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 **

Lead (as Pb) : 0.005 mg/L Nickel (as Ni) : 0.03 mg/L *Not in our NABL Scope,

**Analysed by Sub Contractor (Not in our NABL Scope)

SR.

NO.

SAMPLING

LOCATION

TOTAL

ALKALINITY

(AS CACO3)

T.H.

(AS

CACO3)

C.H.

(AS

CACO3)

Cl-

SO4—2

Ca

Mg

(mg/L)

1 Project-site

(GW1)

132.0 147.0 82.78 40.02 48.55 32.38 15.12

2 Saykha (GW2) 121.0 121.0 39.34 38.53 26.47 14.97 19.61

3 Vagra (GW3) 164.0 113.0 50.84 29.45 20.65 19.58 15.59

4 Juned (GW4) 152.0 142.0 62.99 36.14 23.84 24.44 19.25

5 Bhersam (GW5) 144.0 131.0 68.20 44.62 25.92 26.53 15.26

6 Kothia (GW6) 127.0 109.0 43.36 35.28 18.76 16.58 15.95

7 Khojbal (GW7) 133.0 119.0 49.12 27.84 20.65 18.89 16.98

8 Keshrol (GW8) 121.0 123.0 55.51 30.72 29.02 21.45 16.46

9 Vagra Pond (SW1) 214.0 159.0 82.66 25.44 24.32 32.33 18.55

10 Keshrol Pond

(SW2)

107.0 156.0 72.16 62.34 50.16 28.12 20.86




3.5 LAND ENVIRONMENT

3.5.1 METHODOLOGY FOR SOIL MONITORING

Soil samples were collected from nine different locations during study on April 16, 2017 in

the study area (0-20 cm depth). The locations selected for collection of soil samples are

shown in Figure 3.5 and presented in Table 3.13. The analysis results of soil samples are

given in Table 3.14.

TABLE - 3.15

___________________________________________________________________________

SAMPLING LOCATIONS: SOIL QUALITY

SR.

NO.

SAMPLING

LOCATION

BEARING

W.R.T. PROJECT

SITE

APPROXIMATE RADIAL

DISTANCE

FROM PROJECT SITE

(KM)

1 Project-site (SO1) --- ---

2 Saykha (SO2) SW 0.51

3 Vagra (SO3) NE 6.85

4 Juned (SO4) NE 4.30

5 Bhersam (SO5) SE 3.50

6 Kothia (SO6) SW 3.40

7 Khojbal (SO7) SW 8.9

8 Keshrol (SO8) SW 9.25




FIGURE - 3.5

___________________________________________________________________________

LOCATIONS OF SOIL SAMPLING STATIONS




TABLE - 3.16

___________________________________________________________________________

PHYSICO-CHEMICALS CHARACTERISTICS OF SOIL

Sr.

No.

Parameter Project

Site

(SO1)

Saykh

a

(So2)

Vagra

(SO3)

Juned

(SO4)

Bhersa

m

(SO5)

Kothi

a

(SO6)

Khojba

l

(SO7)

Keshrol

(SO8)

Leachate (%) 10.0 10.0 10.0 10.0 10.0 10.0 10.0 10.0

1. PH 7.10 7.82 7.54 7.62 7.45 7.95 7.23 7.71

2. Temperature (0C) 24.7 25.2 24.5 24.7 25.1 25.0 24.8 25.3

3. Moisture (%) 4.19 3.70 3.85 4.90 4.39 5.02 5.90 5.39

4. SO4—2

(mg/kg) 118.1 131.1 285.2 172.2 109.1 173.3 203.4 495.2

5. Chlorides (mg/kg) 214.5 243.6 595.4 502.6 175.2 209.4 330.6 512.0

6. Total hardness

(mg/kg)

740.2 755.23 575.2 670.2 652.25 532.2 702.1 498.16

7. Cal. Hardness

(mg/kg)

374.75 397.46 274.75 362.5 382.24 273.4 420.41 269.46

8. Bulk density (g/cm3) 1.25 1.15 1.25 1.15 1.20 1.24 1.11 1.25

9. Calcium (mg/kg) 150.2 159.3 110.12 145.3 153.2 109.6 168.5 108

10. WHC (%) 64.57 69.16 67.31 65.97 65.71 54.82 46.53 65.57

11. Porosity (%) 52.83 56.60 52.83 56.60 54.71 53.20 58.07 52.83

12. Grain Size (%)

Gravel 1 0 25 3 0 1 2 4

Coarse sand 4 5 5 9 1 2 3 8

Medium sand 5 6 3 6 6 14 1 21

Fine sand 9 7 15 20 15 5 8 8

Silt + Clay 81 82 52 62 78 78 87 59


___________________________________________________________________________

PHYSICO-CHEMICALS CHARACTERISTICS OF SOIL (HEAVY METALS)

Sr.

No.

Parameter

(mg/kg)

Project

Site

(SO1)

Saykha

(So2)

Vagra

(SO3)

Juned

(SO4)

Bhersam

(SO5)

Kothia

(SO6)

Khojbal

(SO7)

Keshrol

(SO8)

1. Na 2452 526 562 705 996 2546 755 885

2. Cu+2

BDL BDL BDL BDL BDL BDL BDL BDL

3. Arsenic BDL BDL BDL BDL BDL BDL BDL BDL

4. cadmium 0.059 0.035 0.075 0.063 0.094 0.068 0.021 0.027

5. K 526 3642 4745 3210 4595 4842 5032 6416

6. Ni+2





7. Pb+2


Note:

Minimum Detectable Limit:

Nickel – 0.1 mg/kg

Copper – 0.5 mg/kg

3.5.2 SOIL CLASSIFICATIONS

3.5.2.1 METHOD OF PREPARATION

The soil classification map has been prepared by extracting the areas under different soil

categories from the 1:50,000 scale maps prepared by National Bureau of Soil Survey and Land

use Planning (NBSS & LUP). The maps were scanned and geo-referenced before taking out the

information for the desired area. The study area, towns and village locations have been

added for ease of spatial reference. Locations of towns and villages have been extracted from

Census of India (CoI) maps, Survey of India (SoI) topographical maps and confirmed with

satellite data.

3.5.2.2 DESCRIPTION OF SOIL CHARACTERISTICS AND AREA UNDER DIFFERENT SOIL TYPES

Table 3.15 provides the soil type and area under different soils within the area of interest.

3.5.2.3 SOIL CHARACTERISTICS MAP

A map depicting the characteristics of major soil categories in the project area is presented

in Figure 3.6. The map marks the area within 10 km with project site as a centre. Town and

village locations are also depicted to facilitate ease of reference.




TABLE 3.17

___________________________________________________________________________

SOIL CHARACTERISTICS UNDER PROJECT AREA

CATEGORY AREA_

SQ KM DESCRIPTION TAXONOMY1 TAXONOMY2 CLASS SUB_CLASS

A 2.24

Deep, well drained, calcareous,

fine soils on very gently sloping

alluvial plain with slight erosion

and slight salinity; associated with

very deep, imperfectly drained,

calcareous, fine-loamy soils with

slight erosion.

Fine, mixed

(calcareous),

hyperthermic

Fluventic Ustochrepts

Fine-loamy, mixed

(calcareous),

hyperthermic Udic

Ustochrepts

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

B 0.34

Very deep, moderately well

drained, fine soils on very gently

sloping alluvial plain with

moderate erosion and moderate

salinity; associated with very deep,

moderately well drained

calcareous, fine soils with

moderate erosion.

Fine, montmorillonitic

(calcareous),

hyperthermic Typic

Chromusterts


(calcareous),

hyperthermic Udic

Chromusterts

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

C 5.60


drained, fine soils on very gently

sloping alluvial plain with

moderate erosion and moderate

salinity; associated with very deep

moderately well drained,

calcareous, fine soils with

moderate erosion


(calcareous),

isohyperthermic Typic

Chromusterts


(calcareous),

hyperthermic Udic

Chromusterts

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

D 61.12


drained, calcareous, very fine soils

on very gently sloping alluvial plain

with slight erosion and moderate

salinity; associated with very deep,


calcareous, fine soils with slight

erosion and slight salinity

Very fine,

montmorillonitic

(calcareous),

hyperthermic Typic

Chromusterts


(calcareous),

hyperthermic Vertic

Ustochrepts

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

E 40.62


drained, very fine soils on nearly

level alluvial plain with slight

erosion and moderate salinity;

associated with very deep,


calcareous, fine soils on very gently

sloping lands with slight erosion

Very fine,

montmorillonitic

(calcareous),

hyperthermic Typic

Chromusterts


(calcareous),

hyperthermic Typic

Chromusterts

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

F

204.03


drained, very fine soils on nearly

level alluvial plain with slight

erosion and slight salinity;

associated with very deep,


calcareous, very fine soils with

slight erosion

Very fine,

montmorillonitic

(calcareous),

hyperthermic Typic

Chromusterts

Coarse-loamy, mixed,

hyperthermic Typic

Camborthids

SOILS OF

WEST

COAST

(SOILS OF

GUJARAT

PLAIN)

SOILS OF

ALLUVIAL

PLAINS

(Courtesy: Environmental Information Centre, New Delhi)




FIGURE-3.6

SOIL CHARACTERISTICS MAP




3.6 GEOLOGICAL DATA

3.6.1 METHOD OF PREPARATION

Geologically, in Bharuch area the basement rocks are comprises of sandstone and limestone

of Bagh Formation (Middle to Upper Cretaceous). Bagh Formation are overlain by the Deccan

Volcanics (Upper Cretaceous to Eocene), which mainly consist rock units of Basalt and

Rhyolite. The Deccan Volcanics are non-conformably overlain by the Tertiary (Lower Eocene

to Pliocene) rocks represented by Vagadkhol, Nummulite, Tarkeshwar, Babaguru, Kand and

Jhagadia formations, in the ascending order of superposition. These formations comprise

clay, sandstone, limestone, marl, siltstone and conglomerate. The Tertiary rocks are further

overlained by the Quaternary sediments (Holocene) which have been differentiated on the

basis of their environment of deposition. They comprise older tidal flat and tidal marsh

deposits of Rann Clay formation, flood plain deposits of Katpur formation representing fluvial

environment of deposition, coastal dune and sand dune deposits of Akhaj Formation,

representing Aeolian environment of deposition and younger tidal flat deposits (spit/bar and

shoal) of the Mahuva formation, representing marine environment of deposition.

3.6.2 DESCRIPTION OF GEOLOGICAL CLASSIFICATION AND AREA UNDER DIFFERENT

FORMATIONS

3.6.2.1 GEOLOGY

Geologically the major part of the state is covered by hard rock comprising of gneisses,

schists, phyllites, sand stone and basalts remaining area in the north and central is accupied

by the soft rock including coastal alluvium. District Bharuch is mainly occupied by the soft

rocks like alluvium, tertiary in the north but as we will move to the south the district is

covered with hard rocks and few hilly areas.

3.6.2.2 HYDROLOGY

Hydrologically the areas have soft rock aquifers dug wells at the depth of 10 to 25 m, and

tube wells at the depth of 50 to 100 m. The levels of ground water productivity of this type

of rocks are mapped by violet colour, the difference in the discharge is shown through the

difference in the intensity of the colour (light colour=discharge (lpm) 200 to 300 in dug wells




and 400 to 600 lpm in the tube well, and dark shade shows the discharge to 200 to 300 lpm

in dug wells and 600 to 1200 lpm in tube wells.

3.6.2.3 GROUND WATER UTILIZATION ( CRITICAL BLOCKS)

Based on state of groundwater development, the various blocks/talukas in a district are

categorized as over-exploited, critical, semi critical & safe categories. In case, where annual

groundwater withdrawals are more than 100% of the annual recharge availability, it is

categorized as over-exploited, meaning that all the annually replenish able groundwater is

already being used up. In cases of talukas, where the annual withdrawals are in the ranges

of 90% to 100%, in relative to the annual available groundwater recharge, they are

categorized as critical blocks. The talukas/blocks, in which the range is between 70% to 90%,

are categorized as semi critical. The safe category of talukas/blocks has stage of

groundwater development between 70% in relative to annual recharge availability.

Accordingly the various talukas in the district, coming under the project area are categorized

as follows:

District Semi- critical Critical Over- exploited

Bharuch Amod - -

Jhagadia - -

Groundwater Resource Availability, Utilization in Bharuch:

1. Annual Replenishable Ground Water Resource:

• Monsoon Season:

� Recharge from rainfall: 20380 mm

� Recharge from other sources: 1994 mm

• Non-monsoon Season:

� Recharge from rainfall: 0

� Recharge from other sources: 5504 mm

• Total: 27878 mm

2. Natural discharge during non-monsoon Season: 1394 mm

3. Net Annual Ground Water Availability: 26484 mm

4. Annual Ground Water Draft:




• Irrigation: 13349 mm

• Domestic and Industrial use: 1835 mm

• Total: 15184 mm

5. Projected Demand for Domestic and Industrial uses up to 2025: 2729 mm

6. Ground Water Availability for future irrigation: 10406 mm

Stage of Ground Water Development (%): 57

3.6.2.4 DRAINAGE PATTERN

• The land is flat. The topography of the land is flat, so that there is no change in Drainage

pattern at project site.

• The drainage pattern has been captured from the satellite images and updated with the

help of various secondary data sources available. The drainage pattern has been over-

layed on the administrative boundary map and has been presented as Figure – 3.8.

• The area is well drained by River Bhukhi, flowing in the south direction and River Bhadra,

flowing in west direction of the study area. The River Narmada is flowing in the southern

part of the area. The Gulf of Khambhat is in the west. The site concerned is a flood prone

area, covered with mud.

The drainage pattern of fourth order has been identified within the area of interest.




3.6.3 GEOLOGICAL MAP

A map depicting the major geological features in the project area is presented in Figure 3.7.

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.

FIG. 3.7 GEOLOGICAL MAP OF BHARUCH DISTRICT




FIGURE - 3.8

DRAINAGE PATTERN




3.7 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 an

environmental impact assessment, which would help determine the impact of the project

development activity on the land use pattern.

3.7.1 METHOD OF DATA PREPARATION

The land use / land cover has been presented in the form of a map prepared by using IRS P6

LISS-III (10-NOV-2009) and procured from the National Remote Sensing Agency (NRSA),

Hyderabad. The satellite data has been processed using ERDAS Imagine software supported

with ground checks and ground truth verification. Area and distance calculations have been

carried out using GIS software after geo-referencing the interpreted data with the help of

Survey of India (SoI) topographical maps of the scale 1:50,000.

A map depicting major land use/ land cover classes comprising lands under agriculture, fallow

land, open/degraded vegetation; lands falling under water bodies, scrub and lands under

inhabitations is presented at Figure 3.8. The map also marks the area within 10 km of the

project site as the area of interest. Land use and Land Cover with Towns and Village Locations

A map depicting major land use/ land cover classes along with the village locations in the area

of coverage is presented at Figure 3.9. The land use classification within a distance of ten

kilometers from the project location and the areas falling under the respective classifications

are as per the following:




FIG. 3.9 Process Methodology

Procurement of Satellite

Imagery

Preparation of Base Map

using topographical maps

Data Preparation

- Radiometric correction

- Geometric correction

Preparation of Signature

Confusion Matrix

First Level Classification

Field Verification/Ground

Truth

Updated information

from field

Second Level

Classification

Accuracy Estimation Area Estimation Map Output

Pre field process

Field process

Post field process




TABLE – 3.18 ___________________________________________________________________________

AREAS UNDER DIFFERENT LANDUSE

Area Statistics of Landuse / Landcover Map

Sl.No. Class Names Area (In

Hectares) Area (In Sq.Km.) Area %

1 Water Body 102.13 1.02 0.33

2 Open / Barren Land 1171.69 11.72 3.73

3 Agriculture Land 9706.81 97.07 30.92

4 Fallow Land 17891.81 178.92 56.99

5 Open / Degraded Vegetation 1696.81 16.97 5.40

6 Plantation / Orchards 115.81 1.16 0.37

7 River & Canal 220.69 2.21 0.70

8 Settlement & Habitation 375.56 3.76 1.20

9 Industrial Area 9.31 0.09 0.03

10 Miscellaneous 105.75 1.06 0.34

11 River Bed 0.94 0.01 0.00

Total 31397.31 313.97 100.00




FIGURE – 3.10

LANDUSE / LANDCOVER




3.8 ECOLOGICAL INFORMATION

Introduction

Bharuch (formerly commonly known as Broach) in India, is a district in the southern part of

the Gujarat peninsula on the west coast of state of Gujarat with a size and population

comparable to that of Greater Boston. The Narmada River outlets into the Gulf of Khambhat

through its lands and that shipping artery gave inland access to the kingdoms and empires

located in the central and northern parts of the sub-continent of India. The geographical

location of the district is 21.30° to 22.00° N Latitude and 72.45° to 73.15° E Longitude. The

district has eight Talukas, Bharuch (District Headquarter), Ankleshwar, Valia, Jhagadia,

Vagra, Aamos, Hansot and Jambusar. The total area of the district is 5,253 sq km, as per the

census of 2001; the population is 1.3 million, with 261 persons per sq. km. The district is

situated at the mouth of River Narmada. The major rivers flowing through the district are:

Narmadha, Dhadhar, Kim and Kaveri.

Climate

The weather of Bharuch district is hot and dry-starting from mid-march till mid-June, mid-

during summer season weather remains hot and dry. While from mid-June till end of

September weather remains humid and can be considered pleasant. From October-

November weather is bit hot. From December to February climate remains cool

Rainfall

The average rainfall of the district is mm.

Biogeography

According to Rodgers and Panwar (1988), Gujarat has parts of four biogeographic zones:

Zone 3. The Indian Desert

Province 3A - Kutch

Zone 4. The Semi-arid Zone:

Province 4B - Gujarat – Rajputana

Zone 5. The Western Ghats:




Province 5A - Malabar Coast

Province 5B - Western Ghat Mountains

Zone 10. The Coast of India:

Province 10A - West Coast

The project area falls at Zone 4: The Semi-arid zone, Province 4B – Gujarat-Rajputana.

3.8.1 PHYSIOGRAPHY

The region provides a combination of most of the geo-environmental features for the

development of favorable ecosystems. The alluvial sediments and reasonable water

resources have provided impetus towards developing human induced ecosystems of

agricultural cropping agro-forestry and horticulture. The elevation range of the region is

about 20 m showing a very gentle flat gradient of 1:800 to 1:1000. The region shows more

or less a flat topography with a series of sections cut by deeply incised channels of rivers

flowing across the region. The riverbanks are generally marked by levee deposits, creating a

ridge type banks with higher elevations than the general ground level. The flat topography is

dotted by low height sandy mounds of stabilized dunes. Formation of ravine landscape is

quite common on most of the riverbanks due to deep gully erosion. The rivers are prone to

heavy floods and land erosion.

3.8.2 FOREST

Bharuch area is characterized by tropical dry deciduous forests. The total forest area of

district is 1449.68 sq.km. That accounts for 0.73 % of the total geographical area of the

district. (Courtesy: Environmental Information Centre, New Delhi)




3.8.3 FLORA

Some of the flora found in Bharuch area is listed below:

TABLE – 3.19

___________________________________________________________________________

LIST OF FLORA

Sr.

No.

Scientific Name

Common Name Family

I Trees

1 Acacia aurriculifarmis Bangali Babool Mimoceae

2 A. leucopholia Aniar Mimoceae

3 A. catechu Khair Mimoceae

4 A. ferrungula Pandhara Khair Mimoceae

5 A. nilotica Babul Leguminoceae

6 A. lebbeck Siris Leguminoceae

7 A. procera Siris Leguminoceae

8 A. polycantha Garad Mimoceae

9 Adina cordifolia Hed Rubiaceae

10 Aegle marmelos Bela Rutaceae

11 Ailanthus excelsa Maharukh Simaroubaceae

12 Alangium salvifolium Ankol Alangiaceas

13 Albizia odoratissimus Siris Leguminoceae

14 Annogeissus latifolia Dhavda Combritaceae

15 Annona squamosa Sitafal Annonaceae

16 Azardirachta indica Nim Moraceae

17 Bahuania purpurea Kachamar Leguminosae

18 Bombax ceiba Semal Verbenaceae

19 Bridelia retusa Asta (Kathmohli) Leguminosae

20 B. squamosa Asan Leguminoceae

21 Buchanania lanzan Charoli Anacardiaceas

22 Butea monospesma Palas Leguminoceae

23 Callistemon lancealatus Bottlebrush Mytraceas

24 Casuarina equisetifoier Sura Casuarineae

25 Careya arborea Kumbh Mytraceae

26 Casearia elliptica Manjo Symydaceae

27 Caesearia graveoiens Dedak manio Samidacea

28 Cassia fistula Sunari Leguminoceae

29 Cestrum noctusnum Ralkirani Solana ceae

30 Cochiospermum religiosun Ganeri Cochlospermaceds

31 Cocas nicifera Nariyal Palmeae

32 Cordia dichotoma Gundi Boranginacea

33 Dalbergia paniculata Dhobin Leguminoceae

34 D. latifolia Sisso Leguminoceae

35 Murraya koenigii Karlilimb Rata ceae

36 Ixora parviflora Kara Rubiaceae

37 I. nigricans Kukeri Rubiaceae

38 Delonix elala Gulmohar Leguminoceae

39 Diosphyros melanoxylon Tendu Ebenaceae

40 Dolichandrone falcate Mallar sing Bignoniaceae




41 Elaeodendron roxburghii Alinar Ceiastracea

42 Eucalyptus globules Safeda Eucalyptaceae

43 Emblica officinalis Aonla Euphobiaceae

44 Erithina uliginosa Pungara Leguminoceae

45 Eramphis uliginosa Almi Rubiaceas

46 Ficus. Religiosa Pipal Moraceae

47 F. rumphii Pilari Moraceae

48 F. benghalensis Bara Moraceae

49 Flacourtia indica Rankdi Bixaceae

50 Garua pinnata Kakad Burseraceae

51 Griwia teliaefolia Dhaman Tiliaceae

52 Haidwickia bipinnata Aniar Caesalpiniacea

53 Holoptelia intigrifolia Valva Uticaceae

54 Kydia calycina Bhindi Malvaceae

55 Lagerstroemia lanceolata Nano Leguminoceae

56 L. parviflora Sidha Leguminoceae

57 Michellia champaca Champa Bignoneaceae

58 Lannea caromadalica Modad Anacardiaceae

59 Madhuca indica Mahua Sapotaceae

60 Mangifera indica Amm Anacardiaceae

61 Miliusa tomentosa Gulambh Annonacea

62 Milligntonia hortensis Indian Coral Tree Bignoniaceae

63 Mitragyna parvifolia Kalam Rubiaceae

64 Michelia Champaca Champa Magnoliaceae

65 Moringa oliefera Shevga Moringaceae

66 Musa paradisiacea Kela Musaceae

67 Oroxyium indicum Tetu Bignoniaceae

68 Phoenix sylvestris Shindi Palminae

69 Prosopis juliflora Babul Mimoceae

70 P. cinerarea Babul Mimoceae

71 Pithecelobium ducle Chisbalai Leguminoceae

72 Pongamia pinnata Karanja Leguminoceae

73 Pisidium guajava Guava Mutraceae

74 Pterocarpus marsupium Bija Leguminoceae

75 Punica grantalum Anar Pomegrannatae

76 Sapindus emerginatus Aritha Sapindaceae

77 Soymida febrifuga Rohan Meliaceae

78 Poleathia langifolia Ashok Apoctnaceae

79 Saraca indica Ashok Apoctnaceae

80 Thevetia neirifolia Pilakanton Apoctnaceae

81 Sterculia urens Kodaya Sterculiaceae

82 Syzygium cuminii Jamun Myrtaceae

83 Terminalia crenulata Sadad Leguminoceae

84 T. bellirica Behada Combretaceae

85 T. arjuna Arjun Combretaceae

86 T. caltapa Jangli badam Combretaceae

87 Tamarindus indica Tentuli Leguminoceae

88 Tecoma stans Nellow bell Bisgnonia ceae

89 Tectona grandis Sag Verbanaceae

90 Trema orientalis Gol Ulmaceae

91 Wrightia tinctoria Kudo Apocynacea

92 Zizyphus xylocarpus Ghatbor Rhamnaceae




93 Z. mauritiana Bordi Rhamnaceae

Shrubs

1 ARGEMONE MEXICANA Darudi Papaveraceae

2 CARANTHUS RESUS Sudufuli Apocyanaceae

3 C. CALATROPIS Mundar Asclepiadaceae

4 CALATOPIS GIGANTEAN Rui Asclepiadaceae

5 CARRISSA CARANDAS Karvand Apocyaninnae

6 CLERODENDRUM MULTYFOLIUM Multaiforum Verbenaeae

7 GYMNOSPORIA SPINOSA Spinosa Rekii Leguminoceae

8 LANTANA CAMERA Ghaneri Verbanaceae

9 OPUNTIA DILLENII Nivdang Cactacealea

10 EUPHORBIA NERIFOLIA Wavding Celastraceae

11 OCIUM GRATISSIUM Rantulro Labiateae

12 HELICTERIES ISORA Atai Sterculiaceae

13 FICUS HISPIDA Tet umaro Moraceae

14 DATURA FASTUASA Dhotara Solanaceae

15 VITEX NEGUNDO Nirgudi Verbaceae

16 CASSIA TORA Tarota Leguminoceae

17 ZIZYPHUS NUMMULARIA Beri Rhannaceae

18 EUPHORBIA TIRUCOLLI Thor Euphorbiaceae

Bamboos

1 DENDROCALAMUS STRICTUS Manvel Grammineae

2 ABRUS PRECATORIUS Gunj Leguminoceae

3 CAPPARIS SEPIRARIA Lamtjar Cappariaceae

4 COCCULUS HIRRUTUS Asanwel Menispermaceae

5 COMBRETUM OVALIFOLIUM Jal Combratae

6 CAYRATIA CARNOSA Khatumbo Vitaceae

Grasses

1 ANDROPOGON PUMILUS Kusal Gramineae

2 CENCHRUS SETGERUS Dhramnu Gramineae

3 CYNODON DACTYLON Durva Gramineae

4 CYMBOPOGEN MARINIL Rosha Gramineae

5 HETEROPOGON CONTORTUS Gawat Gramineae

6 SORGHUM HALEPENSE Baru Gramineae

7 THEMEDA TRIANDRA Bhathdu Gramineae

Crops

1 RICINUS COMMUNIS Arand Euphorbiaceae

2 SACCHARUM OFFICINARUM Ganna Gramineae

3 SORGHUM VULGAE Jowar Gramineae

4 ZEA MAYS Makea Gramineae

5 ARACHIS HYPOGAEA Ground nut Logumin

6 ORYZA SATIVA Chawar Gramineae

Macrophytes

1 EICHHORNIA CRASSIPES Jalkumbhi Pontederiace

2 IPOMEA AQUALICA Kalmisay Volvulaceae

3 TRAPA LATIFOLIA Water chestnual Volvulaceae

4 NELUMBO NUCIFERA Lotus Nymphaceae

5 AZOLLA PINNATA Common duckweed Lemnaceae

Source: Vegetation survey and data from State Forest Dept. Bharuch Gujarat




3.8.4 FAUNA

TABLE – 3.20

___________________________________________________________________________

LIST OF FAUNA

Sr.

No.

Scientific Name Common Name Family

1 Acridothers tristis Common myna Sturnidae

2 A. ginginianus Bank myna Sturnidae

3 Athene brama Spotted owlet Striginae

4 Aegithina tiphia Common Lora Lrenidae

5 Ardeola grayee Pond Heron Ardeidae

6 Amaurornis phoenicurus Whitebrested Waterhen Phasinidae

7 Babulcus ibis Cattle Egret Ardeidae

8 Centropus cinensis Crow-phesant Cuculidae

9 Columba livia Blue Rock Pigeon Columidae

10 Corvus splendens House Crow Carvidae

11 Coracious benghalensis Indian Roller Coracidae

12 Dicrurus adsimilis Black Drongo Dieruridae

13 Dinophum benghalense Goldenbacked Woodpecker Picidae

14 Eudynamys scolopacea Koel Cuculidae

15 Fracolinus francollinus Black partiridge Pharianidae

16 Halcyon rustica Whitebrested Kingfisher Aicenidae

17 Hirundo rustica Common swallow Hirundinidae

18 Lanius exubitor Grey Shrike Daniidae

19 Launchura malabarica Whitethroated munia Estrildinae

20 Megalaima rubricapilla Smallgreen barbet Capilonidae

21 M. malabarica Crimsonbrestwd Barbet Capilonidae

22 Merops orientalis Littlegreen Bea-eater Miropidae

23 Milvus migrans Patih Kite Accipitridae

24 Motacilla maderatensis Large pied wagtail Motacillidae

25 Nactarinia asiatica Purplerumpled sunbird Nectarinidae

26 Nectarinia minima Small sunbird Nectarinidae

27 Oriolus oriolus Golden Oriole Oriolidae

28 Orthotomus sutorius Tailor Bird Pachycephaline

29 Passer domesticus House Sparrow Passerinae

30 Psittacula cyanocephala Blossamheaded parakeet Psittacidae

31 Pycnonotus caffer Redvented bulbul Pycnonotidae

32 Ploceus philipinensis Weaver bird Plocidae

33 Sexicoloides fulicate Indian Robin Corvidae

34 Sopsychus saularis Magpie Robin Corvidae

35 Streptopelia chinensis Spotted dove Columbidae

36 S. senegalensis Little brown dove Columbidae

37 Sternus pagodramus Brahiminy myna Sternidae

38 Turdoides caudatus Common Babbler Muscicapidae

39 Upupa epops Hoopoe Upupidae

40 Vanellus indicus Redwattled Lapwing Jacanidae

41 Metopidius indicus Brongewinged jacana Jacanidae

42 Ardea alba Large egrd Ardeidae

43 A. cinerea Grey Heron Ardeidae

44 Falica atra Coot Rallidae




45 Phalacrocorax niger Little cormorant Phalacrocoracidae

46 MUNTIACUS MUNTJAK Barking deer Bovidae

47 FALIS CHAUS Jungle cat Falidae

48 MYAENA HYAENA The striped hyana Canidae

49 PRESBYTIS ENTELLUS Hanuman langur colobinae

Source: Survey of Avifauna under the study area.




3.9 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 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.

3.9.1 SETTLEMENTS AND DEMOGRAPHIC PATTERN

3.9.1.1 METHOD OF DATA PREPARATION

The land use/land cover has been presented in the form of a map prepared by using the IRS-P

6 LISS-III, procured from the National Remote Sensing Agency (NRSA), Hyderabad. The

satellite data has been processed using ERDAS Imagine software supported with ground

checks and ground truth verification wherever required. 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.

3.9.1.2 DEMOGRAPHIC DATA WITHIN THE REGION OF INTEREST

On an average, Taluka: Vagra has population density of about 94 persons per sq. km. (2001

Census data), 114 persons per sq. km. (2011 Census data), compared to the Bharuch District,

which has a population density of about 238 persons per sq. km. (2001 Census data), 238

persons per sq. km. (2011 Census data). Population density within 10 km radius of the site is

only 101 persons per sq. km. (2011 Census data), while population density within 5 km

radius of site is 120 persons per sq. km. (2011 Census data). The population details (i.e.

population distribution and population density) of the Taluka Vagra, District Bharuch and

the study area within 10 km radius and 5 km radius are given in Table 3.20. And their

graphical representations are shown in Figure 3.10.




TABLE – 3.21

DEMOGRAPHIC DATA

Sr.

No.

Village

Name

CD

Block

Name

No. of

Household

Total

Population

Total

Male

Total

Female

Population

<06 years

Male<06

years

Female<06

years

1 Sayakha Vagra 231 1072 560 512 81 38 43

2 Vagra Vagra 1560 7724 3924 3800 936 487 449

3 Juned Vagra 84 443 226 217 57 26 31

4 Bhersam Vagra 325 1461 735 726 158 67 91

5 Khojbal Vagra 287 1513 782 731 209 112 97

6 Kothia Vagra 111 555 279 276 68 30 38

7 Saran Vagra 273 1346 686 660 173 84 89

8 Pisad Vagra 151 708 362 346 89 49 40

9 Rahad Vagra 185 931 473 458 110 62 48

10 Aragama Vagra 223 1188 611 577 154 76 78

11 Ankot Vagra 162 739 399 340 96 48 48

12 Vorasamni Vagra 475 2514 1250 1264 247 119 128

13 Vilayat Vagra 444 2203 1133 1070 235 129 106

14 Vansi Vagra 270 1522 796 726 201 110 91

15 Amleshwar Vagra 494 2392 1261 1131 213 112 101

16 Navetha Vagra 196 974 472 502 105 46 59

17 Pipalia Vagra 316 1609 823 786 189 91 98

18 Vahiyal Vagra 250 1170 607 563 123 60 63

19 Sutrel Vagra 190 958 482 476 124 68 56




TABLE – 3.21 (CONTD.)

DEMOGRAPHIC DATA

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 Sayakha Vagra 76 41 35 413 210 203

2 Vagra Vagra 396 200 196 1666 855 811

3 Juned Vagra 24 12 12 197 100 97

4 Bhersam Vagra 27 15 12 874 440 434

5 Khojbal Vagra 40 20 20 425 225 200

6 Kothia Vagra 45 25 20 236 117 119

7 Saran Vagra 54 22 32 351 190 161

8 Pisad Vagra 38 18 20 234 123 111

9 Rahad Vagra 31 16 15 552 281 271

10 Aragama Vagra 24 14 10 361 201 160

11 Ankot Vagra 50 25 25 135 61 74

12 Vorasamni Vagra 91 47 44 655 329 326

13 Vilayat Vagra 73 36 37 833 434 399

14 Vansi Vagra 28 14 14 401 213 188

15 Amleshwar Vagra 96 46 50 1233 641 592

16 Navetha Vagra 105 48 57 364 172 192

17 Pipalia Vagra 52 24 28 475 235 240

18 Vahiyal Vagra 77 39 38 505 266 239

19 Sutrel Vagra 42 23 19 412 212 200

(Courtesy: Census Dept., GOI)




TABLE – 3.22 ___________________________________________________________________________

POPULATION DENSITY

Name Population

(Persons)

Population

Density

(Person / sq. km.)

Sex ratio

(No. of females per 1000

males)

Within 5 km Radius (2011) 9397 120 943

Within 10 km Radius

(2011)

31022 101 956

Taluka Vagra (2011) 100044 114 870

District Bharuch (2011) 1551019 238 925





FIGURE-3.11

POPULATION DENSITY




3.9.1.3 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 Bharuch, Taluka Vagra and within 10 km

radius and 5 km radius of project site are given in Table 3.20 while their graphical

representation is shown in Figure 3.11. Literacy rate in Bharuch District, as per 2011 Census

data is 72.09 %, with 77.32 % among male and 66.44 % among female. Literacy rate in Vagra

Taluka as per 2011 Census data is 70.47 % with 77.56 % among males and 62.32 % among

females.

Within 10 km radius of the study area, the literacy rate is observed 69.26 % having 75.28 %

among males and 62.70 % among females, whereas literacy rate within 5 km radius of study

area is 65.37 % having 72.51 % among males and 57.79 % among females.

TABLE 3.23

___________________________________________________________________________

LITERACY RATE

Name Male Literacy (%) Female Literacy (%) Total Literacy (%)

Within 5 km Radius (2011) 72.51 57.79 65.37

Within 10 km Radius

(2011)

75.28 62.70 69.26

Taluka Vagra (2011) 77.56 62.32 70.47

District Bharuch (2011) 77.32 66.44 72.09





TABLE 3.23 (CONTD.) ___________________________________________________________________________

LITERACY RATE


Sr. No. Village

Name

CD

Block

name

Population

Literate

Male

Literate

Female

Literate

Population

Illiterate

Male

Illiterate

Female

Illiterate

1 Sayakha Vagra 753 440 313 319 120 199

2 Vagra Vagra 5532 2983 2549 2192 941 1251

3 Juned Vagra 287 158 129 156 68 88

4 Bhersam Vagra 864 500 364 597 235 362

5 Khojbal Vagra 1045 587 458 468 195 273

6 Kothia Vagra 366 218 148 189 61 128

7 Saran Vagra 801 461 340 545 225 320

8 Pisad Vagra 534 294 240 174 68 106

9 Rahad Vagra 603 352 251 328 121 207

10 Aragama Vagra 898 484 414 290 127 163

11 Ankot Vagra 533 325 208 206 74 132

12 Vorasamni Vagra 1875 997 878 639 253 386

13 Vilayat Vagra 1451 840 611 752 293 459

14 Vansi Vagra 1103 613 490 419 183 236

15 Amleshwar Vagra 1637 913 724 755 348 407

16 Navetha Vagra 705 375 330 269 97 172

17 Pipalia Vagra 1026 584 442 583 239 344

18 Vahiyal Vagra 787 449 338 383 158 225

19 Sutrel Vagra 648 368 280 310 114 196




FIGURE-3.12

LITERACY DATA




3.9.2 VEGETATION COVER AND FOREST BOUNDARIES

3.9.2.1 METHOD OF PREPARATION

The vegetation cover for the area of interest has been prepared by extracting the areas under

fou-ID LISS III data for the past two years for the State of Gujarat. There is no Reserved

Forests and Protected Forests within the 25 km radius area from project site. The project site

and area of interest have been added for ease of spatial reference.

The vegetation classification criterion used for this study area is given as follows:

The forest cover is classified based on Forest Survey of India into Dense (> 40% crown density

different vegetation classification provided by the Forest Survey of India (FSI) based on IRS),

open (between 10 to 40 % crown density) and Scrubs (shrubby bush of less than 10 % crown

density). The vegetation classification criterion used for this study area is given as follows:

Dense Vegetation is the lands with forest cover with canopy density of equal or more than

40 percent.

Medium Vegetation is the land with forest cover with canopy density of 10 to 40 percent.

Open Vegetation is the land with forest cover with canopy density less than 10 percent.

Scrubs are the lands generally in and around forest areas, having bushes and/or poor tree

growth chiefly of small or stunted trees with a canopy density less than 10 percent.

.




3.9.2.2 AREA UNDER DIFFERENT VEGETATION CLASSIFICATION

TABLE- 3.24

3.9.2.3 MAP OF VEGETATION CLASSIFICATION AND FOREST BOUNDARIES

A digital map comprising layers of vegetation classification, forest boundaries and town and

village locations to facilitate reference is attached as Figure – 3.12.

Area Statistics Forest Map

Sr.No. Class Names Area (In Hectares) Area (In Sq.Km.) Area %

1 Water Body 3054.94 30.55 1.56

2 Non Vegetation Area 86509.19 865.09 44.13

3 Mangrove(Sparse) 1095.81 10.96 0.56

4 Mangrove(Dense) 1468.63 14.69 0.75

5 Open/Degraded Vegetation 1284.38 12.84 0.66

6 Vegetation Medium Density 648.63 6.49 0.33

7 Plantation/Orchards 169.31 1.69 0.09

8 Marshy Vegetation 3495.94 34.96 1.78

9 River & Canal 4143.19 41.43 2.11

10 Sea 93914.75 939.15 47.91

11 River Bed 157.50 1.58 0.08

12 Seasonal Water Body 99.31 0.99 0.05

Total 196041.56 1960.42 100.00




FIGURE – 3.13

VEGETATION CLASSIFICATION AND FOREST BOUNDARIES




3.9.3 OCCUPATIONAL STRUCTURE

In economic development of the region its geographical location, natural resources,

business and employment, industries and manpower play vital role. Table 3.22 provides the

occupational patterns in all villages falling within the area of interest.

TABLE 3.25

OCCUPATIONAL STRUCTURE

Sr. No. Village

Name

CD

Block

name

Total

Work

Population

Main

worker

Population

Main

Cultivator

Population

Main

Agriculture

Population

Main

Household

Population

Main

Other

Population

Marginal

Worker

Population

Non

Worker

Population

1 Sayakha Vagra 368 363 94 231 0 38 5 704

2 Vagra Vagra 2719 1881 213 304 50 1314 838 5005

3 Juned Vagra 195 194 34 131 1 28 1 248

4 Bhersam Vagra 682 659 135 452 1 71 23 779

5 Khojbal Vagra 523 362 75 161 7 119 161 990

6 Kothia Vagra 265 223 44 162 0 17 42 290

7 Saran Vagra 392 388 26 313 1 48 4 954

8 Pisad Vagra 315 181 89 81 0 11 134 393

9 Rahad Vagra 397 379 63 269 0 47 18 534

10 Aragama Vagra 405 388 42 161 1 184 17 783

11 Ankot Vagra 313 266 56 169 0 41 47 426

12 Vorasamni Vagra 757 636 118 337 1 180 121 1757

13 Vilayat Vagra 986 962 96 704 3 159 24 1217

14 Vansi Vagra 509 421 61 257 0 103 88 1013

15 Amleshwar Vagra 939 703 177 365 12 149 236 1453

16 Navetha Vagra 459 450 60 296 2 92 9 515

17 Pipalia Vagra 639 615 131 362 5 117 24 970

18 Vahiyal Vagra 568 562 91 423 2 46 6 602

19 Sutrel Vagra 350 337 54 237 3 43 13 608

(Courtesy: Census Dept., GOI) (Courtesy: Environmental Information Center, New Delhi)

1) CD Block name

2) Total Work Population

3) Main worker Population

4) Main Cultivator Population

5) Main Agriculture Population

6) Main Household Population

7) Main Other Population

8) Marginal Worker Population

9) Non Worker Population




3.9.4 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

4.8.There are 16 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, 3 villages have both primary and secondary

education schools. 14 villages have adult education facility. 4 villages have other education

institution. 13 villages in the impact zone have community health workers,3 villages have

primary health sub centre, 12 villages have registered private practitioners while 3 villages

have family planning center, 1 village have primary health center. In the study area drinking

water facilities are good as well water is available almost in all the villages, 4 villages have

tap water, 1 village have hand pumps, 1 villages have river water. Tank water is available in

15 villages.

Post office facility is available in 9 villages while 1 village has post and telegraph facility.

Telephone facility is available in 1 village. Almost all villages are well connected through a

network of Pucca road and Kachcha approach road. Bus is the main mode of transportation

and is available in all villages. All the villages get electricity for all purpose i.e. domestic,

agriculture and industrial.




TABLE 3.26

DETAILS OF AMENITIES AVAILABLE STUDY AREA

Village Educational Medical Drinking Water Post & Telegraph

GPS PPS GSS PSS GEC PEC PHC M&

CWC

FWC T TW/

BH

R/C PO P&T T

Sayakha 1 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Vagra 4 3 0 1 2 0 0 0 0 2 1 2 1 0 1

Juned 1 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Bhersam 2 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Khojbal 1 0 1 0 2 0 0 0 0 2 2 2 2 0 1

Kothia 1 0 0 0 2 0 0 0 0 2 1 2 2 0 1

Saran 2 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Pisad 1 0 0 0 2 0 0 0 0 2 1 1 2 0 1

Rahad 1 0 0 0 2 0 0 0 0 2 1 1 2 0 1

Aragama 1 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Ankot 1 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Vorasamni 2 0 1 0 2 0 0 0 0 2 2 1 2 0 1

Vilayat 1 0 0 0 2 0 0 0 0 2 1 2 2 0 1

Vansi 1 0 0 0 2 0 0 0 0 2 2 2 2 0 1

Amleshwar 2 0 1 0 2 0 0 0 0 2 1 2 2 0 1

Navetha 1 0 0 0 2 0 1 0 0 2 2 2 2 0 1

Pipalia 1 0 0 1 2 0 0 0 0 2 2 2 2 0 1

Vahiyal 1 0 1 0 2 0 0 0 0 2 1 2 2 0 1

Sutrel 1 0 0 0 2 0 0 0 0 2 1 2 2 0 1




TABLE 3.26(CONTD..)

DETAILS OF AMENITIES AVAILABLE STUDY AREA

Village Approach to road Power Supply

PR KR ED EAG EC EA

Sayakha 1 2 1 1 1 1

Vagra 1 1 1 1 1 1

Juned 1 1 1 1 1 1

Bhersam 1 2 1 1 1 1

Khojbal 1 2 1 1 1 1

Kothia 1 1 1 1 1 1

Saran 1 1 1 1 1 1

Pisad 1 1 1 1 1 1

Rahad 1 1 1 1 1 1

Aragama 1 1 1 1 1 1

Ankot 1 1 1 1 1 1

Vorasamni 1 1 1 1 1 1

Vilayat 1 1 1 1 1 1

Vansi 1 1 1 1 1 1

Amleshwar 1 2 1 1 1 1

Navetha 1 2 1 1 1 1

Pipalia 1 2 1 1 1 1

Vahiyal 1 1 1 1 1 1

Sutrel 1 1 1 1 1 1




ABBREVIATIONS

1. Education

P-Primary Elementary School

H-Matriculation or Secondary

O-Other Educational Institution

PUC-Higher Secondary/Intermediate/pre-University/junior Collage

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.




3.9.5 GROUND WATER HYDROLOGY

Introduction

The district is mainly grounded with alluvial rock formation. The tube well has been

constructed significantly in the depth of 65 to 230m. The state ground water Level ranges

from 2 to 35m bgl (below ground level). The tube well discharge ranges from 325 to 3400

litters per minute for duration ranges of 3 to 14 meters.

District: Bharuch

FIG. 3.14 GROUND WATER MAP




Geology: Geologically the major part of the state is covered by hard rock comprising of

gneisses, schists, phyllites, sand stone and basalt. Remaining area in the north and central is

occupied by the soft rock including coastal alluvium. District Bharuch is mainly occupied by

the soft rocks like alluvium, tertiary in the north but as we move to the south the district is

covered with hard rocks and few hilly areas.

Hydrology: Hydrologically the areas have soft rock aquifers with dug wells at the depth of 10

to 25m, and tube wells at the depth of 50 to 100m. The level of ground water productivity of

this type of rocks are mapped by violet colour, the difference in the discharge is shown

through the difference in the intensity of the colour (light colour discharge-ipm) 200 to 300

in dug wells and 400 to 60 ipm in the tube well, and dark shade shows the discharge to 200

to 300 ipm in dug wells and 600 to 1200 ipm in tube wells.

The hard rock aquifers dug well are found at the depth of 10 to 25m and bore well at the

depth of 100 to 200m. The areas with extensive hard rock aquifers where pores space of

rocks have secondary permeability are called ‘fractured permeability’. The intensity can be

measured through the darkness in the colour, that is green which is used to map the hard

rock aquifers, the discharge varies from 60 to 150 ipm in dug wells areas, 100 to 300 ipm in

bore wells.

Groundwater Utilization (Critical Blocks)

Based on state of groundwater development, the various blocks/talukas in a district are

categorised as over-exploited, critical, semi critical & safe categories. In case, where annual

groundwater withdrawals are more than 100% of the annual recharge availability, it is

categorised as over-exploited, meaning that all the annually replenishable groundwater is

already being used up. In cases of talukas, where the annual withdrawals are in the ranges

of 90% to 100%, in relative to the annual available groundwater recharge, they are

categorised as critical blocks. The talukas/blocks, in which the range is 70 % to 90%, are

categorised as semi critical. The safe category of talukas/blocks has stage of groundwater

development below 70% in relative to annual recharge availability.




Accordingly the various talukas in the district, coming under the project area are categorised

as follows:

Groundwater Resource Availability, Utilization in Bharuch:

1 Annual Rainfall: There are two main types

For Monsoon season

a recharge from rainfall 20380 mm

b recharge from other resource 1994 mm

For non-monsoon season

a recharge from rainfall 0

b recharge from other resource 5504 mm

2 Total recharge: in Bharuch district the total recharge is 27878 mm

3 Net Annual Ground water Availability: 26484 mm

4 Annual ground water Draft: there are two types

a Irrigation 13349 mm

b domestic and industrial uses 1835 mm

c total annual ground water draft 15184 mm

5 Projected demand for Domestic and industrial uses up to 2025: 2729 mm

6 Stage of Ground water development in percentage: 57%

District Semi- critical Critical Over- exploited

Bharuch Amod - -

Jhagadia - -

- -

- -

- -




Decadal Water Level Data of Bharuch District of Gujarat:

District Location Decadal Mean Water

Level (1993-2002)

DTW

Nov-03

Decadal

Fluctuation

Bharuch Amayar 3.234 2.71 0.524

Arethi 6.126 4.18 1.946

Bhadkdra 6.128 6.25 -0.122

Bharuch 6.664 6.87 -0.206

Bhensli 4.985 3.35 1.635

Chikada 2.734 3.17 -0.432

Dahegam 9.709 6.88 2.829

Dediapada 5.888 4.6 1.288

Garudeshwar 11.478 7.1 4.378

Hirapura 4.86 8.1 -3.24

Llav 3.836 2.26 1.576

Jambusar 5.289 8.64 -3.351

Jambusar 8.048 2.35 5.698

Jesajpur 7.992 6.03 1.962

Jetpur 3.04 3.6 -0.56

Juna Borbhata 6.325 5.55 0.775

Kanbi Pitha 2.121 1.04 1.081

Kaswa 7.237 3.97 3.267

Kavachiya 4.253 3.36 0.893

Kavi 11.505 11.57 -0.065

Khota Amba 1.042 2.12 -1.078

Luhara 6.192 4.66 1.532

Mahegam 8.791 6.75 2.041

Modoliya 5.894 3.93 1.964

Mokhdi 5.889 6.2 -0.311

Motwan 2.074 2.47 -0.396

Nani Singlot 7.271 7.75 -0.479

Navetha 8.96 7.75 1.21

Nirnavi 7.454 8.5 -1.046

Panoli 3.087 1.85 1.237

Rasela 11.548 10.4 1.148

Raymal 3.843 1.45 2.393

Ringani 3.026 2.42 0.606

Roja Tankaria 10.439 12.05 -1.611

Sajod 3.536 1.2 2.336

Sarod 15.561 16.3 -0.739

Selemba 6.507 7.27 -0.763

Simodra 5.599 3.88 1.719

Tankari 2.852 2.18 0.672




3.9.6 DRAINAGE PATTERN

METHOD OF DATA PREPARATION

The drainage pattern has been captured from the satellite images and updated with the

help of various secondary data sources available. The study area of 10 km radius around the

Project Site is in the West and East of the Dahej Reserve Forest as well as that of Luvara

Reserve Forest which is in the South-West direction, within Taluka Vagra of District Bharuch

in Gujarat. The area is well drained by River Narmada, flowing in south direction of the study

area.

3.9.7 DIGITAL TERRAIN MODEL

Digital Terrain Model is defined as three dimensional model of earth’s surface, provided in a

digital form. This gives a quantitative model of landform. Often the terms of DTM are used for

model for containing discrete data on elevation. It is a computer simulation model to show

relief, based on three dimensional data. The DTM for the study area, within a 10 km buffer

around the project site, is extracted using Survey of India topographical sheet of 1:50,000

scale by capturing contours and spot heights.




FIGURE – 3.14

GROUND WATER HYDROLOGY




FIGURE – 3.15

DRAINAGE PATTERN




FIGURE – 3.16

DIGITAL TERRAIN MODEL




CHAPTER - 4:

ANTICIPATED ENVIRONMENTAL IMPACTS

& MITIGATION MEASURES

4.1 IDENTIFICATION OF IMPACTS

Various sources of pollution with respect to wastewater, the flue gas / process emission,

hazardous waste and noise generation along with their qualitative and quantitative analysis

as well as measures taken to control them are discussed herein with details. The network

method was adopted to identify potential impact, which involves understanding of cause-

condition-effect relationship between an activity and environmental parameters. This

method involves the "road map" type of approach to the identification of second and third

order effect. The basic idea is to account for the project activity and identify the type of

impact that could initially occur followed by the identification of secondary and tertiary

impacts.

Identified potential impacts for the various components of the environment, i.e. air, noise,

water, land and socio-economic, are presented in Figure 4.1. It should be noted that in these

illustrations the lines are to be read as "might have an effect on".




FIGURE – 4.1

IMPACT NETWORK ON AIR ENVIRONMENT

Project

Activity Construction Operation

Phase Phase

Release of Air Release of

Pollutants Heat

Primary Change in Impact on Particulates Climatic

Impacts Air Quality Visibility Deposition on Changes

Water, Land

Aesthetic Impact on Impact on

Impact Agricultural Flora & Fauna

Produce

Secondary Impact on Human

Impacts Health

Tertiary Impact on Impact on

Impacts Economic Output Socio - Cultural

Environment




FIGURE – 4.1 CONTD.

IMPACT NETWORK ON NOISE ENVIRONMENT

Project

Activity Construction Operational

Phase Phase

Noise Emission

Primary

Impacts Change in

Ambient

Noise Level

Secondary Health Risks Impact on Work Migration of Birds,

Impacts Output and Reptiles & Population

Efficiency


Impacts Economic Socio-cultural

Output Environment





IMPACT NETWORK ON WATER ENVIRONMENT

Project

Construction Phase Operational Phase

Activity Change in Surface Releases of

Morphology Wastewater

Impact on Runoff/

Seepage

Primary Impact on Impact on Environmental

Impacts Hydraulics of Water Quality Health and

Water Courses Aesthetic Risk

Secondary Impact on Impact on Cost of Water Impact on

Impacts Hydraulic of Aquatic Life Treatment Amenity /

Water Cources Recreation

Impact on Economic Output Impact on Socio-Cultural

Impacts Environment





IMPACT NETWORK ON GROUND WATER ENVIRONMENT

Project

Cnstruction Operational

Phase Phase

Activity Distrubance Release of

of Soil Waste-water

on Land

Primary Change in Groundwater Change in Structure Addition / Removal

Impacts Regime : Soil Moisture / of Soil : Ground of Substances or

water Level / Flow Level Heat to / form

Pattern / Salt Water the Soil

Instruction

Secondary Impact on Soil Biota Impact on Flora Impact on

Impacts and Fauna Landscape

Impact on Agriclutural Impact on Livestock

Production


Impacts Economic Socio - Cultural

Out Put Environment





IMPACT NETWORK ON LAND ENVIRONMENT

Project

Activity Construction Operational

Phase Phase

Primary Disturbance Disposal of

Impacts of land Wastewater

& Sludge on Land

Change in soil Change in Ground Toxic Substances

Texture & Permeability Water Regime / Salt on Land, Particulate

Water Intrusion Deposition on Land

Secondary Impact on Soil Salinity Impact on

Impacts Landscape Flora & Fauna


Impacts Agricultural Produce Live Stock

Impact on Impact on Socio-

Economic Output Cultural Environment





IMPACT NETWORK ON SOCIO-ECONOMIC & CULTURAL ENVIRONMENT

Project

Activity Operational Phase Construction Phase

Primary Economic Input Economic Output Demand for Wark Force

Impacts Capital/C&M Cost Product Cost

Net Income

Output

Secondary Change in Development Better Air, Water Empolyment Demand for Demand for Aesthetic

Impacts Economic Base of Ancillary Product Land, Noise Opportunity Communication Infrastructural Risk

of The Region Industries Avaliability Pollution Facilities Facilities

Saving of Foreign

Exchange Effect On Effect On Effect On Effect on

Human Health Agriculture & Visual Buildings

Fisheries Environment Materials

Mounments

Tertiary Effect On Water Supply, Effect On Educational Effect On Human, Nature &

Impacts Sewerage & Soild Waste Medical, Transport Recreational Facilities

Management Facilities Facilities




4.2 PREDICTIONS AND EVALUATION OF IMPACTS

An impact can be defined as any change in physical, chemical, biological, cultural and/or

socioeconomic environment that can be attributed to activities related to alternatives under

study for meeting the project needs. Impact methodology provides an organized approach

for prediction and assessing these impacts.

Scientific techniques and methodologies based on mathematical modeling are available for

studying impacts of various project activities on environmental parameters.

The nature of the impacts due to said project activities are discussed here in detail. Each

parameters identified in the proceeding chapter, is singularly considered for the anticipated

impact due to various activities listed. The impact is quantified using numerical scores 0, 1,

2, 3, 4 and 5 in increasing order of activity. In order to assess the impact accurately, each

parameter is discussed in detail covering the following:

1) Project activities likely to generate impact

2) Quantification and prediction of impact

4.2.1 WATER ENVIRONMENT

Water Consumption & Waste Water Generation is given in Table 2.2. Details of ETP are

discussed in Topic 2.4.3 of Chapter 2. Hence, overall there won’t be any significant adverse

impact due to proposed activity on the water environment. Ground water and soil will not

get contaminated, as M/s. Nutraplus India Ltd. (Unit-2) is not going to discharge any effluent

on land. With the above, it can be said that there will be no significant adverse impact on

surface and ground water or soil quality.




4.2.2 AIR ENVIRONMENT

The dispersion of pollutants in the atmosphere is a function of several meteorological

parameters viz. temperature, wind speed and direction, mixing depths, inversion level, etc.

A number of models have been developed for the prediction of pollutant concentration at

any point from an emitting source. The Industrial Source Complex – Short Term (ISCST3)

dispersion model is a steady-state Gaussian plume model. It is most widely accepted for its

interpretability. It gives reasonably correct values because this obeys the equation of

continuity and it also takes care of diffusion, which is a random process. For the present

study, this model is used for the prediction of maximum ground level concentration (GLC).

The proposed air emissions at M/s. Nutraplus India Ltd. (Unit-2) are SPM, SO2, NOx, HCl, Cl2

& HBr. The site specific and monitored details considered for input data for the software

“ISC-AERMOD View” by Lakes Environmental, Canada for prediction of impact on air

environment are given in Table 4.1. The site-specific hourly meteorological data measured

at site is given in Table 3.5. In order to conduct a refined air dispersion modeling using

ISCST3 and ISC-PRIME short-term air quality dispersion models, the site specific hourly

meteorological data measured at site is pre-processed using the U.S. EPA PCRAMMET and

U.S. EPA AERMET programs. Before starting air dispersion modeling with ISC-AERMOD View,

a building downwash analysis using BPIP View was done. BPIP View is a graphical user

interface designed to speed up the work involved in setting up input data for the U.S. EPA

Building Profile Input Program (BPIP) and Building Profile Input Program – Plume Rise Model

Enhancements (BPIP-PRIME).

The air pollution caused by the gaseous emissions from a single or small group of stacks is a

local phenomenon. Its impacts will occur at a distance ranging from within the immediate

vicinity of the stack to several kilometers away from the stack. Maximum ground level

concentration will occur within this range. All plumes at more downwind distances from the

source by stack emission become so diluted by diffusion in the ambient atmosphere, that

concentrations of pollutants become negligible. The maximum ground level concentration

for different parameters is given in Table 4.2. Isopleths for SPM, SO2, NOx, HCl, Cl2 & HBr are




given in Figure 4.2. Adequate measures shall be taken to minimize air pollution by providing

air pollution control equipment. Flue gases are discharged from stacks at adequate height

(as per CPCB norms).




TABLE – 4.1

DETAILS OF EMISSION FROM STACK & VENTS

*Permissible Limit

SR.

NO.

OPERATING

PARAMETER

UNIT FLUE GAS SOURCE OF EMISSION

BOILER

(1,2)

THERMOPACK

UNIT

D.G. Sets-1

1. Stack height Meter 30 30 11

2. Diameter Meter 0.8 0.8 0.1

3 Flue Gas

Temperature

0K 403 423 513

4. Air Pollution

Control Equipment

- Multi cylcone

separator

with bag filter

and scrubber

Multi cylcone

separator with

bag filter and

scrubber

-

5. Flue Gas Velocity m/s 6.12 6.13 6.91

6. Emission

concentration

SPM

SO2

NOx

HCl

Cl2

NH3

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

150*

(0.343)

262*

(0.599)

94*

(0.215)

-

-

-

-

-

-

150*

(0.343)

262*

(0.571)

94*

(0.205)

-

-

-

-

-

-

150*

(0.005)

262*

(0.008)

94*

(0.003)

-

-

-

-

-

-




SR.

NO.

OPERATING

PARAMETER

UNIT PROCESS GAS SOURCE OF EMISSION

PROCESS VENT

NO. 1 NO. 2 NO. 3 NO. 4

1. Stack height Meter 20 20 20 20 2. Diameter Meter 0.3 0.3 0.3 0.3 3 Flue Gas

Temperature

0K 303 313 303 303

4. Air Pollution

Control

Equipment

- Two Stage

Scrubber

(Water +

Alkali)

Two Stage

Alkali

Scrubber

Two Stage

Ammonia

Scrubber

Two Stage Ammonia Scrubber

5. Flue Gas

Velocity

m/s 5.4 5.5 5.5 5.5

6. Emission

concentration

SPM

SO2

NOx

HCl

Cl2

NH3

HBR

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

mg/Nm3

(g/s)

-

262*

(0.098)

-

-

-

20*

(0.007)

-

-

-

-

-

-

-

-

-

-

-

-

09*

(0.003)

-

-

-

-

-

-

-

-

-

-

-

-

175*

(0.002)

- - - - - - - - - - - - -- - - - -

30* (0.002)




FIGURE - 4.2

ISOPLETHS FOR PM




FIGURE - 4.2 (CONTD.)

ISOPLETHS FOR SO2





ISOPLETHS FOR NOx





ISOPLETHS FOR HCl





ISOPLETHS FOR Cl2





ISOPLETHS FOR NH3


ISOPLETHS FOR HBR




TABLE -4.2

SUMMARY OF ISCST3 MODEL OUTPUT FOR PM, SO2, NOx

SR.

NO.

LOCATIONS X, Y

CO-

ORDINATES

CONCENTRATION

PM

(µg/m3)

SO2

(µg/m3)

NOx

(µg/m3)

HCl

(µg/m3)

CL2

(µg/m3)

NH3

(µg/m3)

HBR

(µg/m3)

1. Project-site

(A1)

(0,0) 0.000 0.000 0.000 0.000 0.000 0.000 0.000

2. Saykha (A2) (-340,-340) 0.0606 0.434 0.119 0007 0.0027 0.0002 0.0002

3. Vagra (A3) (2340,6670) 0.0549 0.109 0.034 0.002 0.0004 0.0003 0.0003

4. Juned (A4) (3780,2230) 0.090 0.185 0.056 0.002 0.0009 0.0006 0.0001

5. Bhersam

(A5)

(3230,-

1670)

0.080 0.166 0.050 0.00218 0.0008 0.0006 0.0004

6. Kothia (A6) (-2780,-

2230)

0.0263 0.054 0.017 0.0007 0.0002 0.0002 0.0000

7. Khojbal

(A7)

(-7880,-

4340)

0.0127 0.026 0.008 0.00026 0.0001 0.00007 0.0000

8. Keshrol

(A8)

(-4450,-

8000)

0.020 0.042 0.013 0.00042 0.0001 0.0001 0.0000

As manufacturing activities have not yet started, the predictions were made using CPCB

permissible limit as these concentrations will in no case be exceeded. Ground level

concentrations calculated for proposed activities are superimposed on existing ambient air

quality monitoring results and combined values (Table 4.3) are found within permissible

National Ambient Air Quality Standards.




TABLE 4.3

___________________________________________________________________________

PREDICTED AMBIENT AIR QUALITY FOR PM, SO2, NOx, HCl, Cl2 & HBr Unit: µg/m3

Sr.

No.

Sampling LocationSPM SO2 NOx HCl Cl2 NH3 HBR

average

1. Project-site (A1)132.25 76.12 45.23 BDL BDL BDL BDL

2. Saykha (A2) 144.22 81.99 44.24 BDL BDL BDL BDL

3. Vagra (A3) 139.32 84.26 43.18 BDL BDL BDL BDL

4. Juned (A4) 134.22 79.67 40.26 BDL BDL BDL BDL

5. Bhersam (A5) 138.11 79.40 39.20 BDL BDL BDL BDL

6. Kothia (A6) 131.58 75.50 38.16 BDL BDL BDL BDL

7. Khojbal (A7) 129.14 70.90 38.99 BDL BDL BDL BDL

8. Keshrol (A8) 119.06 67.92 41.13 BDL BDL BDL BDL

BDL – Below Detectable Limit

4.2.3 NOISE ENVIRONMENT

Noise level around the plant site was measured. These values (Table-3.10) represent status

of Noise levels. Adequate noise control measures such as mufflers, silencers at the air

inlet/outlet, anti vibration pad for equipment with high vibration, earmuff and earplugs to

the operators, etc. will be provided. Housing / casing will be provided for all noise

generating machines. The noise level within plant will be less than 75 dB(A).

4.2.4 HAZARDOUS WASTE DETAILS

Hazardous wastes generation is given in Table 2.3.

4.2.5 INFRASTRUCTURE AND SERVICES

The plant site is located in a well-developed industrial area, which has all essential facilities

such as water, power, fuel, post, telecommunication, bank, etc. M/s. Nutraplus India Ltd.




(Unit-2) shall get water from GIDC water supply. Estimated power requirement is 3000 HP.

Power will be taken from DGVCL. 1 No. of stand by DG sets will be used as emergency power

back up. The transportation of raw materials and finished products shall be by road. As

stated earlier, the site is near to National Highway no. 8. As a result of proposed project

there will be a marginal increase in transportation activity as compared to present total

traffic upto plant premises. As a result of development of industrial estate, the neighboring

areas have developed for commercial use. The infrastructure services e.g. roads, state

transport, post and telegraph, communication, education and medical facilities, housing,

etc. have improved in the surrounding areas in recent years.

4.2.6 ENVIRONMENTAL HAZARD

Raw material such as different chemicals etc. shall be transported by road and shall be

stored in the plant premises. On site emergency plan shall be prepared for storage and

handling of hazardous chemicals and shall also be submitted to relevant authorities. This

report will be prepared with the consideration of hazards associated with the chemicals and

care should be taken for all aspects of environmental hazards. The project proponent shall

consider all the safety aspects in planning, designing and operation of the plant as per

standard practices. Hence, no adverse impact on this account is anticipated.

4.2.7 HOUSING

Enough number of dwellings is available in nearby towns and villages for accommodating

extra workforce. On neighboring towns or villages, the impact on this account is minimal.

4.2.8 ECOLOGY

The impact due to operation of the project and its activities on the ecological parameters

like natural vegetation, cropping pattern, fisheries and aquatic life, forests and species

diversity could be summarized as below.

4.2.8.1 NATURAL VEGETATION

The industry will develop a green belt on the surrounding periphery. Since the effluents and

emissions generated from the project activities shall be treated and disposed as per the




EMP provisions, adverse impact over any of the ecological components of the environment

is reduced to minimum.

4.2.8.2 CROPS

Since, the project shall be on a non-agricultural land, it shall not alter the crop production of

the area. Further, the necessary environmental protection measures have been planned

under EMP e.g. air pollution control systems shall be designed to take care of even

emergency releases of the gaseous pollutants like SPM, SO2, NOx, HCl, Cl2, HBr and regular

environmental surveillance shall be done, so as not to have any short-term or cumulative

effect on the crops and the natural vegetation of the area.

4.2.8.3 FISHERIES AND AQUATIC LIFE

Since the effluents and emissions generated from the project activities shall be treated and

disposed as per the EMP provisions, proposed project shall not envisaged any adverse effect

on fisheries and aquatic life.

4.2.8.4 AESTHETIC ENVIRONMENT

The proposed activities and further plantation will enhance the aesthetic environment.

4.2.8.5 DEMOGRAPHY, ECONOMICS, SOCIOLOGY AND HUMAN SETTLEMENT

M/s. Nutraplus India Ltd. (Unit-2) will give employment to about 100 Employees (Including

Contract workers). In addition to direct employment, indirect employment shall generate

ancillary business to some extent for the local population. There will be a positive effect due

to improved communication and health services, which have lead to economic prosperity,

better educational opportunities and access to better health and family welfare facilities.

There has been a beneficial effect on human settlement due to employment opportunities

from various industries in region in addition to employment generated by M/s. Nutraplus

India Ltd. (Unit-2) after proposed project more direct and indirect employment shall be

generated.




Local quality of life will be improved. This factor combined with all other mitigation

measures, like proper treatment and disposal of hazardous waste; liquid effluent and

gaseous emission, has minimized the adverse impact on ecology and has a beneficial impact

on human settlement and employment opportunities. There has been a beneficial impact on

the local socio-economic environment. There shall be no displacement of any population in

plant area. Any major activity that may lead to resettlement of the people is considered as

permanent impact. Hence, there is no permanent impact on this account. The increasing

industrial activity will boost the commercial and economical status of the locality up to some

extent.

Socio-Economic Environment

Environmental Impact Assessment is a study or an estimate of the probable positive or

negative impact a proposed project could have on the environment, consisting of natural,

social and economic aspects. An assessment of socio-economic environment forms an

integral part of an EIA study. Therefore, base-line information for the same was collected

during the study period. The base-line S.E. data collected for the study region has been

identified in four major indicators namely- Demography, civic amenities, Economy and social

culture.

Employment:

During construction phase of the company, skilled and un-skilled manpower will be required

and their requirement will be met with from the local community. M/s. Nutraplus India Ltd.

(Unit-2) will give employment to 100 Employees (Including Contract workers). With the

employment opportunities, local people’s income will increase and thereby, their economic

status will boost up. Further, secondary jobs shall also increase in the local area to provide

day-to-day needs/services to the working men. Demand for essential daily utilities in the

market will also temporarily increase to some extent.




Public Health:

During construction period the workers will be provided wills safe water supply, low-cost

sanitation facilities, first Aid Treatment, necessary personal protective equipment etc, to

prevent an increase in diseases related to personal hygiene. With some other industrial

units coming up in the surrounding area, Govt. dispensary, medical check-up, medicines,

services of nurses & doctors etc. are likely to be increased with a view to taking care of

general health of the local community.

Education:

Presently, every village has a primary school upto VII std. and for higher standard education,

the students, both boys and girls, have to go to Bharuch. With increase in population due to

industrial growth, the surrounding villages may start higher standards upto X and XII. Not

only male students but female students can also take advantage of the some and thereby,

percentage of literate population in the local area may increase.

Transport:

With increased employment opportunities and higher economic status of the local

community and with an increase in market conditions, transport facilities by way of buses,

two-wheeler & four-wheeler vehicles will develop in future. Thus, overall development of

the local community and their health is likely to become a matter of fact with the co-

operation and support of industrial organizations of the local area. To sum up, it could be

said that there will be a positive effect due to improved communication and health services,

which would lead to economic prosperity, better educational opportunities and access to

better health and family welfare facilities. There will be a beneficial effect on human

settlement due to employment opportunities from various industrial establishments in local

area in addition to employment generated by M/s. Nutraplus India Ltd. (Unit-2). There is

likely to be a beneficial impact on the local Socio-Economic environment. The increasing

industrial activity will boost up the commercial and economical status of the locality to some

extent.

1. This project is on non-agricultural land and therefore, it is not likely to alter the crop

production.




2. The manufacturing unit will adopt comprehensive environmental plan covering

several environment protection measures, to reduce the environmental pollution

resulting from the project.

To control the emission from process and utility stacks, the company would regularly

examine, inspect and test its emission to make sure that the emission is below the

permissible limit. With this, the status of sanitation and community health of the area would

not change.

4.2.8.6 FOREST, NATIONAL PARKS / SANCTUARIES

There is no reserved forest & no national park or sanctuary within 10 km radius of the plant.

There shall be no impact on the same.

4.2.8.7 PLACES OF ARCHAEOLOGICAL/HISTORICAL/RELIGIOUS/TOURIST INTEREST

There is no place of archaeological, historical, religious or tourist interest within the study

area i.e. 10 km radius of plant site. Hence, there shall be no impact on places of interest.

4.3 MATRIX REPRESENTATION

The parameters discussed are presented in the form of a matrix in Table 4.4. The impact

matrix relating the parameters to the activities during operation phase and construction

phase is presented in Table 4.5. The quantification of impact is done using numerical scores

0 to 5 as per the following criteria.

Score Severity criteria

0 No impact

1 No damage

2 Slight/ Short-term effect

3 Occasional reversible effect

4 Irreversible/ Long-term effect

5 Permanent damage

The scores for various parameters and activities are presented in Table 4.6.




4.3.1 CUMULATIVE IMPACT CHART

The total negative impact of various activities on any one parameter is represented as a

cumulative score and the cumulative scores of various parameters are given in the form of a

cumulative impact chart presented in Table 4.7. Any particular parameter having an

individual score greater than 5 or cumulative score of 20 implies serious effects due to the

project and calls for suitable mitigation measures. It is evident from the matrices that the

resultant impact is beneficial to the local population and due to export (and import

substitution) the resultant impact is beneficial to our country.

TABLE - 4.4

___________________________________________________________________________

IMPACT IDENTIFICATION MATRIX (CONSTRUCTION PHASE)

ACTIVITIES

DURING

CONSTRUCTION

PHASE

Air

Quality

Noise

&

Odour

Water

Quality

Land

Quality

Infrastru

cture

Services Env.

Hazards

Terrestrial

Ecology

Land use

Socio-

Economic

Status

Aquatic

Ecology

Water

Requirement

× x x × × ×

Material

Storage/

Transport

× × × × × × × × x ×

Material

Handling

× × × × × × ×

Utilities × × × ×

Effluent

Discharge

× x × × × x

Gaseous

Emissions

× × x × x x x

Fugitive

Emissions

× × x × x x x

Solid Waste

Disposal

× × × × x × ×

Spills & Leaks × × × × × ×

Shutdown/

Startup

×

Equipment

Failures

× x

Transport of

Workers

× × × ×

Movement of

Vehicles

× × x × ×

Medical &

Other Needs

× ×




TABLE – 4.4 (CONTD.)

___________________________________________________________________________

IMPACT IDENTIFICATION MATRIX (OPERATION PHASE)

ACTIVITIES

DURING

OPERATION

PHASE

Air

Quality

Noise

&

Odour

Water

Quality

Land

Quality

Infrastru

cture

Services Env.

Hazards

Terrestrial

Ecology

Land use

Socio-

Economic

Status

Aquatic

Ecology

Water

Requirement

x X X

Raw material

Storage/

Transport

X X X X X

Raw Material

Handling

X X X X

Utilities X X X X

Effluent

Discharge

X X X X X X

Gaseous

Emissions

X X X

Fugitive

Emissions

X X X X

Solid Waste

Disposal

X X X X X X

Product

Storage/

Handling

X X X

Spills & Leaks X X X X X X X X

Shutdown/

Startup

X X X X

Equipment

Failures

X X X

Plant

Operations

X X X X X X X X

Transport of

Workers

X X X

Movement of

Vehicles

X X X

Medical &

Other Needs

X X X




TABLE - 4.5

__________________________________________________________________________

CONSTRUCTION & OPERATION STAGE POTENTIAL IMPACTS & MITIGATIVE MEASURES

ENVIRONMENTA

L COMPONENTS

POTENTIAL IMPACTS SOURCES OF IMPACT MITIGATIVE MEASURE REMARKS

Water Quality Deterioration of water

quality

Construction activity &

abstraction of water for

construction

requirement and

sanitation in housing

for workers.

Generation of industrial

& Domestic effluent.

Proper management of

surface water run off

shall be made

Effluent treatment

plant (ETP)

Sewage Treatment

Plant (STP)

ZLD Scheme shall be

implemented. In order

to achieve the ZLD high

COD stream will be

treated in solvent

sripper & low COD

stream will be treated

in ETP followed by R.O.

and treated water will

be reused in process

Minor adverse impact

Air Quality Increase in SO2, NOX,

SPM & HCl, Cl2 & NH3

concentrations in

ambient air

Process emission &

Fugitive emissions

Control equipment for

fugitive emissions

Adequate stack heights

& APCE

No remarkable increase

in GLCs.

NAAQ Standards are

met

Minor adverse impacts

on ambient air quality

Socio-Economic Overall growth &

development of area,

increased employment,

improvement in

infrastructure and

growth of downstream

industries

Project activities General area planning

in advance by GIDC and

classified as notified

industrial estate by

GIDC

Beneficial change

Terrestrial

Ecology

Minor loss of habitat-

flora & fauna, loss of

agricultural land

Project activities Green belt Proper

management of solid

waste

No impact

Noise Increased noise level Project operation Noise abatement at

generation point &

green belt before

receptor

Marginal impact

Infrastructure &

Services

Improved

communication,

transport, housing,

educational & medical

facilities

Project Development has been

gradual

Beneficial impact

Environmental

Hazards

Risk to environment &

neighboring population

Handling and storage of

chemicals, solvents &

fuels

On site & off site

Disaster management

plan &

Safe practices

Insignificant adverse

impact




TABLE - 4.6

___________________________________________________________________________

ENVIRONMENTAL IMPACT MATRIX

Activities Environmental Parameter

Air

Quality

Noise &

Odour

Water

Quality

Land

Environ

ment

Infrastr

ucture

Servi

ces

Environ

mental

Hazard

Housing Terrestrial

Ecology/

Land use

Socioec

onomic

Status

Aquatic

Ecology

Water

Requirement

0 0 1 0 1 1 1 0 0 0 1

Effluent

Discharge

0 0 1 1 1 1 1 0 1 0 0

Gaseous

Emissions

1 0 0 0 1 0 1 0 1 0 0

Fugitive

Emissions

1 0 0 0 1 0 1 0 1 0 0

Solid Waste

Disposal

1 0 1 1 1 1 1 0 0 0 0

Raw Material

Storage/

Transport

1 1 0 2 2 1 1 0 1 1 0

Raw Material

Handling

1 1 0 1 0 0 1 0 1 0 0

Product

Storage

1 0 0 1 0 0 1 0 0 0 0

Spills & Leaks 1 1 1 1 1 1 1 0 1 0 0

Shut down/

Start up

1 1 1 0 1 1 0 0 1 1 0

Equipment

Failure

1 1 1 0 0 1 1 0 1 0 0

Plant

Operations

1 1 1 0 1 1 1 1 1 1 0

Transport of

workers

1 1 0 0 1 1 1 0 1 1 0

Movement of

Vehicles

1 1 0 1 1 1 1 0 1 1 0

Housing

Needs

0 1 0 1 1 1 0 1 0 1 0

Utilities 1 1 1 0 0 1 1 0 0 0 0

Cumulative

score

13 10 8 9 13 12 14 2 11 6 1




TABLE - 4.7

___________________________________________________________________________

CUMULATIVE IMPACT CHART

ENVIRONMENTAL

PARAMETER

TOTAL CUMULATIVE

SCORE

Air Quality 13

Noise and Odour 10

Water Quality 8

Land Requirement 9

Infrastructure 13

Service 12

Environmental Hazards 14

Housing 2

Terrestrial Ecology/ Land use 11

Socio Economic Status 6

Aquatic Ecology 1




CHAPTER – 5:

ENVIRONMENTAL MONIORING PLAN

5.1 PROJECT ENVIRONMENT MONITORING PLAN

M/s. Nutraplus India Ltd. (Unit-2) will adopt comprehensive environmental monitoring

plan which is essential to take into account the changes in the environment. The

objective of monitoring is:

• To verify the result of the impact assessment study in particular with regards to

new developments.

• To follow the trend of parameters which have been identified as critical

• To check or assess the efficiency of controlling measures

• To ensure that new parameters, other than those identified in the impact

assessment study, do not become critical through the commissioning of new

project.

To monitor effectiveness of Control Measures:

• Monitor daily, Assess effectiveness of the Control Measures being implemented,

Explore the need to modify or add new Control Measures particularly if a

violation is observed & Report weekly.

• Regular monitoring of environmental parameters is made to find out any

deterioration in environmental quality.

• Monitoring of the proposed project shall be regularly conducted. The attributes,

which merit regular monitoring, are specified underneath

Environment monitoring plan for proposed plant has described in Table:-5.1 along with

Environment Components, parameter, standards to be followed, location and

frequency.




TABLE:-5.1

PROJECT ENVIRONMENT MONITORING PLAN

Environmental

Component

Parameters Standards Frequency

Air Environment

AAQM at plant site As prescribed by GPCB

including PM2.5, PM10,

SO2, NOx, HCl, Cl2, HC

& VOCs

Prescribed

by CPCB

Once in a month in upwind

and downwind direction.

Stack emission

monitoring of

emissions sources

Parameters prescribed

by GPCB

In stack

Prescribed

by GPCB

Once In a Month

Fugitive emissions/

work place

monitoring within

the plant side

VOC Prescribed

by GPCB

Regular

Water Environment

Analysis of treated

effluent


by GPCB

Prescribed

by GPCB

Once a day by Company,

Once a month by NABL Lab.

Ground water

quality

Colour, pH, TDS, TSS,

Sulphates, Chlorides,

BOD3, COD, oil and

grease, etc.

Water

quality

Standards

Once a Season

Noise Environment

Ambient Noise at

plant site

Noise level in dB(A) As per

National

Noise

Standards

Once In a Month

Soil Environment

At plant site Analysis of pH,

conductivity,

Sulphates, calcium,

magnesium, Cl-

-- Pre and post monsoon

season by Company




5.1.1 LABORATORY FACILITIES

M/s. Nutraplus India Ltd. (Unit-2) will develop its own laboratory equipped with

different equipment i.e. analytical balance, pH meter, COD heating apparatus, oven,

incubator and necessary glass-wares. In addition to that M/s. Nutraplus India Ltd. (Unit-

2) will develop quality control laboratory which will be equipped with sophisticated

equipments. Equipment of quality control laboratory will also available for analysis of

environment parameters. M/s. Nutraplus India Ltd. (Unit-2) will do regular monitoring

to ensure that pollution will be limited to below prescribed limits and to take corrective

action. 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 equipments of each

department is under respective department heads.

5.1.2 DOCUMETATION & RECORDS

The environmental department in respect of operation of pollution control facility

maintains following records.

� Instruction manual for operation and maintenance of pollution control equipments.

� Log sheet for self-monitoring of pollution control equipments.

� Manual for monitoring of Air, water for Ambient conditions

� Instruction manual for monitoring of water, solid and gaseous parameter

discharged from the factory and also for various parameters of pollution control

facilities.

� Stationary records as per the Environmental Acts.

� Monthly and annual progress reports.




CHAPTER – 6

RISK ASSESSMENT & DISASTER MANAGEMENT PLAN

In order to support the environment impact assessment and environment management

plan, following additional studies have been included in the report.

• Risk assessment

• Disaster Management Plan

• On site and off site emergency action plan

• Occupational Health and Safety Management System

6.1 RISK ASSESSMENT

6.1.1 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 t-he 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.




6.1.2 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;

• Emergency Plan, which includes Occupational and Health Safety Plan;

6.1.3 METHODOLOGY

Quantitative risk assessment (QRA) is a means of making a systematic assessment of the

risks from hazardous activities, and forming a rational evaluation of their significance, in

order to provide input to a decision-making process. The term ‘quantitative risk assessment’

is widely used, but strictly this refers to the purely numerical assessment of risks without

any evaluation of their significance. The study has been conducted based on the premises of

a traditional Quantitative Risk Assessment. The key components of a QRA are explained

below, and illustrated in Figure-6.1 and Figure-6.2.




FIGURE – 6.1

QRA METHODOLOGY




FIGURE–6.2

FLOW CHART FOR QUANTITATIVE RISK ASSESSMENT

Start Identify Risk Areas

Select a Risk Area

Identify Failure Cases

Select a Failure Cases

Identify Consequence Outcomes

Select Consequence Outcomes

Determine Frequency

Estimate Consequence

Record Frequency and Consequence in a summary Table

Have all Consequence outcomes been studied?

Have all failure cases been studied?

Have all risk areas been studied?

Draw Risk Contours Finish

Yes

Next Next




6.1.4 HAZARD IDENTIFICATION

Identification of hazards in the proposed project activity is of primary significance of the

analysis, and quantification. Hazard states the characteristics of system/plant/process that

presents potential for an accident. All the components of a system/plant/process need to be

thoroughly examined to assess their potential for initiating or propagating an unplanned

event/sequence of events, which can be termed as an accident.

6.1.4.1 IDENTIFICATION OF HAZARDOUS AREAS

The procedure for QRA starts with identification of major risk areas in the installation.

At M/s. Nutraplus India Ltd. (Unit-2), major risk areas are as follows:

• Bulk storage area for Raw Materials at ambient temperature and atmospheric pressure.

• Process Plant involving pumping, transportation, reactors, distillation, heating, cooling,

etc.

• Bulk loading and unloading from storage tanks to road takers and vice versa.

6.1.4.2 IDENTIFICATION OF FAILURE CASES FOR HAZARDOUS AREAS

• Release due to catastrophic failure of storage tanks or process vessels.

• Rupture of connected pipe with storage tank or process vessels.

• Continuous release at significant rates for long durations transfer pipelines caused by

sudden, major break of the pipeline.

• Continuous release at low rate through small holes or cracks in piping and vessels, flange

leaks, and leakage from pump glands and similar seals.

It is to be noted that for Quantitative Risk Assessment, worst case scenarios has been

considered, though their frequency of occurrence is much lower than the cases of small

leaks.




6.1.4.3 MAJOR HAZARDOUS AREAS

The hazardous chemical storage area is shown in Figure-6.3. The major Hazardous chemicals

to be stored, transported, handled and utilized within the plot area are summarized in the

Table-6.1. Other hazards and control measures are summarized in Table-6.2. Facilities /

System for process safety, transportation, fire fighting system and emergency capabilities to

be adopted are stated below.

FIGURE-6.3

HAZARDOUS CHEMICAL STORAGE AREA




TABLE-6.1

STORAGE AND HANDLING DETAILS OF HAZARDOUS CHEMICALS

SR.

NO

NAME OF THE MATERIAL TYPE OF

HAZARD

SIZE

(KL)

NO.

TANK STORAGE

1 N-HEXANE FLAMMABLE 30 1

2 TOLUENE FLAMMABLE 30 6

3 METHANOL FLAMMABLE 30 4

4 BENZENE FLAMMABLE 30 1

5 METHYLENE CHLORIDE FLAMMABLE 30 2

6 MONO CHLORO BENZENE FLAMMABLE 30 2

7 ETHYL ACETATE FLAMMABLE 30 3

8 EDC FLAMMABLE 30 1

9 HCL CORROSIVE 30 2

10 PHENOL CORROSIVE 25 1

11 LIQ . BROMINE CORROSIVE 30 1

12 H2SO4 CORROSIVE 30 1

13 CAUSTIC SODA LYE TOXIC 30 1

14 NITRIC ACID (98%) TOXIC 30 1

15 LIQ NITROGEN TOXIC 30 1

16 ACETONE FLAMMABLE 30 2

CYLINDER

23 CHLORINE GAS TOXIC 10 1

24 MMA GAS TOXIC 5 1

25 AMMONIA GAS TOXIC 2 1




DRUM STORAGE FORMALDEHYDE PCBA H

2O

2 (50 %)

MIBK 3, 5, 6 TRI CHLORO SALICYLIC ACID THIONYL CHLORIDE

HYDROSO 6-AMINO PENICILLANIC ACID(6-APA) PARA CHLORO ANILINE

MONO METHYL CHLORO

ACETIC ACID

MIBK THF

ANILINE DIBROMO DIMETHYL HYDANTOIN CHLOROFORM

CHLORO ACETYL CHLORIDE AZOBISISOBUTYRONITRILE PIVALOYL CHLORIDE

DI METHYL ANILINE SODIUM BIO-CARBONATE SOLN MCA

CYAANAMIDE SOLUTION (L-

500)

METHYL ANTHRANILATE ACETONE

5 CHLORO 2 NITRO ANILINE

TRANS 4-AMINO CYCLOHEXANOL DMF

BUTYL ACETATE IPA HCL AMMONIUM THIOCYNATE

2 METHYL 5

NITROMIDAZOLE

L(+)TARTARIC ACID N- PROPANOL

ACETIC ANHYDRIDE ETHYLENE OXIDE ISO BUTYL BENZENE

ONCB BUTYL ACETATE PARA CHLORO ANILINE

PHOSPHORIC ACID FORMALDEHYDE DIMETHYL SULPHOXIDE

ORTHO NITRO TOLUENE N-PROPYL BROMIDE N-BUTANOL

FORMIC ACID H2O2 PYRIDINE

BAG STORAGE RANEY NICKEL IRON POWDER SODIUM HYDROSULPHITE

SODIUM HYDROXIDE ARSENIC TRIOXIDE SODIUM BORO HYDRIDE

MANGANESE DIOXIDE PHOSPHOROUS OXY CHLORIDE N-METHYL PIPERAZINE

PIPERAZINE DANE SALT 2, 4 –DI CHLORO – 6-

AMINO PHENOL

RESORCINOL HYFLOSUPERCEL 3 HYDROXY

ACETOPHENONE

BETA PICOLINE ALUMINIUM CHLORIDE 2 ETHYL HEXANOIC ACID

PALLADIUM CHARCOAL

CATALYST

POTASSIUM CARBONATE SODA ASH

SODIUM SALT KOH THIOPHENOL

DIMETHYL CARBONATE 4-CHLORO-2- AMINO PHENOL (4CAP) SODIUM SULPHATE

SODIUM NITRITE




TABLE 6.2

OTHER HAZARDS AND CONTROL

SR.

NO.

NAME OF THE POSSIBLE

HAZARD OR

EMERGENCY

ITS SOURCES

&

REASONS

ITS EFFECTS ON

PERSONS, PROPERTY

& ENVIRONMENT

PLACE OF ITS

EFFECT

CONTROL MEASURES PROVIDED

1 BOILER

(1) Burning

(2) Physical injury

(3) Explosion

Over pressure in the boiler if

safety valve not working.

Water level indicator not

working. Low water level

indicator fail. High temp.

System fails.

Minor/Major Injury

Loss of human life

Loss of property (Loss

of Main/ Machine

Material)

Boiler House and

surrounding places

Lower & Upper Level Indication System provision. Safety valves

for pressure control fixed temp. & pressure indicator provided.

Blow down & blowing system provided for cleaning tube and

shell. Soft water used. Inter locking provided on pumps, FD fan, ID

fan. Periodical checking & inspection maintenance done. Yearly

inspection done by Boiler Inspector

2 ELECTRICITY

(1) Burning

(2) Fire

(3) Shock

Loose Contacts, Weak

earthling Short Circuit

Improper Insulation

Burning, Shock,

Death

Surrounding the

accident area

Proper Earthing, Periodical Checking of joints, proper insulations

of Equipments, etc. Flame proof fitting in solvent storage area,

bounding and jumpers to all solvent barrier lines provided.

3 HOUSE KEEPING

(1) Physical

(2) Burning

(3) Fire

(4) Chemical Exposure

Bad House keeping Physical / Chemical

Thermal Burn Injury

(Major / Minor)

In all surrounding

areas i.e. Storage,

Plants

Proper Handling, regular cleaning, Proper placement of material

(RIGHT THING AT THE RIGHT PLACE)

4 PIPE LINE LEAKAGES

Spillages etc.

(1) Corrosion

(2) Toxic gas release

Leaking of pipe line due to

corrosion, Loose contact etc.

Physical / Chemical

Thermal Burn Injury

(Major / Minor)

Plant area Proper maintenance, Proper Selection of Material for pipe lines,

Immediate attention, Earthing provided, flame proof fitting, NO

SMOKING Boards displayed.

5 Structural Failure Inside the factory (Corrosion) Injury/Death to

persons, damage to

property

Within the factory Automatic operation Periodic Testing of safety valves Regular

Inspection and Maintenance

6 Toxic Release from

outside

Outside the factory Injury/Death Within & outside

the unit

Alarm, Evacuation rescue & shelter/ Welfare




7 Natural Calamity Nature Injury / Death to

persons, damage to

property

Within & outside

the unit

Alarm, Evacuation rescue & shelter/ Welfare




TABLE 6.3

HAZARDOUS PROPERTIES OF THE CHEMICALS, COMPATIBILITIES, SPECIAL HAZARD AND ANTIDOTES

SR. NAME OF CHEMICAL HAZARD FLASH

POINT 0

C

BP 0

C

LEL

%

UEL

%

SP.GR.

20 0

C

VD SOLUBILITY

WITH

WATER at

20 0 C

NFPA

H F R

HAZARDOUS COMBUSTION

PRODUCT

TLV

TWA

ppm

IDLH

ppm

LC50/LD50

mg/m3

Antidote

1. Hexane

CAS No. 110-54-3

F -22 69 1.0 8.1 0.659 3 0.2 mg/

100 ml

1 3 0 Fire may produce irritating,

corrosive and/or toxic gases

50 1100 - No Specific

Antidote

2. Toluene

CAS No. 108-88-3

F 4 110.6 1.2 8 0.86 3.2 700 mg/L 2 3 0 Moderately dangerous; when

heated, emits toxic fumes

which can react vigorously

with oxidizing materials

200 500 49 gm/m3/

4H

Diazem – 1

mg/Kg.(Intrave

nous),

Epinephina,

Efidrine

3. Methanol

CAS No. 67-56-1

F 11 64.5 6 36.5 0.793 1.11 Very soluble 1 3 0 Fire will produce irritating,


200 - 64000

ppm/4h

10 mg

diazepam

through

injection

4. IPA

CAS No. 67-63-0

F 12 82.4 2 12.7 0.785 2.1 Miscible 1 3 0 Fire may produce irritating,


400 2000 - No specific

Antidote

5. EDC

CAS No. 107-06-2

F 13 83.5 6.2 16 1.253 3.42 0.87

g/100ml

1 3 0 Toxic and irritating gases

(hydrogen chloride,

phosgene) are generated.

1 50 - No specific

Antidote

6. MEG

CAS No. 107-21-1

F 111 195 1.8 12.8 - 2.6 Miscible 2 1 0 Carbon monoxide, irritating

and toxic fumes and gases,

carbon dioxide

50 - - -

7. Phenol

CAS No. 108-95-2

T 81 181.7 1.3 9.5 1.057 3.24 9 g/100ml 4 2 0 Unburned vapor is toxic

Yields flammable vapors

when heated, which will

form explosive mixtures with

air

5 250 125 mg/l 24

hr

Activated

charcoal and

240

ml milk

8. Thionyl Chloride

CAS No. 7719-09-7

C 140 76 - - - 4.1 Reacts 4 0 2 Fire will produce irritating,

corrosive and/or toxic gases.

Reaction with water may

generate much heat which

will increase the

concentration of fumes in

the air

- - 500 ppm

for 1 Hr

Natural Oil and

One table

spoon

Sodium or

Magnesium

Sulphate with

One glass of

Water

9. Sulphuric Acid C - 290 - - 1.84 3.4 Miscible 4 0 2 Toxic fumes of oxides of 1 mg/m3 - 510 Sodium Hydro-




CAS No. 7664-93-9 with water,

liberates

much heat

sulfur when heated to

decomposition. Will react

with water or steam to

produce toxic and corrosive

fumes. Reacts with

carbonates to generate

carbon dioxide gas, and with

cyanides and sulfides to form

poisonous hydrogen cyanide

and hydrogen sulfide

respectively

mg/m3/2H Carbonate (4%

Conc.), Milk,

Lime Juice,

Milk

of Magnesia

10 HCl

CAS No. 7647-01-0

C 11 -85.06 - - 1.19 1.25 Miscible 3 0 1 Non-combustible, substance

itself does not burn but may

decompose upon heating to

produce corrosive and/or

toxic fumes

5 50 3124 ppm Sodium Hydro-

Carbonate (4%

Conc.)

11 Bromine

CAS No. 7726-95-6

C - 58.7 - - 3.11 5.5 Slightly

soluble

3 0 0 Fire may produce irritating,


0.1 3 2600 mg/kg Put two or

three

drops of

Pontocane (0.5

solution) or

Benoxinate

(Novesine) 0.4

%. If problem

in

respiration,

give

milk, butter-

milk

or lemon juice

or

make a small

cotton ball and

drench with

ethanol or

ether

solution drops

and put it near

victim’s nose

for

Smell. Apply

Pure oxygen.




12 Chlorine

CAS No. 7782-50-5

T - -34.6 - - 1.424 2.5 Reacts 4 0 0 When heated, it emits highly

toxic fumes

- - 1017 milk, milk

butter

and milk of

Magnesia.

13 Diethyl Amine

CAS No. 109-89-7

F -23 55.5 1.8 10.1 0.671 2.5 Miscible 3 3 0 Vapors are irritating Vapors

are heavier than air and may

travel considerable distance

to a source of ignition and

flash back

25 200 - No Specific

Antidote

14 Dimethyl Formamide

CAS No. 68-12-2

F 57.8 153 2.2 15.2 0.949 2.51 Easily

soluble in

cold water,

hot water

2 2 0 These products are carbon

oxides (CO, CO2), nitrogen

oxides (NO, NO2)

10 - 2800 mg/kg Calcium

Gluconate

10 ml

in 10% solution

through

injection

15 Acetic Acid

CAS No. 64-19-7

C 40 118 4 16 1.015 2.1 Infinitely

soluble

3 2 2 Carbon dioxide and carbon

monoxide may form when

heated to decomposition.

May also release toxic and

irritating vapors

10 - 5620 ppm/

1h

Sodium Hydro-

Carbonate (4%

Conc.), Milk,

Lime Juice,

Milk of

Magnesia

16 Dimethyl Sulphate

CAS No. 77-78-1

T 83 189 3.6 23.2 1.33 4.35 2.8 g/100ml 4 2 1 Combustion may produce

irritants and toxic gases

1 7 45 ppm 4

hrs

Sodium Hydro-

Carbonate (4%

Conc.), Milk,

Lime Juice,

Milk of

Magnesia

17 Acetaldehyde

CAS No. 75-07-0

F -38 20.1 4 57 - 1.52 Miscible 2 4 2 Produces irritating vapor

when heated Vapors are

heavier than air and may

travel a considerable

distance to a source of

ignition and flash back.

200 2000 - -

18 Nitric Acid

CAS No. 7697-37-2

C - 121 - - 1.408 >1 Miscible 4 0 1 Non-combustible, substance

itself does not burn but may

decompose upon heating to

produce corrosive and/or

toxic fumes

2 25 260

mg/m3/30M

Sodium Hydro-

Carbonate (4%

Conc.), Milk,

Lime Juice,

Milk of

Magnesia

19 Liq. Ammonia

CAS No. 7664-41-7

T 11 -33.34 15 30 0.9 0.597 54 g/100 ml 3 1 0 Hock-sensitive compounds

are formed with mercury,

silver and gold oxides.

50 300 2000

ppm/4-hr

Wash with

Lactic

Acid, Apply




soframycin

Smelling

Ethanol

or Ether

20 Pyridine

CAS No. 110-86-1

F 17 115 1.8 12.4 0.9780 2.73 Soluble 3 3 0 Nitrogen oxides, carbon

monoxide, carbon dioxide

5 1000 28500

mg/m3/1H

Activated

Charcoal

21 Dichloromethane

CAS No. 75-09-2

T -4 39.8 13 22 1.325 2.9 10-50 mg/ml 2 1 0 Dissociation products

generated in a fire may be

irritating or toxic

50 2300 14400

ppm/7H

Hydrocortisone

(200 mg at

every

4 hrs.) Aspirin

and if

pneumonia

gives

antibiotics

22 Formic Acid

CAS No. 64-18-6

C 48 100.7 12 38 1.22 1.6 Miscible 3 2 0 Toxic vapor generated in fires 5 30 6200

mg/m3

Sodium Hydro-

Carbonate (4%

Conc.), Milk,

Lime Juice,

Milk

of Magnesia

F = Fire T = Toxic H = Health Hazard Class F = Fire Hazard Class

E = Explosive R = Reactive R = Reactive Hazard BR = Burning Rate

BP = Boiling Point LEL = Lower Explosive LimitTLV = Threshold Limit Value PPM = Parts Per Million

UEL = Upper Explosive Limit SP.GR = Specific Gravity STEL = Short Term Exposure Limit NFPA = National Fire Protection Association-USA

VD = Vapour Density ER = Evaporation Rate C = Corrosive




6.1.4.4 CONTROL MEASURES WHILE STORAGE OF HAZARDOUS CHEMICALS

For Above Ground Non PESO Storage Tank Farm:

• SS storage tank provided as per IS code.

• Dyke wall provided to storage tank.

• Level gauge provided with low level high level auto cut-off provision.

• Fire hydrant monitor with foam trolley facility provided.

• FLP type pump provided.

• Double static earthing provided to storage tank.

• Double Jumper clip provided to all pipeline flanges.

• Road tanker unloading procedure prepared and implemented.

• Lightening arrestor, PPEs provided.

• Safety shower, eye wash provided.

• NFPA labeling system adopted for drums as well as storage tanks.

Safety Measures for Acid Storage Tank Area:

• Storage tank will be stored away from the process plant.

• Tanker unloading procedure will be prepared and implemented.

• Caution note and emergency handling procedure will be displayed at unloading area and

trained all operators.

• NFPA label will be provided.

• Required PPEs like full body protection PVC apron, Hand gloves, gumboot, Respiratory

mask etc. will be provided to operator.

• Neutralizing agent will be kept ready for tackle any emergency spillage.

• Safety shower, eye wash with quenching unit will be provided in acid storage area.

• Material will be handled in close condition in pipe line.

• Dyke wall will be provided to all storage tanks, collection pit with valve provision.

• Double drain valve will provided.

• Level gauge will be provided on all storage tanks.




• Safety permit for loading unloading of hazardous material will be prepared and

implemented.

• TREM CARD will be provided to all transporters and will be trained for transportation

Emergency of Hazardous chemicals.

• Fire hydrant system with jockey pump as per TAC norms will be installed.

Bromine Storage & Handling Safety

• The amount of bromine in storage will be kept to a minimum.

• Minimize the dispersal of bromine vapors by locating the storage area on low ground.

Low curbs or walls (called dikes), 200 mm high, will be provided to protect the area from

external flooding and to minimize the dispersal of bromine vapors. The minimum dyked

volume will be equivalent to the largest storage tank plus 10%.

• Adequate size sump will be provided for collecting bromine spills and pump away

collected rainwater and fire-fighting water.

• Floors will be of impervious construction, preferably concrete.

• Bromine ISO tank should be stored no closer than 10 meters from human or animal

consumable articles. Explosives and flammable materials should not be stored close to

bromine.

• There should be a strengthened approach way for emergency vehicles on two sides of

the installation.

• Hoses will be PTFE with stainless steel braid covering and carbon steel flanges. Screwed

fittings will not used.

• Provide lightning protection.

• There would be sufficient bromine storage tank capacity or an empty ISO tank to

accommodate the transfer of bromine from a leaking container

• Area where bromine will be used or stored will be enclosed so that unauthorized persons

and animals are prevented from entering the area. Adequate lighting will be provided to

allow sufficient night surveillance. Surveillance will be provided 24 hours a day.

• Personnel escape routes will be clearly marked and it will be maintained without any

obstructions including adequately sized doors and windows.




• Facilities like offices, eating, showering and changing rooms, will be located in up wind

direction and remote from the area where bromine is handled or stored. Provide an

adequate supply of clean water for washing and showers.

• Emergency siren, telephone will be provided in storage area for the reporting of

accidents or emergency situations. The emergency telephone numbers will be displayed

at prominent locations and it include the fire department, ambulance service, emergency

response team, hospital and police.

• A wind sock will be provided which will clearly visible from all points on the site and

replaced as required. This is required for indicating wind strength and direction.

• Emergency respirator equipment cabinets (Cupboard) will be installed not more than 30

meters or ten seconds walking distance from any location in the storage area.

• Showers and eyewash fountains will be provided, clearly marked, well lit and with

unobstructed access.

• Signs will be posted prominently at the site entrance and throughout the installation with

area maps showing access ways, hydrant locations, emergency showers, location of

emergency equipment and emergency telephone numbers.

• All management and operating personnel involved in the use or handling of bromine will

undergo safety training, in addition to specific task training.

• Only experienced well-trained operators will be allowed to receive and unload bromine

receptacles.

• The management will ensure that emergency response plans have been made and

coordinated with the emergency response local authorities.

• Bromine glass bottle capacity 2.5 litters and six bottles are stored in one packing box.

• Bromine will be stored in dry and cool place and well ventilated area.

• Safety permit for hazardous material loading unloading will be prepared and

implemented.

• Fire hydrant system and water sprinkler system installed at tank farm area.




Safe Transportation Procedure to be adopted for Bromine ISO container

The driver and assistant driver of any vehicle transporting bromine should comply with the

following requirements:

• GPS will be installed in all the trucks and ISO container vehicle.

• Driver and assistant will be trained in using GPS.

• Open space separated from public highway and public dwellings, where public does not

normally pass. No passengers are allowed.

• The crew shall know how to use fire-fighting appliances.

• The driver or driver's assistant may not open a package containing bromine.

• Bromine receptacles are not to be checked with open flames.

• No smoking is permitted around the transport unit or in the vicinity of the vehicle during

handling operations.

• The engine is to be shut off during all handling operations unless required to drive

pumps, hoist, etc.

• Parking brakes are to be applied whenever parked.

• If the vehicle is parked on a road at night or with poor visibility, warning signs are to be

placed 10 meters ahead of and behind the vehicle.

• TREM CARD provided to all transporters and trained for transportation Emergency of

Hazardous chemicals.

Following Personal Protective Equipments are to be made compulsory when handling

Bromine

• American National Standards Institute (ANSI) approved chemical safety goggles at all

times when handling Br2.

• Use a full face shield over eyewear.

• Full body protection PVC suite

• Eyewash fountains should be located in areas where bromine is handled, used or stored.

• When in danger of contact with liquid bromine, wear an approved chemical resistant

suit.

• Leather or other non-woven ANSI approved steel-toed shoes or Gum boot




• Protective rubber boots should be worn over shoes for extra protection.

• Have NIOSH approved respirators and self-contained breathing apparatus available.

• Gloves: 100% Nitrile rubber gloves or Neoprene gloves

Safety Practices in the Work Area

• We will inform our all employees of the potential hazards of contact with bromine and

train them in appropriate first-aid procedures.

• Bromine handling areas will be clearly marked and restricted to qualified, trained

personnel only.

Ventilation

• We will maintain bromine vapor concentration in the work area to less than 0.1 ppm

with adequate exhaust hoods, ventilation systems and scrubbers. Analyze air for proper

control.

• Transfer or repackage bromine only in a controlled, closed environment.

• Exhaust ventilating systems will be used in enclosed areas where bromine is handled.

Containers and Storage

• Bromine glass bottle capacity 2.5 litters and six bottles are stored in one packing box.

• Bromine will be stored in dry and cool place and well ventilated area.

Neutralization in Case of Spillage Leakage

• Neutralization with sodium Bisulfite requires 3 moles of sodium hydroxide: 1 mole

sodium Bisulfite: 1 mole bromine.

• Neutralization with sodium sulfite requires 2 moles sodium hydroxide: 1 mole sodium

sulfite: 1 mole bromine.

• The weights and volumes specified include a 10% excess of sodium hydroxide and

sodium bisulfate or sodium sulfite.




Emergency Procedures

• In case of bromine emergencies, follow recommended first aid and emergency response

procedures adopted

Transportation Emergencies

• In emergency situations resulting from vehicle accidents:

• Notify the local police, fire departments, emergency responders and the carrier.

• Isolate the area.

• Any person not dressed in proper protective clothing and not using a NIOSH approved

self-contained breathing apparatus should be kept a safe distance away.

• Call to the supplier

• Seek immediate medical assistance for those injured and follow recommended first aid

procedures.

Leaking Containers

• When handling a leaking bottle personal protective clothing, goggles and NIOSH

approved self contained breathing equipment must be worn.

• Clear contaminated area of non-essential personnel and send them to assembly point.

• Maintain a slight ammonia atmosphere throughout the clean up. Carefully release

anhydrous ammonia gas to neutralize bromine vapor. The ammonia gas will convert

bromine to white ammonium bromide “Smoke.”

• Do not allow liquid bromine and liquid ammonia to combine; a violent reaction will

occur. Ammonia (16 to 25% by volume) can form an explosive mixture with air. Pour

hypo solution*, lime and water slurry or soda ash solution over the spill. Hypo-bromine

reactions produce hydrobromic acid.

• Dry sodium thiosulphate and liquid bromine produce a violent reaction; do not mix them.

• Using cold water, wash neutralized bromine into a sump for transfer to an approved

waste disposal facility where the waste can be processed.

• Ventilate the area to remove the ammonium bromide and any bromine fumes. Scrub the

floors and equipment with soap and water.




First Aid Procedure

• Immediate medical assistance is required if bromine is swallowed, inhaled or has

contacted the eyes or skin.

• If bromine has been ingested, do not give anything by mouth. Seek medical attention

immediately. Do not induce vomiting.

• If bromine has been inhaled, move the exposed person to a well ventilated area. Seek

medical attention immediately. The victim should be placed in a comfortable sitting or

partly reclining position. The exposed individual should avoid exertion. If vomiting occurs,

turn the patient on his side to avoid choking. Keep the patient warm. If the patient is

coughing and showing signs of respiratory distress, properly trained personnel should

administer oxygen.

• For skin contact, the affected area must be flooded immediately with large amounts of

clean water from a safety shower or other appropriate source of flowing water. Seek

medical attention immediately. All contaminated clothing, including shoes, should be

removed as quickly as possible while the victim is under the shower. Washing should be

continued for a minimum of 30 minutes. If possible, continue to wash the affected area

during transport to medical facilities. (Extended wash times of two hours or more have

proven beneficial.)

• If bromine liquid or vapor contacts the eyes, they must be irrigated immediately with

large amounts of running water. Eye wash stations are preferable for irrigation. If one is

not available, a hose, water source with a liberal, gentle flow may be utilized. The eyelids

must be held apart during irrigation to ensure contact of water with all accessible tissues

of the eyes and lids. Eyes should be washed continuously for a minimum of 30 minutes. If

possible, continue flushing the eyes while transporting the employee to a physician. In all

cases of bromine injury, obtain immediate medical attention. Provide emergency

personnel with information about all materials used by the person and provide

appropriate information about bromine and first aid procedures.




For Drum Storage Area:

Some chemicals will be received at plant in drums by road truck and stored in a separate

drum storage area.

• FLP type light fittings will be provided.

• Proper ventilation will be provided in Godown.

• Proper label and identification board /stickers will be provided in the storage area.

• Conductive drum pallets will be provided.

• Drum handling trolley / stackers/fork lift will be used for drum handling.

• Separate dispensing room with local exhaust and static earthing provision will be made.

• Materials will be stored as per its compatibility study and separate area will be made for

flammable, corrosive and toxic chemical drums storage.

• Smoking and other spark, flame generating item will be banned from the Gate.

For Chlorine:

Following steps will be adopted:

• SOP will be prepared for safe handling of Chlorine tonners.

• Chlorine Emergency Kit will be procured and kept ready at chlorine shed.

• Chlorine Hood with blower will be provided with scrubbing arrangement.

• Safety Shower and eye wash will be provided in Chlorine shed area.

• Tonner handling EOT crane will be installed in Chlorine shed area for safe Tonner

handling.

• Safety Valve will be provided on chlorine header line and it will be connected to caustic

scrubber.

• SCBA sets will be kept ready at chlorine handling area.

• Safety valve will be provided on vaporizer header and outlet of safety valve connected to

scrubber.

• Flow and temperature controllers will be provided on process line.




6.1.4.5 PRECAUTIONS DURING STORAGE AND TRANSPORTATION OF HAZARDOUS

CHEMICALS LIQUIDS

• Always use the road tankers having authorization for transporting the said liquids.

• Vendor will be asked to provide MSDS to Tanker Driver.

• Tankers will have clearly marked identification of material being contained with

mentioning Safety Card.

• Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

• Provide muffler on exhaust while entering tanker within premises.

• Ensure Earthing Boss connection before starting any transferring.

• SOP to cover routine checking of Tank farm area to be carried out for checking any spillage

/ leakage.

• Tanks will be inspected physically daily for having any visual abnormality.

• Readings of Temperature & Pressure will be noted, recorded & reported immediately for

abnormality.

• Safety instruments like rupture disc, safety valves will be checked at defined duration for

intakeness.

• Scheduled testing of tanks to be done for thickness testing.

• Tanks to be painted on regular interval defined as per laws to protect them from

atmospheric corrosion.

• Barrels to be checked for proper fixing of bungs before sending it outside the premises.

• Barrels to be monitored physically daily for developing any pressure or vacuum within it on

long storage.

• Concerned persons will be trained properly to use spill kit in case of observing any spillage

inside warehouse.




SOLIDS

• Vendor will be asked to provide MSDS to Truck Driver.

• Driver to have concerned Safety Officer’s contact details to contact him in case of

emergency.

• Provide muffler on exhaust while entering truck within premises.

• SOP to cover routine checking of Bags & Containers for checking any damage.

• Containers to be tested for safe racking & transportation.

• Proper PPE to be used while handling the material & concerned persons to be trained for

usage of the same.

• Concerned persons will be trained properly to use spill kit in case of observing any

spillage inside warehouse.

The major hazards in the M/s. Nutraplus India Ltd. (Unit-2) are described below.

• Toxic hazard due to leakage of hazardous chemicals Chlorine, Bromine etc. from storage

tank.

• Corrosive hazard due to leakage of chemicals like HCl, H2SO4 etc. from storage tank or

Carboys.

• Electrical hazards due to the electrical major equipment/ machinery, operations,

welding, motors, and heavy lift devices, cabling, human intervention (short circuit

possibility), maintenance work (due to machinery breakdown etc.), plant lighting related

electrical hazards.

• Possibility of human injury due to working with mechanical machines, manual handling

etc.

• Possibility of injury during chemicals handled, during operations and due to intoxication.

• Major dropped objects hazard due to large number of physical handling steps /

operations involved with crane/ overhead lifting/ hoisting equipment.

• Fires in any part of the plant working areas – there is a possibility of rapid escalation if it

is not brought under control quickly.

• Possibilities of fire hazards at transformers, switchgear and other electrical equipment

etc.




TABLE 6.4

Transportation, Unloading and handling procedure for n- Hexane, Toluene, Methanol,

Ethanol, EDC

SR.

NO.

ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

1 Transportation of

Solvents like n-

Hexane, Toluene,

Methanol, EDC etc.

by road tanker

Leakage& Spillage

Fire,& explosion,

Toxic release

• Check the source of leakage point.

• Do not touch damaged containers or spilled material unless

wearing appropriate protective clothing.

• Stop leak if you can do it without risk.

• Use water spray to reduce vapors; do not put water directly

on leak, spill area or inside container.

• Keep combustibles (wood, paper, oil, etc.) away from spilled

material.

• Isolate the area

• Isolate the container

• Training will be provided to driver and cleaner regarding the

safe driving, hazard of Flammable chemicals, emergency

handling, use of SCBA sets.

• TREM card will kept with TL.

• SCBA set will be kept with TL.

• Fire extinguishers will be kept with TL.

• Flame arrestor will be provided to TL exhaust.

• Instructions will be given not to stop road tanker in populated

area.

• Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE.

• Appropriate PPEs will be kept with TL.

2 n-Hexane, Toluene,

Methanol, EDC etc.

Road tanker

unloading at site

Leakage& Spillage

Fire,& explosion,

Toxic release








material.






• Spray the water on leakage

• Priority will be given to Tanker to immediately enter the

storage premises at site and will not be kept waiting near

the gate or the main road.

• Security person will check License, TREM CARD, Fire




extinguisher condition; SCBA set condition, Antidote Kit,

required PPEs as per SOP laid down.

• Store officer will take sample as per sampling SOP from

sampling point.

• After approval of QC department unloading procedure will be

allowed be started.

Following precautions will be adopted during unloading

• Wheel stopper will be provided to TL at unloading platform.

• Static earthing will be provided to road tanker.

• Tanker unloading procedure will be followed according to

check list and implemented.

• Flexible SS hose connection will be done at TL outlet line.

• The quantity remaining in the hose pipeline will be drained to

a small underground storage tank, which will be

subsequently transferred by nitrogen pressure to the main

storage tank thus ensuring complete closed conditions for

transfer from road tanker.

• All TL valves will be closed in TL.

• Finally earthing connection and wheel stopper will be

removed.

• Only day time unloading will be permitted.

3 Storage tank safety Leakage& Spillage,

Fire, Explosion

Toxic release.








material.






• Spray the water on leakage

• SS storage tank will be provided as per IS code.

• Dyke wall will be provided to storage tank.

• Level transmitter will be provided with low level high level

auto cut-off provision.

• Vent will be connected to water trap and vent of water trap

will be provided with flame arrestor.

• Water sprinkler system will be provided to storage tank.

• Fire hydrant monitor with foam attachment facility will be

provided.

• Dumping / Drain vessel/alternate vessel will be provided to

collect dyke wall spillage material.

• FLP type pump will be provided.

• Nitrogen blanketing will be provided to storage tank.




• Double static earthing will be provided to storage tank.

• Double Jumper clip will be provided to all Solvent handling

pipeline flanges.

4 n- Hexane,

Toluene, Methanol,

EDC Solvents

transfer from

storage tank to Day

tank

Leakage& Spillage

due to Line

rupture, Flange

Gasket failure, Fire,

Explosion, Toxic

release.

• Double mechanical seal type FLP type pump will be provided.

• Double on / off switch will provided at tank farm and process

area near day tank. Pump auto cut off with day tank high

level will be provided.

• Flame arrestor will be provided on day tank vent.

• Over flow will be provided for additional safety and it will be

connected to main storage tank.

• NRV will be provided on pump discharge line.

• Double Jumper clip will be provided to all solvent handling

pipelines.

• Double static earthing will be provided to day tank.

5 n- Hexane,

Toluene, Methanol,

EDC transfer from

Day tank to reactor

Leakage, Spillage

due to Line

rupture, Flange

Gasket failure, Fire,

Explosion, Toxic

release.

• Gravity transfer.

• Total quantity of day tank material will be charged in to

reactor at a time.

• NRV will be provided on day tank outlet line.

• Static earthing will be provided to storage tank.

• Double Jumpers will be provided to pipeline flanges.

Bromine Transportation, Unloading and handling Procedure:

SR.NO. ACTIVITY TYPE OF POSSIBLE

HAZARD

MITIGATION MEASURES

1 Transportation of

Bromine by ISO

container

Leakage, Spillage,

Toxic release

• Leak check with ammonia torch and detect the leak point.

• ELIMINATE all ignition sources (no smoking, flares, sparks

or flames in immediate area).

• Do not touch damaged containers or spilled material

unless wearing appropriate protective clothing.


• Prevent entry into waterways, sewers, basements or

confined areas.

• Absorb or cover with dry earth, sand or other non-

combustible material and transfer to containers.

• Do not get water inside containers.

• GPS will be installed in all the trucks and ISO container

vehicle.

• Driver and assistant will be trained in using GPS.

• Open space separated from public highway and public

dwellings, where public does not normally pass. No

passengers are allowed.

• The crew shall know how to use fire-fighting appliances.

• The driver or driver's assistant may not open a package

containing bromine.

• Bromine receptacles are not to be checked with open

flames.




• No smoking is permitted around the transport unit or in the

vicinity of the vehicle during handling operations.

• The engine is to be shut off during all handling operations

unless required to drive pumps, hoist, etc.

• Parking brakes are to be applied whenever parked.

• If the vehicle is parked on a road at night or with poor

visibility, warning signs are to be placed 10 meters ahead

of and behind the vehicle.

• TREM CARD provided to all transporters and trained for

transportation Emergency of Hazardous chemicals.

• All trucks having 1 kg Sodium Thiosulphate bag.


safe driving, hazard of Bromine emergency handling, use

of SCBA sets and neutralizing agent.

• SCBA set will be kept with ISO container truck.

• All the ISO container truck will be equipped with Global

Positioning system (GPS) and route will be predefined.

• Clear Hazard Identification symbol and emergency

telephone number will be displayed as per HAZCHEM

CODE.

• Appropriate PPEs will be kept with Truck.

3 Bromine ISO

container loading

and handling at

site

Leakage, Spillage,

toxic release


• ELIMINATE all ignition sources (no smoking, flares, sparks

or flames in immediate area).

• Do not touch damaged containers or spilled material

unless wearing appropriate protective clothing.



confined areas.




• Directly ISO container will be placed at storage area and

connected with process tank.

• Wear recommended personal protective equipment during

connection of ISO container.

• Make sure the absorber unit is working and capable of

handling vented bromine fumes.

• BE SURE THAT DRY AIR (DEW POINT -40"C) OR DRY

NITROGEN is available in ample supply and its pressure is

controlled below 3 atm. gauge.

• Check that all the Iso-container valves are closed and blind

flanges are in place.

• Remove the blind flange above the red valve.

• Connect your pressure release line to the red valve outlet.

Use a new rubber gasket (use limit - 24 hours) to ensure

tight connection.

• Open the red valve slowly and then the depressurizing




valve, to release any pressure which might have

developed in the Iso-container.

• Remove the blind flange above the yellow valve.

• Connect your line to the yellow valve outlet. Use a new

rubber gasket (use limit - 24 hours) to ensure tight

connection.

• Open the yellow valve and all the valves in your liquid

unloading line.

• Close the depressurizing valve.

• Open the pressurizing valve, at first slowly (to check for

bromine leaks), then fully, to start bromine unloading. Use

only enough pressure to lift the bromine to the high point

in the unloading system.

• NEVER EXCEED 3 ATM. PRESSURE

• When air/nitrogen blows through the unloading line into

your storage tank, the Iso-container is empty.

• Close the pressurizing valve.

• Close the yellow valve and then all the other valves in your

liquid unloading line.

• Slowly open the depressurizing valve to release the

air/nitrogen pressure on the Iso-container to your

absorber unit. Wait 5 minutes.

• Close the red valve and then the depressurizing valve.

• Cautiously disconnect your liquid unloading line from the

yellow valve of the Iso-container. Replace its blind flange,

tightening all the bolts. Do not forget to reinstall the

proper gasket.

• Disconnect your pressure release line from the red valve of

the Iso-container. Replace its blind flange, tightening all

the bolts. Do not forget to reinstall the proper gasket.

• If there has been a bromine spillage, wash it off the Iso-

container with plenty of water to prevent corrosion. Small

bromine spills on the ground may be neutralized with a

clear soda ash or a sodium thiosulphate solution. Then

dispose of in a manner approved by the local authorities.

• Close the cover dome and pin it securely.

• Mark the Iso-container EMPTY (use erasable means).

• Bromine Iso tanks should be stored no closer than 10

meters from human or animal consumable articles.

Explosives and flammable materials should not be stored

close to bromine.

• There would be sufficient bromine storage tank capacity or

an empty ISO tank to accommodate the transfer of

bromine from a leaking container

• Area where bromine will be used or stored will be enclosed

so that unauthorized persons and animals are prevented

from entering the area. Adequate lighting will be provided

to allow sufficient night surveillance. Surveillance will be




provided 24 hours a day.

• Personnel escape routes will be clearly marked and it will be

maintained without any obstructions including adequately

sized doors and windows.

• Facilities like offices, eating, showering and changing rooms,

will be located in up wind direction and remote from the

area where bromine is handled or stored. Provide an

adequate supply of clean water for washing and showers.

• Emergency siren, telephone will be provided in storage area

for the reporting of accidents or emergency situations.

The emergency telephone numbers will be displayed at

prominent locations and it include the fire department,

ambulance service, emergency response team, hospital

and police.

• A wind sock will be provided which will clearly visible from

all points on the site and replaced as required. This is

required for indicating wind strength and direction.

• Emergency respirator equipment cabinets (Cupboard) will

be installed not more than 30 meters or ten seconds

walking distance from any location in the storage area.

• Showers and eyewash fountains will be provided, clearly

marked, well lit and with unobstructed access.

• Signs will be posted prominently at the site entrance and

throughout the installation with area maps showing

access ways, hydrant locations, emergency showers,

location of emergency equipment and emergency

telephone numbers.

• All management and operating personnel involved in the

use or handling of bromine will undergo safety training, in

addition to specific task training.

• Only experienced well-trained operators will be allowed to

receive and unload bromine receptacles.

• The management will ensure that emergency response

plans have been made and coordinated with the

emergency response local authorities.

• Safety permit for hazardous material loading unloading will

be prepared and implemented.

Fire hydrant system and water sprinkler system installed

at tank farm area.




Chlorine Transportation, Unloading and handling Procedure:


HAZARD

MITIGATION MEASURES

1 Transportation of

Chlorine Tonners

by road tanker

Leakage, Spillage,

Toxic release


• ELIMINATE all ignition sources (no smoking, flares, sparks or

flames in immediate area).





confined areas.





safe driving, hazard of Chlorine emergency handling, use of

SCBA sets.


• SCBA set will be kept with TL.

• Instructions will be given not to stop Chlorine road truck in

populated area.

• Clear Hazard Identification symbol and emergency telephone

number will be displayed as per HAZCHEM CODE.


2 Chlorine tonners

unloading at site

Leakage, Spillage,

toxic release








confined areas.





storage premises at site and will not be kept waiting near

the gate or the main road.


extinguisher condition; SCBA set condition, required PPEs as

per SOP laid down.

3 Chlorine tonners

storage shed

Leakage, Spillage,

Toxic release.











confined areas.




• SOP will be prepared for safe handling of Chlorine toners.

• Chlorine Emergency Kit will be procured and kept ready at

chlorine shed.

• Chlorine Hood with blower will be provided with scrubbing

arrangement.

• Safety Shower and eye wash will be provided in Chlorine shed

area.

• Tonner handling EOT crane will be installed in Chlorine shed

area for safe tonner handling.

• Safety Valve will be provided on chlorine header line and it

will be connected to caustic scrubber.

• SCBA sets will be kept ready at chlorine handling area.

• Safety valve will be provided on vaporizer header and outlet

of safety valve connected to scrubber.

• Flow and temperature controllers will be provided on process

line.

4 Chlorine tonners

connected with

header

Leakage, Spillage

due to Line

rupture, Toxic

release.








confined areas.




• Teflon or copper tube will be used for connection with

header.

• Pressure gauge and safety valve will be provided on header

line.




Transportation, Unloading and handling procedure for Phenol:


HAZARD

MITIGATION MEASURES

1 Transportation of

Phenol by road

tanker

Leakage, Spillage,

Toxic release

• Training will be provided to driver and cleaner regarding

the safe driving, hazard of Flammable chemicals,

emergency handling, and use of SCBA sets

administration.


• Instructions will be given not to stop road tanker in

populated area.

• Clear Hazard Identification symbol and emergency

telephone number will be displayed as per HAZCHEM

CODE.


• Emergency telephone numbers list for OFF site

emergency agencies will be provided in TREM CARD.

2 Phenol Road tanker

unloading at site.

Leakage, Spillage,

toxic release, fire


storage premises at site and will not be kept waiting

near the gate or the main road.


extinguisher condition, required PPEs as per SOP laid

down.

• Store officer will take sample as per sampling SOP from

sampling point.

• After approval of QC department unloading procedure

will be allowed be started.


• Wheel stopper will be provided to TL at unloading

platform.

• Tanker unloading procedure will be followed according to

check list and implemented.

• Flexible hose connection will be done at TL outlet line and

checked for no leakage.

• Every time rubber gasket will be changed.

• The quantity remaining in the hose pipeline will be

drained to a small container, which will be subsequently

transferred to the main storage tank thus ensuring

complete closed conditions for transfer from road

tanker.

3 Phenol Storage

tank safety

Leakage, Spillage,

Toxic release.

• Storage tank will be stored away from the process plant in

tank farm area.

• Caution note and emergency handling procedure will be

displayed at unloading area and trained all operators.


• Required PPEs like full body protection PVC apron, Hand




gloves, gumboot, Respiratory mask etc. will be provided

to operator.

• Safety shower, eye wash with quenching unit will be

provided in acid storage area.


• Dyke wall will be provided, collection pit with valve

provision.

• Jacketed tank will be provided and steam heating will be

provided in jacket.


• Level gauge will be provided on storage tank.

• Safety permit for loading unloading of hazardous material

will be prepared and implemented.

• Fire hydrant system with jockey pump as per TAC norms

will be installed.

4 Phenol transferred

from storage tank

to Day tank

Leakage, Spillage

due to Line

rupture, Flange

Gasket failure,

Toxic release.

• Double mechanical seal type pump will be provided.

• Over flow will be provided for additional safety and it will

be connected to main storage tank.

• NRV will be provided on pump discharge line.

• Flange Guard will be provided to all flanges.

5 Phenol transfer

from Day tank to

reactor.

Leakage, Spillage

due to Line

rupture, Flange

Gasket failure,

Toxic release.

• Gravity transfer.

• Double valve will be installed on day tank outlet line.

• Total quantity of day tank material will be charged in to

reactor at a time.

• Flange guard will be provided to pipeline flanges.

6.1.5 CONSEQUENCE ANALYSIS

In a plant handling hazardous chemicals, the main hazard arises due to storage, handling &

use of these chemicals. If these chemicals are released into the atmosphere, they may cause

damage due to resulting fires or vapour clouds. Blast Overpressures depend upon the

reactivity class of material between two explosive limits.

Operating Parameters

Potential vapour release for the same material depends significantly on the operating

conditions. Especially for any liquefied gas, the operating conditions are very critical to

assess the damage potential. If we take up an example of ammonia, if it is stored at ambient

temperature, say 30oC, and then the vapour release potential of the inventory is much

higher as compared to the case if it is stored at 0oC.




Inventory

Inventory Analysis is commonly used in understanding the relative hazards and short listing

of release scenarios. Inventory plays an important role in regard to the potential hazard.

Larger the inventory of a vessel or a system, larger the quantity of potential release. The

potential vapour release (source strength) depends upon the quantity of liquid release, the

properties of the materials and the operating conditions (pressure, temperature). If all

these influencing parameters are combined into a matrix and vapour source strength

estimated for each release case, a ranking should become a credible exercise.

Loss of Containment

Plant inventory can get discharged to Environment due to Loss of Containment. Certain

features of materials to be handled at the plant need to the clearly understood to firstly list

out all significant release cases and then to short list release scenarios for a detailed

examination. Liquid release can be either instantaneous or continuous. Failure of a vessel

leading to an instantaneous outflow assumes the sudden appearance of such a major crack

that practically all of the contents above the crack shall be released in a very short time. The

more likely event is the case of liquid release from a hole in a pipe connected to the vessel.

The flow rate is depending on the size of the hole as well as on the pressure, which was

present, in front of the hole, prior to the accident. Such pressure is basically dependent on

the pressure in the vessel. The vaporisation of released liquid depends on the vapour

pressure and weather conditions. Such consideration and others have been kept in mind

both during the initial listing as well as during the short listing procedure. In the study,

Maximum Credible Loss accident methodology is to be used, therefore, the largest potential

hazard inventories have been considered for consequence estimation.

6.1.5.1 DAMAGE CRITERIA

In consequence analysis, use is made of a number of calculation models to estimate the

physical effects of an accident (spill of hazardous material) and to predict the damage

(lethality, injury, material destruction) of the effects. The calculations can roughly be divided

in three major groups:




a) Determination of the source strength parameters;

b) Determination of the consequential effects;

c) Determination of the damage or damage distances.

The basic physical effect models consist of the following.

Source strength parameters

* Calculation of the outflow of liquid, vapour or gas out of a vessel or a pipe, in case of

rupture. Also two-phase outflow can be calculated.

* Calculation, in case of liquid outflow, of the instantaneous flash evaporation and of the

dimensions of the remaining liquid pool.

* Calculation of the evaporation rate, as a function of volatility of the material, pool

dimensions and wind velocity.

* Source strength equals pump capacities, etc. in some cases.

Consequential effects

* Dispersion of gaseous material in the atmosphere as a function of source strength,

relative density of the gas, weather conditions and topographical situation of the

surrounding area.

* Intensity of heat radiation [in kW/ m2] due to a fire or a BLEVE, as a function of the

distance to the source.

* Energy of vapour cloud explosions [in N/m2], as a function of the distance to the

distance of the exploding cloud.

* Concentration of gaseous material in the atmosphere, due to the dispersion of

evaporated chemical. The latter can be either explosive or toxic.

It may be obvious, that the types of models that must be used in a specific risk study

strongly depend upon the type of material involved:

- Gas, vapour, liquid, solid

- Inflammable, explosive, toxic, toxic combustion products

- Stored at high/low temperatures or pressure

- Controlled outflow (pump capacity) or catastrophic failure?




Selection of Damage Criteria

The damage criteria give the relation between extent of the physical effects (exposure) and

the percentage of the people that will be killed or injured due to those effects. The

knowledge about these relations depends strongly on the nature of the exposure. For

instance, much more is known about the damage caused by heat radiation, than about the

damage due to toxic exposure, and for these toxic effects, the knowledge differs strongly

between different materials.

In Consequence Analysis studies, in principle three types of exposure to hazardous effects

are distinguished:

1. Heat radiation, from a jet, pool fire, a flash fire or a BLEVE.

2. Explosion

3. Toxic effects, from toxic materials or toxic combustion products.

In the next three paragraphs, the chosen damage criteria are given and explained.

Heat Radiation

The consequence caused by exposure to heat radiation is a function of:

• The radiation energy onto the human body [kW/m2];

• The exposure duration [sec];

• The protection of the skin tissue (clothed or naked body).

• The limits for 1% of the exposed people to be killed due to heat radiation, and for

second-degree burns are given in the table herein:

Damages to Human Life Due to Heat Radiation

Exposure

Duration

Radiation for

1% lethality

(kW/m2)

Radiation for 2nd

degree burns

(kW/m2)

Radiation for

first degree

burns (kW/m2)

10 Sec 21.2 16 12.5

30 Sec 9.3 7.0 4.0




Since in practical situations, only the own employees will be exposed to heat radiation in

case of a fire, it is reasonable to assume the protection by clothing. It can be assumed that

people would be able to find a cover or a shield against thermal radiation in 10 sec. time.

Furthermore, 100% lethality may be assumed for all people suffering from direct contact

with flames, such as the pool fire, a flash fire or a jet flame. The effects due to relatively

lesser incident radiation intensity are given below.

Effects Due To Incident Radiation Intensity

INCIDENT

RADIATION

kW/m2

TYPE OF DAMAGE

0.7 Equivalent to Solar Radiation

1.6 No discomfort for long exposure

4.0 Sufficient to cause pain within 20 sec. Blistering of skin (first degree burns are likely)

9.5 Pain threshold reached after 8 sec. second degree burns after 20 sec.

12.5 Minimum energy required for piloted ignition of wood, melting plastic tubing etc.

Explosion

In case of vapour cloud explosion, two physical effects may occur:

* A flash fire over the whole length of the explosive gas cloud;

* A blast wave, with typical peak overpressures circular around ignition source.

As explained above, 100% lethality is assumed for all people who are present within the

cloud proper.

For the blast wave, the lethality criterion is based on:

* A peak overpressure of 0.1 bar will cause serious damage to 10% of the

housing/structures.

* Falling fragments will kill one of each eight persons in the destroyed buildings.

The following damage criteria may be distinguished with respect to the peak overpressures

resulting from a blast wave:




Damage Due To Overpressures

Peak Overpressure Damage Type

0.83 bar Total Destruction

0.30 bar Heavy Damage

0.10 bar

0.03 bar

Moderate Damage

Significant Damage

0.01 bar Minor Damage

From this it may be concluded that p = 0.17 E+5 pa corresponds approximately with 1%

lethality. Furthermore it is assumed that everyone inside an area in which the peak

overpressure is greater than 0.17 E+ 5 pa will be wounded by mechanical damage. For the

gas cloud explosion this will be inside a circle with the ignition source as its centre.

Intoxication

The consequences from inhalation of a toxic vapour/gas are determined by the toxic dose.

This dose D is basically determined by:

- Concentration of the vapour in air;

- Exposure duration.

Furthermore, of course, the breathing rates of the victim, as well as the specific toxic

mechanism unto the metabolism play an important role.

The dose is defined as D = Cn.t, with:

C = concentration of the toxic vapour, in [ppm] or [mg/m3];

t = exposure duration, in [sec] or [min];

n = exponent, mostly > 1.0; this exponent takes into account the fact that a high

concentration over a short period results in more serious injury than a low

concentration over a relatively longer period of exposure. The value of n

should be greater than zero but less than 5.

The given definition for D only holds if the concentration is more or less constant over the

exposure time; this may be the case for a (semi) continuous source. In case of an




instantaneous source, the concentration varies with time; the dose D must be calculated

with an integral equation:

D = ∫ Cn.dt

For a number of toxic materials, so-called Vulnerability Models (V.M.) has been developed.

The general equation for a V.M. (probit function) is:

Pr = a + b.ln (Cn.t), with

Pr = probit number, being a representation of the percentage of people suffering a

certain kind of damage, for instance lethality

Pr = 2.67 means 1% of the population;

Pr = 5.00 means 50% of the population;

a and b material dependent numbers;

Cn.t = dose D, as explained above.

The values for a and b are mostly derived from experiments with animals; occasionally,

however, also human toxicity factors have been derived from accidents in past. In case only

animal experiments are available, the inhalation experiments with rats seem to be best

applicable for predicting the damage to people from acute intoxication. Although much

research in this field have been done over the past decades, only for a limited number of

toxic materials consequence models have been developed. Often only quite scarce

information is available to predict the damage from an acute toxic exposition. Data

transformation from oral intoxication data to inhalation toxicity criteria is sometimes

necessary. Generally, in safety evaluations pessimistic assumptions are applied in these

transformation calculations. The calculated damage (distance) may be regarded as a

maximum. For the purposes of a response to a major incident, the IDLH value level has been

chosen for the ‘wounded‘criteria. This type of injury will require medical attention.




6.1.5.2 MAXIMUM CREDIBLE LOSS ACCIDENT SCENARIOS

A Maximum Credible Accident (MCA) can be characterised as the worst credible accident. In

other words: an accident in an activity, resulting in the maximum consequence distance that

is still believed to be possible. A MCA-analysis does not include a quantification of the

probability of occurrence of the accident. Another aspect, in which the pessimistic approach

of MCA studies appears, is the atmospheric condition that is used for dispersion

calculations. As per the reference of the study, weather conditions having an average wind

speed of 2.31 m/s have been chosen.

The Maximum Credible Loss (MCL) scenarios have been developed for the Facility. The MCL

cases considered, attempt to include the worst “Credible” incidents- what constitutes a

credible incident is always subjective. Nevertheless, guidelines have evolved over the years

and based on basic engineering judgement, the cases have been found to be credible and

modelling for assessing vulnerability zones is prepared accordingly. Only catastrophic cases

have been considered and not partial or small failures (as is the case in Quantitative Risk

Assessment where contributions from low frequency - high outcome effect as well as high

frequency - low outcome events are distinguished). The objective of the study is emergency

planning, hence only holistic & conservative assumptions are used for obvious reasons.

Hence though the outcomes may look pessimistic, the planning for emergency concept

should be borne in mind whilst interpreting the results.

6.1.5.2.1 CONSEQUENCE ANALYSIS CALCULATIONS

The Consequence Analysis has been done for selected scenarios. This has been done for

weather conditions having wind speed 2.31 m/s. In Consequence Analysis, geographical

location of the source of potential release plays an important role. Consideration of a large

number of scenarios in the same geographical location serves little purpose if the dominant

scenario has been identified and duly considered.




6.1.5.2.2 SOFTWARE USED FOR CALCULATIONS

PHAST MICRO: Phast is the most comprehensive software available for performing Process

Hazard Analysis (PHA), Quantitative Risk Assessment (QRA) and Financial Risk Analysis (FRA).

Our extensively validated software for consequence and risk assessment is used by

governments and industry helping them to comply with local safety regulation and their

own corporate best practice. Phast contains all the discharge, dispersion, effects and risk

models you will need to accurately assess all your major hazards and associated risks. Phast

Consequence provides you with comprehensive hazard analysis facilities to examine the

progress of a potential incident from the initial release to its far-field effects.

TOXIC AND FLAMMABLE IMPACT

It calculates the initial discharge, as the material expands from its storage conditions to

atmospheric, through dispersion, as the material mixes with air and dilutes, and the

subsequent toxic or flammable effects. Phast includes a wide range of models for discharge

and dispersion as well as flammable, explosive and toxic effects.

DISCHARGE

• Phast requires basic information about storage or process conditions and material

properties in order to perform discharge calculations

• The software comes with an integrated material property database containing more

than 1,600 pre-defined pure component chemicals

• Various discharge scenario options have been implemented to represent common

process failures, and model their behaviour. These include:

� Leaks and line ruptures from long & short pipelines

� Catastrophic ruptures

� Relief valve and disc ruptures

� Tank roof collapse

� Vent from vapour spaces

� In building release effects




DISPERSION

The dispersion models within Phast are able to model the following phenomena

• Dispersion of gas, liquid and two-phase releases

• Liquid droplet thermo dynamics calculations and liquid droplet rainout

• Pool spreading and vaporization

• Building wake dispersion effects for vapour releases

FLAMMABLE EFFECTS

For releases of flammable material Phast calculates

• Radiation profiles and contours from a range of fire scenarios including pool fires,

flash fires, jet fires and fire balls, including cross-wind effects on a jet fire

• Vapour Cloud Explosion modeling using industry standards models including the

TNO Multi-energy, Baker Strehlow Tang and TNT Equivalence models

• Overpressure contours from Boiling Liquid Expanding Vapour Explosions

TOXIC EFFECTS

• Graphs of toxic concentration profile

• Indoor and outdoor toxic dose prediction

• Reporting of distance to specific dose and concentration

• Calculated exposure time and use as “averaging time” for passive dispersion effects

PHAST RISK

Phast Risk allows you to combine the flammable and toxic consequences from each

scenario in your QRA model with their likelihood to quantify the risk of fatalities. Phast Risk

allows you to take account of local population distribution, sources of ignition, land usage

and local prevailing weather conditions. It is designed to perform all the analysis, data

handling and results presentation elements of a QRA within a structured framework.

Phast Risk allows you to quickly identify major risk contributors so that time and efforts can

be directed to mitigating these highest risk activities. Based on effects calculations and




population vulnerabilities, Phast Risk can integrate over all scenarios and weather

conditions to estimate the total risk. The established individual and societal risk indicators

are predicted by Phast Risk across your facility and surrounding area using the classical QRA

methodology. Risk ranking reports can be produced at points of strategic importance to

show the relative influence of the various failure scenarios and their contribution to both

the individual and societal risk metrics.

A key benefit of Phast Risk is the ability to identify major risk contributors and differentiate

these from incidents with worst case consequences which might otherwise dominate the

safety reviews. Whilst medium scale incidents have lesser consequences, they may have a

higher frequency, which, when combined with their hazardous effects, generate a higher

level of risk. Time and effort directed to mitigating high consequence but often low

frequency events may not be well spent. Phast Risk helps you direct this effort more

effectively.

Phast Risk also provides facilities to help you manage large quantities of input data,

including scenarios, parameters, wind roses, ignition and population, and combine these in

many ways. This is critical when looking at sensitivity analyses and assessing the merits of a

range of risk reduction measures.

Benefits

• Facilitates cost reduction in terms of losses and insurance

• Allows optimization of plant and process design

• Assist in compliance with safety regulators

• Enables quicker response to hazardous incidents

• Improve engineer’s understanding of potential hazards

• Regular software upgrades incorporate industry experience and expertise, and

advances in consequence modeling technology




6.1.5.2.3 SCENARIOS

TABLE – 6.5

POSSIBLE ACCIDENT SCENARIOS

Scenario MCL Scenario Pressure & Temp. Quantity in KL

1 Release of Methanol NTP 30

2 Release of EDC NTP 30

3 Release of Hexane NTP 30

4 Release of Ethyl Acetate NTP 30

5 Release of Acetone NTP 30

6 Release of Sulphuric Acid NTP 30

7 Release of Bromine NTP 30

8 Release of Toluene NTP 30

9 Spill Pool Evaporation Modules For

HCl Storage Tank Catastrophic

Failure.

NTP 30

10 Release Of Benzene NTP 30

11 Release Of Chlorine NTP 900 Kg

12 Release of Nitric Acid NTP 30

13 Release of MCB NTP 30

14 Etyl Chloride NTP 30

15 MMA Gas NP 1

16 Unconfined Pool Fire Simulations

for Drum Storage Area

NTP 20

Scenario # 1: Release of Methanol

This scenario considers release of Methanol from Storage Tank:

Results indicate:

Catastrophic Rupture

Input Data

Stored quantity - 30 MT

Molecular weight -33.05

Wind speed - 2.31 m/s




Density ( Air) –0. 791 g/cm3

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter

Effect if IHR at Height of simulation

4 70.64 This level is sufficient to cause personnel if unable to reach cover

within 20s; however blistering of the skin (second degree burn) is

likely; 0: lethality

12.5 33.18 This level will cause extreme pain within 20 seconds and

movement to a safer place is instinctive. This level indicates

around 6% fatality for 20 seconds exposure.

37.5 16.8 This level of radiation is assumed to give 100% fatality as

outlined above.

Flash Fire Scenario

Radiation Level

(KW/m2)

Distance in meter Injury Type

4 76 This level is sufficient to cause personnel if unable to reach cover



12.5 49 This level will cause extreme pain within 20 seconds and



37.5 13 This level of radiation is assumed to give 100% fatality as

outlined above.

Fireball Scenario

Radiation Level

(KW/m2)


4 54 Pain after 20secs.

12.5 32 1st degree Burn

37.5 15 100% Fatal




Pool Fire Scenario:

Red – 4 KW/m2

Yellow – 12.5 KW/m2

Green – 37.5 KW/m2




Flash fire Scenario:

Red – 4 KW/m2


Green – 37.5 KW/ m2




Fire ball Scenario:

Red – 4 KW/m2






Scenario # 2: Release of EDC


Input Data




Vapor density (air=1)– 3.34

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)

Distance in meter Effect if IHR at Height of simulation

4 92.3 This level is sufficient to cause personnel if unable to reach cover






37.5 35 This level of radiation is assumed to give 100% fatality as outlined

above.

Dispersion

Release Rate 1000 gms/sec. (assumption)

Hazard Level Concentration (ppm) Distance (meter)

LC50 1414.2 23.42

IDLH 300 49.71

TWA/ TLV 75 116




TOXIC RELEASE:




Pool fire scenario:

Red – 4 KW/m

2






SAFETY PRECUASION:

- Flame proof pumping and other equipments will be provided.

- Transfer will be done in close process,

- Double Static earthling and Jumper clips will be provided on flanges,

- Hydrant system and Fire extinguishers will be provided.

- Automatic Sprinklers will be provided.

- Tanker unloading procedure will be made and followed..

- Dyke around the tank will be provided.




Scenario # 3: Release of N-Hexane

Scenario: 30 KL Hexane

Scenario : POOL FIRE

Input Data Results of Computations

Stored quantity 30 KL Max. IHR at flame centre height 130 Kw/m2

Pool diameter 60(m) Flame centre height 38 meter

Pool liquid depth 0.1 (m) Maximum Flame width 38 meter

Wind speed 2.3 m/s Mass burning rate liquid 5.8 kg/ m2/min.

Liquid Density 779 kg/m3 Flame burnout time 14 Mims.

Incident Intensity of

Heat Radiation ( IHR)

at ground level KW

/m 2

IHR- Isopleths

Distance

( Meters )

Effect if IHR at Height of Simulation

37.5 38.3 Damage to process equipment. 100 % Fatal in 1 Min. 1 %

fatal in 10 sec.

25.0 46.7 Min. to ignite wood ( without flame contact ). 100 % fatal

in 1 Min. Significant injury in 10 sec.

12.5 65.9 Min. to ignite wood (with flame contact). 1 % fatal in 1

min. 1 st deg. burn in 10 sec.

4.0 113.7 Pain after 20 secs. Blistering unlikely.

1.6 179.5 No discomfort even on long exposure.

Results

♦ In the 38.3 meter radius area is considered as 100% fatality in 1 min.

♦ In the 65.9 meter radius first degree burn in 10 sec.

♦ In the 113.7 meter radius area will give pain after 20 seconds. Blistering unlikely.

♦ In the 179.5 meter radius area is considered as safe area and no discomfiture even on long

exposure.




Pool fire scenario:

Red – 4 KW/m2






Scenario # 4: Release of Ethyl Acetate

A release from the Ethyl Acetate Tank;


Basic Input Data

Stored quantity 30 KL

Molecular Weight 88.1

Vapor Density (Air=1) 3.04

Wind speed 2.3 m/s

Temperature Room Temperature

Pressure Atmospheric Pressure

Consequence Results

Pool Fire Scenario

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)


4 62.5 This level is sufficient to cause personnel if unable to reach cove

within 20s; however blistering of the skin (second degree burn)






outlined above.

Vapor Cloud Explosion




Radial

Distance

(m)

Over

Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture

(%)

12.54 34.6 100.0 100.0 100.0 100.0

18.37 12.7 0.3 88.9 100.0 100.0

24.62 1.9 0.0 2.8 10.4 100.0

In case of Unconfined Vapor Cloud Explosion up to 10.67 meter is considered as 100% fatality

and 100% ear drum rupture radius.

In case of Unconfined Vapor Cloud Explosion up to 16.76 meter is considered as 100%

structure damage and up to 22.48meter 100% glass rupture area.

Fire-Ball Scenario

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)


4 72 This level is sufficient to cause personnel if unable to reach

cover within 20s; however blistering of the skin (second

degree burn) is likely; 0: lethality





outlined above.

Flash Fire Scenario

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)












outlined above.




Pool fire scenario:

Red – 4 KW/m2






Fire ball scenario:

Red – 4 KW/m2






Flash fire scenario:

Red – 4 KW/m2






Scenario # 5: Release of Acetone


Input Data




Density ( Air) – 859 kg/m3

Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)









outlined above.


Radial

Distance

(m)

Over

Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture

(%)

4.9 36.8 100.0 100.0 100.0 100.0

5.7 9.1 0.0 79.0 100.0 100.0

9.1 2.4 0.0 3.8 15.6 100.0

In case of Unconfined Vapor Cloud Explosion up to 4.9 meter is considered as 100% fatality and

100% ear drum rupture radius.




In case of Unconfined Vapor Cloud Explosion up to 5.7 meter is considered as 100% structure

damage and up to 9.1 meter 100% glass rupture area.

Fireball Scenario

Fireball Radius: 8.53759 m

Fireball intensity of Heat Radiation (KW/m2) – 132.027

Fireball rate of Energy release (KJ/Sec)- 107943

Fireball total energy released (KJ)- 186149

Fireball duration (Sec) – 1.97821

Radiation Level

(KW/m2)


37.50 15 100% Fatal

22.04 21 Significant Injury

12.5 27 1st

Degree burn


1.6 81 No Injury

Flash Fire

Radiation Level

(KW/m2)


50.79 14 100% Fatal

37.5 19.8 100% Fatal

28.24 22.6 Significant Injury

17.95 26.9 1st

Degree burn

12.5 32.7 Pain after 20secs.


1.6 79 No Injury




Pool fire scenario:

Red – 4 KW/m

2






Fire ball scenario:

Red – 4 KW/m

2






Flash fire scenario:

Red – 4 KW/m

2






Scenario # 6: Release Of Sulphuric Acid

Spill pool evaporation module for Sulphuric Acid due to Catastrophic Rupture of 10 KL

Storage Tank

Input Data



Wind speed – 2.3 m/s

Failure Mode: Catastrophic failure of 4” bottom nozzle and loss of containment


Release rate: 1000 g/s

Results indicate

LC50 – 510 ppm 48.97 meter

IDLH – 3 ppm 570.80 meter

TLV –1 ppm 870.78 meter

Results:-

• LC50 HUMAN (510 ppm) area is up to 48.97 meter,

• IDLH (3 ppm) concentration area is up to 570.80 meter and

• TLV (1 ppm) area is up to 870.78 meter.

Therefore, 570.80 meter area in wind direction is considered as evacuation area.




Scenario:




MITIGATION MEASURES FOR SULPHURIC ACID LEAKAGE:

� Isolate the source if possible without risk.

� If leakage is small, dilute with water and mop up, or absorb with an inert dry material and place in an

appropriate waste disposal container. If necessary: Neutralize the residue with a dilute solution of

sodium carbonate.

� Absorb with DRY earth, sand or other non-combustible material.

� Do not get water inside container. Do not touch spilled material. Use water spray curtain to divert

vapor drift.

� Use water spray to reduce vapors.

� Prevent entry into sewers, basements or confined areas.

� Neutralize the residue with a dilute solution of sodium carbonate.

PREVENTIVE MEASURES TO AVOID SULPHURIC ACID LEAKAGE:

� A dike will be provided to accommodate the full quantity in tank.

� Periodic testing of storage tank will be done by competent person.

� Provide exhaust ventilation or other engineering controls to keep the airborne concentrations of

vapors below their respective TLVs. Storage tank vent is connected to scrubber system.

� Flange guard provided to prevent splash of material.

� Level interlock

� Keep container dry. Never add water to this product.

� In case of insufficient ventilation, wear suitable respiratory equipment. If ingested, seek medical

advice immediately and show the container or the label.

� Avoid contact with skin and eyes. Keep away from incompatibles such as oxidizing agents, organic

materials, metals, alkalis, moisture.

� Storage: Keep container tightly closed. Keep container in a cool, well-ventilated area.

� While handling always use face shield. Full suit. Vapor respirator. Be sure to use an approved/certified

respirator or equivalent.

� Ensure that eyewash stations and safety showers are proximal to the work-station location.




Scenario #7: Release of Bromine


Input Data

Stored quantity - 30 KL




Results indicate (Puff Release)

LC50 – 1075 ppm 57.6

IDLH – 3 ppm 390.3

TLV – 0.1 ppm 800.4

Safety Precuation:

• Preventive maintenance of FLT. Train and license driver will be employed to drive FLT.

• Limit switch, interlock will be provided, Apron, Hand gloves, gumboot, helmet, goggles

will be provided.

• Apron, Hand gloves, gumboot, helmet, goggles will be provided.




Scenario#8: Release of Toluene


Input Data





Results indicate

Pool Fire Scenario

Radiation Level

(KW/m2)









outlined above.


Radial

Distance (m)

Over Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture (%)

5.2 36.2 100.0 100.0 100.0 100.0

5.9 8.9 0.0 77.0 100.0 100.0

8.9 2.0 0.0 3.1 14.5 100.0

In case of Unconfined Vapor Cloud Explosion up to 5.2 meter is considered as 100% fatality and 100%

ear drum rupture radius.

In case of Unconfined Vapor Cloud Explosion up to 5.9 meter is considered as 100% structure damage

and up to 8.9 meter 100% glass rupture area.

Fireball Scenario




Fireball Radius: 8.33656 m


Fireball rate of Energy release (KJ/Sec)- 107389

Fireball total energy released (KJ)- 185056


Radiation Level

(KW/m2)


37.50 14 100% Fatal


12.5 25 1st Degree burn


1.6 75 No Injury

Flash Fire

Radiation Level

(KW/m2)


50.79 13 100% Fatal

37.5 16.1 100% Fatal


17.95 22 1st Degree burn

12.5 27 Pain after 20secs.


1.6 70 No Injury

SAFETY PRECUASION:

- Flame proof pumping and other equipments will be provided.

- Transfer will be done in close process,

- Double Static earthling and Jumper clips will be provided on flanges,

- Hydrant system and Fire extinguishers will be provided.

- Automatic Sprinklers will be provided.

- Tanker unloading procedure will be made and followed..

- Dyke around the tank will be provided.




Pool Fire Scenario

Red – 4 KW/m

2






Fireball Scenario

Red – 4 KW/m2






SCENARIO #9: SPILL POOL EVAPORATION MODULES FOR HCL STORAGE TANK CATASTROPHIC FAILURE


Input Data





Results indicate

LC50 – 149 ppm 45.67 meter

IDLH – 5 ppm 1533.74 meter

TLV –0.75 ppm 2944.00 meter

Results

• LC50 HUMAN (149 ppm) area up to 45.67 meter, Immediate danger to life and health (5 ppm )

concentration area up to 1533.74 meter and TWA (0.75 ppm ) area up to 2944 meter. Therefore 1533.677

meter area in wind direction is considered as evacuation area.




Measures to control and mitigate Emergency:

Measures to be taken to prevent such accident:

• Priority will be given to Tanker to immediately enter the storage premises at site and will not be kept waiting


• Security person will check License, TREM CARD, Fire extinguisher condition, required PPEs as per SOP laid

down.

• Store officer will take sample as per sampling SOP from sampling point.

• After approval of QC department unloading procedure will be allowed be started.



• Tanker unloading procedure will be followed according to check list and implemented.

• Flexible hose connection will be done at TL outlet line and checked for no leakage.

• Every time gasket will be changed.

• The quantity remaining in the hose pipeline will be drained to a small container, which will be subsequently

transferred to the main storage tank thus ensuring complete closed conditions for transfer from road

tanker.

• All TL valves will be closed.

Following precautions will be adopted Storage of such chemicals



• Caution note and emergency handling procedure will be displayed at unloading area and trained all

operators.


• Required PPEs like full body protection PVC apron, Hand gloves, gumboot, Respiratory mask etc. will be

provided to operator.







• Safety permit for loading unloading of hazardous material will be prepared and implemented.

• TREM CARD will be provided to all transporters and will be trained for transportation Emergency of



Mitigation measures to control Emergency:

♦ Safety Shower and eye wash will be provided away from the tank and unloading station.

♦ Sand bags/ buckets will be provided near tank area.

♦ Neutralizing medium (Lime and dry sand) will be kept ready near tank farm.

♦ Emergency siren and wind sock will be provided.

♦ Tele Communication system and mobile phone will be used in case of emergency situations for

communication.

♦ First Aid Boxes and Occupational health centre will be made at site.

♦ Emergency organization and team will be prepared.

♦ Full body protection suite and other PPEs will be kept ready in ECC at site.

♦ Emergency team will be prepared and trained for scenario base emergency. Like Toxic control team, Fire

control team, First aid team, communication and general administration team, Medical team etc.




EMERGENCY RESPONSE

SPILL OR LEAK

· Do not touch damaged containers or spilled material unless wearing appropriate protective clothing.

· Stop leak if you can do it without risk.

· Use water spray to reduce vapors; do not put water directly on leak, spill area or inside container.

· Keep combustibles (wood, paper, oil, etc.) away from spilled material.

Small Spill

· Cover with DRY earth, DRY sand or other non-combustible material followed with plastic sheet to minimize

spreading or contact with rain.

· Use clean non-sparking tools to collect material and place it into loosely covered plastic containers for later

disposal.

· Prevent entry into waterways, sewers, basements or confined areas.




SCENARIO #10: RELEASE OF BENZENE

Scenario 1A: Catastrophic Rupture of Unloading arm of Benzene Tanker and Resultant Pool

Fire

Basic Input Data

Release quantity 30 KL

Molecular weight 78.14


Wind speed 2.31 m/s



Consequence Results

Pool Fire Scenario

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)









outlined above.

Scenario 1B: VCE form Benzene Pool (10 MT) after 10 min evaporation

Radial

Distance

(m)

Over

Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture

(%)

1.44 36.3 100.0 100.0 100.0 100.0

2.57 8.1 0.0 70.9 100.0 100.0

5.72 1.9 0.0 2.9 13.3 100.0

In case of Unconfined Vapor Cloud Explosion up to1.44 meter is considered as 100% fatality







Scenario 1C: Flash Fire Envelope Results

Max distance up t

which LEL

concentration

reached

Max

distance up

to which LEL

concentratio

n reached






movement to a safer place is instinctive. This level

indicates around 6% fatality for 20 seconds exposure.


outlined above.




POOL FIRE SCENARIO

Red – 4 KW/m

2






FLASH FIRE SCENARIO:

Red – 4 KW/m

2






Scenario # 11: RELEASE OF CHLORINE

This scenario considers release of Chlorine from Storage Tank:

Results indicate:

Results

• Point source (3/4” nozzle in the toner) plume release for Chlorine tonner liquid/ gas

phase valve failure

In put Data

Stored quantity 900 Kgs

Rate of release 718 gram/sec.


Density ( Air) 2.49 kg/m3

Hazard Level Concentration (PPM) Ground level distance (Meter)

LC50 1017 166

IDLH 10(ACGIH) 555

STEL 15 Min 1.00(OSHA) 1045

TWA/TLV 0.5 (OSHA) 1524

Results

• LC50 Human (1017 ppm) area up to 166 meter,

• IDLH concentration (10 ppm) area up to 555 meter and

• TLV (0.5 ppm) area up to 1524 meter.

Therefore, in case of chlorine leakage, evacuation up to 555 m in downwind direction is

recommended.




POINT SOURCE PLUME RELEASE FOR CHLORINE TONNER LIQUID/ GAS PHASE VALVE

FAILURE




Mitigation Measures in case of Chlorine Leakage:

• Evacuate the area in down wind direction: Evacuate area in down wind direction up to

300 meter.

• Do not direct water at spill or source of leak.

• If possible, turn leaking containers so that gas escapes rather than liquid.

• Use Chlorine Emergency Kit to attend the leak.

• Absorb the fumes through Chlorine Hood with blower.

Preventive measures to avoid such emergency:

♦ Chlorine Emergency Kit will be procured and kept ready at chlorine shed.

♦ Chlorine Hood with blower will be provided with scrubbing arrangement.

♦ SCBA sets will be kept ready at chlorine handling area.

♦ Safety Shower and eye wash will be provided in Chlorine shed area.

♦ Chlorine absorption system will be provided. In case of chlorine leakage in chlorine shed

it will be suck through blower and it will be scrubbed in Caustic scrubber.

♦ Emergency siren and wind sock will be provided.

♦ Tele Communication system and mobile phone will be used in case of emergency

situations for communication.

♦ First Aid Boxes and Occupational health centre will be made at site.

♦ Emergency organization and team will be prepared as per On site-Off site emergency

planning.

♦ Full body protection suite and other PPEs will be kept ready in ECC at site.

♦ Emergency team will be prepared and trained for scenario base emergency. Like Toxic

control team, Fire control team, First aid team, Communication and general

administration team, Medical team etc.




Scenario #12: Release of Nitric Acid


Input Data



Vapor Density (Air=1) – 2.5

Results indicate

TLV – 4 ppm

Cloud Footprint:




Maximum Concentration:

Safety measures:

• In case of contact with eyes, immediately flush eyes with plenty of water for at least 15

minutes. Cold water may be used. Get medical attention immediately.

• In case of contact with skin, immediately flush skin with plenty of water for at least 15

minutes while removing contaminated clothing and shoes. Cover the irritated skin

with an emollient. Cold water may be used. Wash clothing before reuse. Thoroughly

clean shoes before reuse. Get medical attention immediately.

• Wash with a disinfectant soap and cover the contaminated skin with an anti-bacterial

cream. Get medical attention.

• If inhaled, remove to fresh air. If not breathing, give artificial respiration. If breathing is

difficult, give oxygen. Get medical attention immediately.

• Evacuate the victim to a safe area as soon as possible




Scenario #13: Release of MCB

This scenario considers release of MCB from storage tank:

Scenario : Catastrophic Rupture of Unloading arm of Chloro Benzene Tanker and Resultant

Pool Fire

Basic Input Data






Consequence Results

Pool Fire Scenario

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)









outlined above.




Pool Fire Scenario

Red – 4 KW/m

2






Scenario#14: CATASTROPHIC FAILURE OF CHLORO ETHYLENE TANK

Scenario : Catastrophic Failure Of Chloro Ethylene Tank

Basic Input Data




Consequence Results

Pool Fire Scenario

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)








37.5 Not Reached This level of radiation is assumed to give 100% fatality as

outlined above.




FIRE BALL SCENARIO




MAXIMUM CONCENTRATION FOOTPRINT




Scenario#15: CATASTROPHIC FAILURE OF MMA GAS CYLINDER

Scenario : Catastrophic Failure Of MMA Gas Cylinder

Basic Input Data

Release quantity ?



Consequence Results

Pool Fire Scenario

Radiation Effects

Radiation

Level

(KW/m2)

Distance (meter)

(Category 1.5/F)








37.5 Not Reached This level of radiation is assumed to give 100% fatality as

outlined above.




Scenario#16: Release of IPA

This scenario considers release of IPA from Storage Tank:

Results indicate:


Input Data



Wind speed – 2.31 m/s


Results indicate

Pool Fire Scenario

Radiation

Level (KW/m

Distance in meter









outlined above.


Radial

Distance

(m)

Over

Pressure

(psi)

Fatality lung

Rupture (%)

Eardrum

Rupture (%)

Structure

Damage (%)

Glass Rupture

(%)

6.50 36.7 100.0 100.0 100.0 100.0

6.83 8.4 0.0 73.3 100.0 100.0

10.02 1.9 0.0 2.8 12.8 100.0

In case of Unconfined Vapor Cloud Explosion up to 6.50 meter is considered as 100% fatality




Results

♦ 37.5 KW/m2 IHR - In the 24.5 meter radius area is considered as 100% fatality in 1 min.

♦ 12.5 KW/m2 IHR -In the 43.0 meter radius first degree burn in 10 sec.

♦ 4 KW/m2 IHR -In the 65.0 meter radius area will give pain after 20 seconds. Blistering

unlikely.




Fireball Scenario

Fireball Radius: 6.36m


Fireball rate of Energy release (KJ/Sec)- 68393.6

Fireball total energy released (KJ)- 96888.6


Radiation Level

(KW/m2)


100.20 9.0 100% Fatal

42.09 14.0 100% Fatal

12.5 22.0 1st

degree Burn



1.54 62.0 No Injury

Results


♦ 12.5 KW/m2 IHR - In the 22.0 meter radius first degree burn in 10 sec.

♦ 4 KW/m2 IHR - In the 39.0 meter radius area will give pain after 20 seconds. Blistering

unlikely.

Fireball Scenario

Fireball Radius: 6.36m


Fireball rate of Energy release (KJ/Sec)- 68393.6

Fireball total energy released (KJ)- 96888.6


Radiation Level

(KW/m2)


100.20 9.0 100% Fatal

42.09 14.0 100% Fatal

12.5 22.0 1st

degree Burn



1.54 62.0 No Injury

Results


♦ 12.5 KW/m2 IHR - In the 22.0 meter radius first degree burn in 10 sec.

♦ 4 KW/m2 IHR - In the 39.0 meter radius area will give pain after 20 seconds. Blistering

unlikely.




CLOUD FOORPRINT

MAXIMUM CONCENTRATION




Pool Fire

Red – 4 KW/m

2






FIRE BALL

Red – 4 KW/m

2






Scenario #17: Unconfined Pool Fire Simulations for Drum Storage Area


Input Data



Density ( Air) – 0.867 g/cm3

Results indicate

Pool Fire Scenario

Radiation Leve

(KW/m2)

Distance in meter









outlined above.

Fire Ball Scenario

Radiation Level

(KW/m2)


4 52.8 Pain after 20secs.

12.5 39.9 1st

degree Burn

37.50 15.1 100% Fatal




Scenario:

Pool Fire scenario:

Red – 4 KW/m2






Fire Ball scenario:

Red – 4 KW/m2






Measures to be taken to prevent such accident:

• Priority will be given to Tanker to immediately enter the storage premises at site and will not be kept waiting


• Security person will check License, TREM CARD, Fire extinguisher condition, Antidote Kit, required PPEs as per

SOP laid down.

• Store officer will take sample as per sampling SOP from sampling point.

• After approval of QC department unloading procedure will be allowed be started.



• Static earthing will be provided to road tanker.

• Tanker unloading procedure will be followed according to check list and implemented.

• Flexible SS hose connection will be done at TL outlet line.

• The quantity remaining in the hose pipeline will be drained to a small underground storage tank, which will

be subsequently transferred by nitrogen pressure to the main storage tank thus ensuring complete closed

conditions for transfer from road tanker.

• All TL valves will be closed in TL.

• Finally earthing connection and wheel stopper will be removed.

• Only day time unloading will be permitted.

Following precautions will be adopted Storage of such chemicals



• Caution note and emergency handling procedure will be displayed at unloading area and trained all

operators.


• Required PPEs like full body protection PVC apron, Hand gloves, gumboot, Respiratory mask etc. will be

provided to operator.







• Safety permit for loading unloading of hazardous material will be prepared and implemented.




• TREM CARD will be provided to all transporters and will be trained for transportation Emergency of



For Storage tank farm area:

• Under N2 pressure storage.

• Safety valve provided and storage facility to ensure safe release of HC in case of over pressure.

• Dyke with separate fencing area is provided.

• SOP prepared

• Road tanker unloading procedure prepared

• Work permit followed

• PPEs used

• Safety shower, eye wash provided.

• NFPA labeling system adopted for storage tanks.

• Level indicator at local.

• Alarm for high level & high pressure.

• Automatic fire fighting indication provided for around the storage area

• Sprinkler system will be provided




6.1.6 RISK ASSESSMENT SUMMARY

• From the Risk Assessment studies conducted, it would be observed that by and large,

the risks are confined within the factory boundary walls.

• Based on these studies company has been proposed to plan its facility sitting as well as

location of operator cabin, open area, etc.

• Company has to increase awareness programme in the surrounding vicinity and

educate people for safe evacuation at the time of toxic release.

• A HAZOP study to be carried out for all product plant and storage facilities.

• Induction safety course to be prepared and trained all new employees before starting

duties in plant.

6.1.6.1 PROCESS SAFETY

• Safety measures will be adopted from the design stage.

• Safety Valve and pressure gauge will be provided on reactor and its jacket (if jacket is

provided).

• Utility like Chilling, cooling, vacuum, steaming and its alternative will be provided to

control reaction parameters in a safe manner.

• Free Fall of any flammable material in the vessel will be avoided.

• Static earthing provision will be made at design stage to all solvent handling

equipments, reactors, vessels & powder handling equipments.

• Any reaction upsets will be confined to the reaction vessel itself.

• All emergency valves and switches and emergency handling facilities will be easily

assessable.

• Further all the vessels will be examined periodically by a recognized competent person

under the Gujarat Factory Rules.

• All the vessels and equipments will be earthed appropriately and protected against

Static Electricity. Also for draining in drums proper earthing facilities will be provided.

• Materials will be transferred by pumping through pipeline or by vacuum from drums.

• All solvents and flammable material storage tanks will be stored away from the process

plant and required quantity of material will be charge in reactor by pump.




• Jumpers will be provided on all solvent handling pipeline flanges.

• Caution note, safety posters, stickers, periodic training & Updation in safety and

emergency preparedness plan will be displayed and conducted.

• Flame proof light fittings will be installed in the plant.

• All the Plant Personnel will be provided with Personal Protection

• Equipments to protect against any adverse health effect during operations, leakage,

spillages or splash. PPE like Helmets, Safety Shoes, Safety

• Glasses, Acid-Alkali Proof Gloves etc. will be provided to the employees.

• All employees will be given and updated in Safety aspects through periodic training in

safety.

• Material Safety Data Sheets of Raw Materials & Products will be readily available that

the shop floor.

6.1.6.2 FOR HAZARDOUS STORAGE TANK FARM

• Tank farm will be constructed as per explosive department requirement and separation

distance will be maintained.

• Tanks shall be located and marked in designated area of hazardous chemical storage.

• Static earthing provision will be made for road tanker as well as storage tank.

• Tanks of proper MOC will be selected.

• Flame arrestor with breather valve will be provided on vent line.

• Road tanker unloading procedure will be prepared and implemented.

• Fire load calculation will be done and as per fire load Hydrant System will be provided as

per NFPA std. and Fire extinguishers will be provided as per fire load calculation.

• Spark arrestor will be provided to all vehicles in side premises.

• Flame proof type equipments and lighting will be provided.

• Lightening arrestor will be provided on the top of chimney.

• Trained and experience operator will be employed for tank farm area.

• NFPA label (hazard identification) capacity and content will be displayed on storage tank.




• Solvents will be transferred by pump only in plant area and day tank will be provided.

Overflow line will be return to the storage tank or Pump On-Off switch will be provided

near day tank in plant.

• Jumpers will be provided on solvent handling pipe line flanges.

• Flexible SS hose will be used for road tanker unloading purpose and other temperature

connection.

• All tanks shall be uniformly tagged.

• Level indicator shall be provided in tanks.

• Dyke will be provided.

• Industrial type electric fittings shall be provided.

• Adequate fire fighting equipments will be provided.

• Anti corrosive paint shall be done.

• Safety instruction board will be displayed.

6.1.6.3 FOR DRUM/CARBOY STORAGE AREA

Some chemicals will be received at plant in drums/Carboys by road truck and stored in a

drum/Carboy storage area.

• FLP type light fittings will be provided.

• Proper ventilation will be provided in godown.

• Proper label and identification board /stickers will be provided in the storage area.

• Conductive drum pallets will be provided.

• Drum handling trolley / stackers/fork lift will be used for drum handling.

• Separate dispensing room with local exhaust and static earthing provision will be made.

• Materials will be stored as per its compatibility study and separate area will be made for

flammable, corrosive and toxic chemical drums storage.

• Smoking and other spark, flame generating item will be banned from the Gate.




6.1.6.4 TRANSPORTATION

• Road tanker unloading procedure will be in place and will be implemented for safe

unloading of road tanker.

• Static earthing provision will be made for tanker unloading.

• Earthed Flexible Steel hose will be used for solvent unloading from the road tanker.

• Fixed pipelines with pumps will be provided for solvent transfer up to Day

tanks/reactors.

• Double mechanical seal type pumps will be installed.

• NRV provision will be made on all pump discharge line.

6.1.7 OTHER RISK REDUCTION OPPORTUNITIES

The following opportunities shall be considered as a potential means of reducing identified

risks during the detailed design phase:

• Buildings and plants structures shall be designed for cyclone floods and seismic

events to prevent structural collapse and integrity of weather (water) proofing for

storage of goods;

• Provision for adequate water capacity to supply fire protection systems and critical

process water;

• Isolate people from load carrying/mechanical handling systems, vehicle traffic and

storage and stacks locations;




6.1.8 RECOMMENDATIONS FOR ALARP

The following actions are particularly recommended to be implemented in order to ensure

ALARP (As Low As reasonably practical) performance in the operation: Maintain and ensure

effectiveness of all the safety measures, among others through the following actions:

Raw Material Storage Area

- The raw material storage area should be declared as a prohibited area and should be

provided having at least two exits, “No Smoking” and “Prohibited Area” display

boards, as applicable should be provided at site.

- Regular inspection of tanks/drums/carboys containing raw material to be done to

take care.

- Periodic site inspection should be carried out to ensure that there is no leakage from

any of the drums in the ware house.

- Fire hydrant system needs to be provided in storage area as per TAC standards.

- Smoke detector and fire alarm systems need to be provided.

- Provision of fire doors in ware house area.

Fire access for Tank Farm area and Ware Houses

- Fire access roads should be provided to storage area. The storage tanks/area should

have suitable fire protection and fire fighting facility.

The following features are also important for the project by taking the layout into

consideration:-

• Hinged doors will be swinged outward in an explosion.

• Window panes (if installed) will be shatter proofed or plastic in frame.

• Floors, walls and ceilings will be designed and installed to limit the generation and

accumulation of static electricity.

• All doors must be fire resistant. Floors, walls and ceilings will be designed for at least

2 h of fire resistance.

• Walls or partitions will be continuous from floor to ceiling, and securely anchored.




• Integrity of the wall should be ensured i.e. blast wall not to be broken or drilled as

that can leads to weak spots.

• The building will be constructed of non-combustible materials, on a substantial

frame.

• Restrained deflagration vent panels will be present.

• There will be adequate ventilation, and any heating in rooms will be limited to

steam, hot water, or other indirect means.

Electrical Safety for Whole Facility

• Electrical Safety: All cables and electric fittings shall be constructed, installed,

protected, operated and maintained in such a manner so as to prevent risk of open

sparking.




6.1.9 FIRE FIGHTING SYSTEM

M/s. Nutraplus India Ltd. (Unit-2), management will take into consideration fire prevention

measures at the project planning and during plant commissioning stage to avoid any

outbreak of fire. But looking to the hazardous nature of process and the chemicals that are

handled and processed, the chances of outbreak of fire cannot be totally ignored. Hence to

tackle such a situation a good well laid fire protection system will be provided in the factory.

Details of fire fighting are given in Table 6.3.

TABLE 6.6

FIRE AND TOXICITY CONTROL ARRANGEMENT

SR.

NO.

TYPE CAPACITY NOS. NOS. TOTAL NOS.

1 DCP 10 KG 100 130

210

2 DCP 5 KG 30

3 AFFF FOAM 50 LTR. 50 50

4 ABC 50 KG 15 15

5 CO2 4.5 KG 15 15

Other fire fighting facilities proposed to be installed at site:

� Fire load calculation will be carried out and Fire Extinguishers at different locations

will be provided (as mentioned in above table) as per the TAC guidelines.

� Working staff will be given training to operate DCP and CO2 extinguishers.

� Fire Hydrant Network will be installed as per the calculated requirement for fire

fighting.

� A main fire pump with a capacity of 50 m3/Hr @ 10 Bar/cm

2 will be installed.

� A stand-by diesel pump with equal capacity (50 m3/Hr @ 10 Bar/cm

2) will be

installed. This pump will be used for fire fighting in case of power failure.

� A fire water reservoir with holding capacity of 300 m3 of water shall be provided.

� First Aid Training will be imparted to employees by designated first aid trainee.




6.2 DISASTER MANAGEMENT PLAN

M/s. Nutraplus India Ltd. (Unit-2) shall develop the emergency management system to

tackle the emergency situation, apart from its emergency management system. The detail of

disaster management system is discussed in the following section.

6.2.1 DEFINING THE NATURE OF EMERGENCY

6.2.1.1 LEVEL OF EMERGENCY CAN BE CLASSIFIED IN THREE CATEGORIES.

LEVEL - 1:

The leakage or emergency, which is confinable within the plant, premises. It may be due to -

a) Small fire in the plant

b) Low toxic gas release for short duration.

c) Collapsing of equipment that do not affect out side premises.

LEVEL - 2:

The emergency, which is confinable within the factory premises. It may arise due to -

a) Major fire inside the factory premises.

b) Medium scale explosion confined to the factory premises.

c) Heavy toxic / flammable gas leakage for short duration.

LEVEL - 3:

The emergency, which is not confinable within the factory premises and general public in

the vicinity likely to be affected. It may arise due to -

a) Explosion of high magnitude affecting the adjacent area

b) Heavy / Profuse leakage of toxic / flammable gases for a long duration.




6.2.2 OBJECTIVES OF EMERGENCY MANAGEMENT SYSTEM

The objectives of the emergency management system are summarized as under.

• To identify and assess types of emergencies due to different types of hazards.

• To work out plan with all provisions to handle emergencies and safeguard employees

and people in the vicinity of the factory.

• To provide for emergency preparedness and the periodical rehearsal of the plan.

• To plan mode of proper communication and actions to be followed in the event of

emergency.

• To keep all necessary information with respect to hazard/accident control and

emergency contacts in one document for easy and speedy reference.

• To inform employees, general public and the authorities about the hazards/risk if any

and the role to be played by them in the event of emergency.

• To control and contain the accident.

• To effect rescue and treatment of casualties.

• To inform and help relatives of casualties.

• To secure rehabilitation of affected area and restore normalcy.

• To provide information to media and government agencies.

• To preserve record, equipment etc. for investigating cause of emergency.

• To be ready for “mutual aid” if need arises to help neighboring units.




6.2.3 STRUCTURE OF EMERGENCY MANAGEMENT SYSTEM

M/s. Nutraplus India Ltd. (Unit-2) shall develop an emergency management team. The

management structure includes the following personnel’s;

• Chief Emergency Controller

• Incident Controllers and Deputy Incident Controllers

• Site Main Controllers

• Key Personnel’s

• Essential Workers

• Assembly points

• Emergency control center

• Fire control arrangements

• Medical arrangements

• Other arrangements




6.2.3.1 CHIEF EMERGENCY CONTROLLER

He will be Chief Manager in his absence, the Plant Supervisor will be the Chief Controller till

any one of the designated Manager arrives at Site and assumes overall charge of the

situation. His task will be to co-ordinate all internal and external activities from the

Emergency Control Centre at Main Security Gate from where all operations will be directed.

He shall:

1. Immediately on being informed of the emergency and its location, will arrive at the

scene & handle the situation.

2. Relieve the Incident Controller from responsible of the Main Controller.

3. Co-ordinate to avail services from external agencies like fire brigade, hospitals etc, if

called for, following the declaration of major emergency. If necessary, major

installations in the vicinity may also be informed of the situation.

4. Exercise direct operational control of the unaffected section of the plant.

5. In consultation with the advisory team, expedite the shutting down of loading /

unloading operations of tankers and if necessary, instruct the supervisor / security

personnel to evacuate tankers.

6. Ensure that all employees are evacuated from the affected area and the casualties, if

any, are given necessary medical attention. Instruct P & A Assistant / Security for

rushing casualties to hospitals if required.

7. Liaise with fire and police officials, pollution control board officials and other

statutory bodies and advise them of all possible consequence effects outside the

premises.

8. Arrange for relief of personnel when emergency is prolonged.

9. Issue authorized statement or press release to the news – media.

10. Ensure preservation of evidence for enquiries to be conducted by statutory

authorities.

11. Authorize the sounding of “All Clear” and “Evacuation Siren”.




12. Arrange for obtaining the head – count of all personnel within the premises and

cross-checking with the data from records available for no. of persons within the

premises.

13. Nominate a person from advisory team, to maintain chronological log of event

during the entire period of emergency.

6.2.3.2 INCIDENT CONTROLLER AND DEPUTY INCIDENT CONTROLLER

His primary duties are to take charge at the scene of the incident. In the initial stage he may

be required to take decisions involving the operation of the other plants or to stop or

continue any process and to take technical decisions to control the incident. The deputy

incident controller should take the charge of incident controller, if he is not available due to

any reason. As our factory is running 24 hrs, so each plants shift in charge are being

nominated as I.C (after 'G' Shift) and they will be always available in the shift and can take

charge till the arrival of IC.

Responsibilities/Duties of Incident Controller and Deputy Incident Controller:

• He shall take charge at the scene of incident.

• He may be required to take decisions whether to stop or continue any Process and

take a control the incident or to isolate affected area of the plant and simultaneously

inform / consult senior officers as per requirement.

• He shall immediately assess the gravity of risk and alert panel and field operators to

start controlling their respective section.

• After assessing the level of emergency likely to exist, he shall ad emergency. As per

the assessment of risk, if necessary inform concerned Senior Officer to declare major

emergency and active on-site/off site emergency plan accordingly. As Per the

situation ensure that Site Main Controller (SMC) will be informed.

• He will work under the direction of the SMC, but till his arrival he may have to

execute following responsibilities.

• Ensure that all the Key Personnel are called.




• Direct for evacuation of plant and areas likely to be affected by the emergency.

• He shall communicate to the SMC the type of outside help needed.

• He shall direct all emergency operations within the affected area with the following

priorities.

• Personnel safety, including of surrounding community.

• Minimum damage to Plant, Property and Environment.

• Appropriate actions to minimize loss of Production and Material.

• Give information to the head of fire fighting and rescue team and other emergency

services.

• Depending on the incident, instruct partial or total shut down, isolations,

depressurization, Nitrogen purging, fire fighting, rescue operations.

• Instruct upstream/down stream units to take emergency shut down /cutting off

supply and other appropriate actions and emergency evacuation help etc.

• Direct for search of casualties.

• Evacuate non-essential workers/visitors/contractors to safe assembly points.

• Brief site main controller and keep him informed about the developments.

• Pressure evidences. This will be necessary for investigation for cause and concluding

preventive measures.




6.2.3.3 SITE MAIN CONTROLLER

He will have an overall responsibility for directing operations & calling outside help from

Emergency Control Centers. He is required to take decisions after consultation with the

Senior Manager available at site.

The Shift Engineer of non-affected Plant will act as SMC till arrival of the designated SMC at

Emergency Control Centre (ECC). Until the arrival of SMC, he may have to execute following

responsibilities.

• As soon as he received the information or comes to know about the incident, he

shall proceed to Emergency Control Room (Control Room) and shall take charge of

the incident. If Control Room gets affected due to unfavorable wind direction, Fire

Control Room shall be used as alternate Emergency Control Room.

• He has overall responsibility for directing emergency action, operation and calling

outside help.

• He shall ensure that all the Key Personnel are called.

• He shall assess the gravity of situation with the help of Incident Controller (IC), Plant

Manager and Key Personnel and after quickly assess the situation, shall find out the

of emergency from Incident Controller (l C), and declare the emergency.

• Level-l: Emergency - may be handled within the plant premises.

• Level-2: Emergency - On Site Emergency plant shag be activated.

• Level-3: Emergency - Action to be taken to operate Off-Site Emergency Plan.

• He shed direct all emergency operations within the affected area with the following

priorities.

• Personnel safety, including of surrounding community.

• Minimum damage to Plant, Property and Environment.

• Appropriate actions to minimize loss of Production and Material.

• He shall direct for evacuation of plant and areas likely to be affected by the

emergency.

• He shall continuously review and assess possible developments to determine most

probable course of events and actions.




• He shall assess the situation and ensure that whatever resources needed is made

available and utilized in a co-ordinate manner.

• He shall direct the safe shut down of plants in construction with incident controller

and Key Personnel, if necessary.

• He shall check that all non-essential workers, visitors, contractors are evacuated to

safe assembly points and head count is completed.

• He shall give instructions to the Incident controllers, Fire fighting and Rescue teams.

• He shall, if necessary arrange for evacuation of neighboring population.

• He shall ensure that search for casualties, within the affected area has been carried

out and arrange for hospitalization of victims and additional medical help, if

required.

• He shall ensure that liaison will be made with outside agencies such as Police

Services, Fire Services, Expert on Health and Safety, Meteorological Office, District

Emergency Authorities, Collector and Senior Inspector of Factories. Provide advice

on possible effects to areas outside the factory.

• He shall arrange for up to date records of emergencies.

• He shall advice not to re-start the plants unless it is declared safe to start by

competent authorities.

6.2.3.4 KEY PERSONNELS

Key Personnel are required to provide and to implement the decisions made by the SMC in

the light of information received on the developing situation at the time of emergency. As

necessary, they will decide the actions needed to shutdown plants, evacuate personnel,

carryout emergency engineering work, arrange for supplies of equipments, utilities, carryout

environment monitoring, provide catering facilities, liaise with police, fire brigade and other

local authorities, relative of casualties, hospital, press & neighboring industries. Action at

assembly points, outside shelters and mutual aid center under the direction of the SMC. All

the key personnel and other called in so to assist shall report to the ECC. They shall be

available at any time on duty or on call or on oil duty or holiday.




6.2.3.5 ESSENTIAL WORKERS

A task force of essential trained workers (expert’s team) is available to get the work done by

the Incident Controller and the Site Main Controller. Such work will include:

1) Fire fighting and spill control till a Fire Brigade takes the charge.

2) To help the Fire Brigade and mutual aid teams, if it is so required.

3) Shutting down plant and making it safe.

4) Emergency engineering work e.g. isolating equipment, material process, providing

temporary by-pass lines, safe transfer of materials, urgent repairing or replacement,

electrical work, etc.

5) Provision of emergency power, water, lighting, instruments, equipments, materials, etc.

6) Movement of equipment, special vehicle and transport to or from the scene of the

accident.

7) Search, evacuation, rescue and welfare.

8) The injured is given First Aid.

9) Moving tankers or other vehicles from area of risk.

10) Carrying out atmospheric test and pollution control.

11) Manning of assembly points to record the arrival of evacuated personnel. Manning for

outside shelters and welfare of evacuated persons there.

12) Assistance at causalities reception areas to record details of causalities.

13) Assistance at communication centers to handle out going and in coming calls and to act

as messengers if necessary.

14) Manning of works entrances in liaison with the police to direct emergency vehicles

entering the work, to control traffic leaving the works and to turn away or make

alternative safe arrangements for visitors, contractors and other traffic arriving at the

works.

15) Informing surrounding factories and the public as well as directed by the Site Main

Controller.

16) Any special help required.




6.2.3.6 ASSEMABLY POINT

In affected & vulnerable plants, all nonessential workers (who are not assigned any

emergency duty) are evacuating the area & report to a specified Assembly Points. Each

assembly Point will be clearly marked by a Conspicuous notices & provided with an

identification numbers e.g. Assembly Point No. 1, 2 and so on. Assembly Points are located

at a safe place, well away from area of risk and least affected by the down wind direction.

To ensure that workers do not have to approach the affected area to reach the Assembly

Point proper location and numbers have been marked at Assembly Points. Each Assembly

Point in manned by a nominated person to record the names and dept. Further telephone

to communicated SMC has been provided at each assembly Points. At each Assembly Point

duties of Assembly Point In-charge has been also displayed in brief Before reaching an

Assembly Point or subsequently, if it is required to pass through an affected area or due to

presence of toxic substances. Suitable PPE's including respirators, helmet etc., are issued &

made available with workers.

6.2.3.7 EMERGENCY CONTROL CENTER

The Emergency Control Center is the place or room from where the operations to handle

the emergency are directed and coordinated. Main Control Room will be

earmarked/identified as the Emergency Control Room. Fire Control Room shall be

earmarked/identified as the alternative Emergency Control Room to be operated in case of

unfavorable wind direction. Adequate Telecommunication System will be available in the

Emergency Control Room i.e. Hot Lines, Intercom Walkie-Talkies & External Phones.

The ECC center shall be equipper with the following facilities.

1. Internal and external telephone including STD facility

2. Telephone directory

3. Telephone nos. of mutual aid centers

4. Factory layout plan

5. Map of the area

6. Employee blood group and their address

7. Messengers / Runners for sending messages




8. Adequate numbers of PPE'S

6.2.3.8 FIRE CONTROL ARRANGEMENTS

6.2.3.8.1 FIRE FIGHTING, GAS LEAK CONTROL AND RESCUE OPERATION

A) Role of Manager (Fire and Safety) / Shift In-Charge (Fire & Safety)

1. Incident Controller will be the only person to direct the fire fighting and Emergency

operation.

2. Keep the constant touch with the SMC / In charge - EHS.

3. Direct the crew members to the scene of emergency and arrange replenishment of

Manpower / equipment / extinguishing media etc.

B) Role of EHS Representative:

1. On being notified about the location of fire/ gas leakage immediately proceed to the help.

2. Decide his line of action in consultation with Incident controller and take appropriate

measures to handle the emergency.

3. Assessing the severity of the incident immediately report to emergency controller about

the gravity of the situation.

4. He will assess the extra requirement required if any from the neighboring industry.

C) Fire crew members

1. On hearing fire alarm, emergency siren they shall immediately report to control room

and proceed to the scene of emergency and work under the direction of IC/ Dy IC.

2. The personal availability at the scene of incident to be made optimize.

6.2.3.9 MEDICAL SERVICES

The roles of Medical officers are as follows;

(a) He will contact immediately to the SMC/IC.

(b) He will render necessary treatment, at Occupational Health Center.

(c) He will arrange for Hospitalization and Treatment at outside hospitals, if required.




(d) He will mobilize in getting the services of External medical agencies, other Para –

medical services etc. and transportation services etc.

(e) He will arrange for extra medical assistance/antidotes, from out, if required.

(f) He will arrange for first-aid trained volunteers for necessary help.

(g) He will liaise with the Government Health Authorities for treatment of the affected

persons nearby.

6.2.3.10 OTHER ARRANGEMENTS

Other arrangements include external transport, cranes, generator sets to supply emergency

power, environment monitoring equipment, rescue items etc. when available resources do

not meet the requirement.

STANDARD OPERATING PROCEDURE (EMERGENCY)

• As soon as emergency alarm is heard, all essential workers shall report to IC or SMC.

• They shall carefully listen to the instructions given by IC or SMC

• According to the type of emergency/accident, they shall get equipped with PPE/Fire

fighting equipment and devices.

• The runner among the workers shall inform SMC/IC and key personnel if they are not at

site.

• The messenger amongst the workers shall deliver messages to nearby units as per the

instructions of SMC/IC.

• The in-charge of medical arrangements shall prepare first-aid and other required

facilities for the injured.

• The other essential workers shall try to control the emergency as per the instructions

given to IC.

• IC would keep SMC informed about the status of control measures being taken at the

site and ask for other requirements e.g. Mutual aid, equipment etc., if he find necessary.

• SMC would co-ordinate with outside agencies regarding control measures being taken,

need for external help, evacuation, medical treatment etc.




6.3 COMMMUNICATION SYSTEM

After the assessment of risk & their possible environmental impact and after making an

organization for the preparedness to control the emergency, the next most essential step is to

make us ready for Communication at the time of emergency. Communication System is a

Crucial Factor while handling emergency.

Company will have quick & effective Communication System through which, any situation,

which can lead to emergency, can be informed or known to.

i. All working inside the plant.

ii. Key Personnel outside during normal working hours & during off-duty hours.

iii. Outside emergency services, Statutory and Local Authorities and

iv. Neighboring facilities and public leaving in vicinity.

Each and every section, Plant & Department of the Factory shall be connected by internal

telephones. External Phone at Office and Residence and Mobile shall be also available with

Key Personnel and top executive of the factory. Hot lines shall be provided with mutual aid

Partner through the Emergency Control Center. The Communication System begins with

raising the alarm declaring the emergency, Telephone messages and Procedure to

communicate the emergency to other persons & General Public.

6.3.1 RAISING THE ALARM

As soon as incident takes place inside the factory and is noticed by someone, the first step is

to raise the nearest manual emergency bell to alert the nearby people. Next, he/she

informs the security persons to raise the emergency siren located at the factory gate. The

security personnel sound the siren, raising and lowering the sound three times in a 10

second “ON”, 5 second “OFF” sequence. All the security employees shall be trained for

operating the siren to announcing the emergency. In case of power failure, manual bell

shall be also provided. The alarm sound informs the I.C and the S.M.C that an emergency

has been created and emergency organization is to be activated. The I.C. rushes to the site

and takes charge of the scene.




Emergency Siren Code

Onsite Emergency

Emergency Siren:-10 sec and 5 sec off for 03 times.

All Clear Emergency:-1 Minute continuously blown for All clear.

Offsite Emergency

Emergency Siren:-10 sec and 5 sec off for 05 times.

All Clear Emergency:-3 Minute continuously blown for All clear

6.3.2 DECLARING THE MAJOR EMERGENCY

Major emergency has to be declared after sufficient and through check because the

declaration of major emergency puts many agencies on action and it may disturb the

running system, which may be Costly at, time or its Consequence may be Serious. Therefore

major emergency must not be decided on whims or immature judgment or without proper

thought. Looking to all the above, we will have taken care to nominate the persons who can

declare the emergency; we will have selected them on the basis of their knowledge &

experience. These persons will be technically qualified and experienced. They shall advice

the Incident Controller or Site Main Controller regarding the type of emergency. On being

convinced, the Site Main Controller or Incident Controller shall declare an ON-SITE

emergency. The decision about major emergency shall be taken as early as possible and

without wasting time so that control action can be started immediately.

NOMINATED PERSONS TO DECLARE MAJOR EMERGENCY

Sr.

No.

Name of the plant

department or location

Duty of designation

given if any under the

on-site/off-site

emergency plan

1 Factory Head.

S.M.C.




2

Dy.Factory Incharge

Dy.S.M.C.

6.3.3 TELEPHONE MESSAGES

After hearing the emergency alarm and during emergency or even while just receiving the

emergency message on phone, Telephone operator should be precise, sharp, attentive and

quick in receiving and noting the message and subsequently effective in further

Communication A form to record emergency telephone calls shall be available with

telephone operator or Person available in Emergency Control Center, who has to record

such calls during emergency. Telephonic messages shall be given out by the telephone

operator to Site main Controller and key personnel as per the instructions of the Incident

Controller. Telephonic messages shall also be given to authorities and external agencies to

describe the type of emergency. All details of emergency shall be collected/delivered

according to this format shall available with the telephone operator.

6.3.4 COMMUNICATION OF EMERGENCY & STATUTORY INFORMATION

6.3.4.1 COMMUNICATION OF EMERGENCY

An effective system to communicate emergency shall be available.

• Inside the factory i.e. workers including key personnel and essential workers, on duty &

inside during normal working hours.

• To key personnel and essential workers not on duty and outside during normal working

hours.

• To the outside emergency services and the Government authorities.

• To the neighboring factory & the General Public in the vicinity.

a) Information to Workers

All personnel inside the factory shall be informed by the sounding of the siren or in case of

electricity by ringing the bell.




b) To key personnel outside during normal working hours

The key personnel outside the factory premises shall be informed as per the need by

external telephones or runners.

c) To the outside Emergency Services and the Authorities

Once the emergency is declared, it is essential that the outside emergency services should

be informed in the shortest possible time. Responsibilities shall be fixed as per the

Incident/Emergency Command structure/plan to contact outside agencies for help and to

communicate to the all the Government and other Authorities such as Fire Brigade, Police,

District Emergency Authorities, Factory Inspectorate & Hospital etc. In case of major

emergency, outside agencies like mutual aid, hospitals, policies, Factory Inspector, Collector,

Fire-brigade etc. shall be informed by telephone or by sending special messenger from

emergency control center.

d) To neighboring factories and the General Public

A major emergency will affect areas outside the works and it is essential that neighboring

factory and General Public, should be informed to enable them to take prompt action to

protect their own workers and to take whatever measures may be possible to prevent

further escalation of the emergency due to effects on their own installations, at the same

time, they may be able to provide assistance as part of a prearranged mutual aid plan.

Further responsibilities shall be fixed to inform the neighboring factories and the General

Public leaving in the vicinity. The neighboring units shall be informed about an emergency

through external telephones or runners. The general public shall be informed about an

emergency using loudspeaker on scooter or rickshaw or car. Help from police shall be

sought if required.




6.3.4.2 STATUTORY INFORMATION

a) Information to Workers

Set of Statutory information regarding types of hazards and their prevention and control as

directed in the Factories Act shall be prepared by the unit. This information shall be printed

in the local language and given in the form of booklet to all workers including contract

workers.

b) To the outside emergency services and authorities

Statutory information in the form of booklet shall be given to outside emergency services

and authorities.

c) To neighboring firms and the general public

Statutory information in the form of booklet will be given to neighboring units and the

general public of the villages in the vicinity of the unit.

INDIVIDUAL RESPONSIBILITY DURING ON SITE EMERGENCY PLAN

1 EVERY INDIVIDUALS Primary responsibilities for all are to ensure that the fire is extinguished

by using suitable fire extinguishers. As soon as fire / leak observed start

shouting FIRE. FIRE and LEAK..LEAK and immediately intimate to incident

controller (HOD / Plant incharges / shift incharges )

2 S.M.C.

Site Main Controller

(Director – Works)

Immediately to be aware of the emergency control centre he will go to

the incident place. He will relieve the incident controller of his

responsibility for overall main control. He will give information to district

authority and decide the nature of help required such as evacuation,

traffic control, warming to the public vehicle requirement etc. He will

inform to head office. He will guide to incident controller.

3 Dy.S.M.C.

Dy. Site Main Controller

(Sr.G.M.-Works)

In absent of S.M.C. Dy.S.M.C. will act as a S.M.C. and if S.M.C. is present

then he will help to I.C. to control emergency.

4 FIRE & SAFETY

EHS DEPARTMENT

He will rush to the incident place and guide to I.C. for the actions to be

taken to tackle the incident. He will organize for Mutual Aid from the




(Manager / Officer) neighbor and D.P.M.C. He will also help to S.M.C.

5 TRANSPORTATION TEAM

P & A DEPARTMENT

(G.M. / Executive / officer)

He will control safe assembly point. He will shift injured person to

hospital. He will organize the additional vehicles if required. If evacuation

require, mobilization of person have to done.

6 INCIDENT CONTROLLER

PRODUCTION DEPARTMENT

(Manager / Executive /

officer)

Shall be incident controller and also act as S.M.C. till S.M.C.’s availability.

His duties will be to assess the situation and take necessary actions deem

fit, looking to the gravity of situation.

7 Plant Operators If fire takes place in plant, he shall inform to the incident controller (shift

officer / supervisor) immediately and follow his instruction. He is

responsible for process isolation and fire fighting.

8 Utility Incharge / Operator He will follow the instruction of incident controller / maintenance

engineer. He is responsible to operate fire hydrant pumps.

9 Electrical Maintenance

(Manager / Officer /

Electrician)

He should contact the incident controller and follow his instruction. If

fire takes place in plant where electrical cables are lying, immediately cut

off power supply to necessary places. If there is a fire in MCC

immediately cut off power supply and starts extinguishing activities.

10 Mechanical Department

(Manager / Exec./Officer/

Fitter)

He should report to incident place and follow the incident controller’s

instructions. Help incident controller for process isolation.

11 QAD Department

(Manager / Exe. / officer)

They should be ready with the first aid box and shift injured person to

safe assembly point / vehicle and follow the instruction of incident

controller.

12 Security Department

(Manager / ASO / Supervisor

/ Guards)

He should be attending the telephone. Also ensuring emergency vehicle

is kept in the running in the ideal condition at the gate area. He should

be ready for gate operation when fire tenders arrives. Restrict outside

person at gate. He should inform key persons of the company. Security

guards will help in fire fighting. Do head count.

13 Evacuation Team

Store Department

(Manager / Officer/ Helper)

Reach near incident place and cordon area. Remove material from

incident places.

6.4 ACTION ON SITE

The activities related to emergency time activities shall be divided into two parts. These are

• Pre-emergency activities

• Post-emergency Activities

6.4.1 PRE-EMERGENCY ACTIVITIES

6.4.1.1 INTERNAL SAFETY SURVEY

A safety committee shall be constituted as per Factories Act. The nominated members of

the committee shall be assigned the responsibility to conduct safety survey once in a month

before safety meeting. The internal safety survey includes –

• Identify various hazards in the factory




• Check whether protective equipments are in sound working condition

• Check various safety installations located at various plants for proper working

• Check sprinklers, showers, etc. in all plants

• Suggest extra modifications/ requirements to make systems more reliable

• Check presence of toxic gases by the help of dragger tube

Frequency of Internal Safety Survey: Once in a month

6.4.1.2 THIRD PARTY SURVEY

A safety survey shall be carried out once in a year by an external agency. It shall include –

• Inspection of building, structures for strength and stability

• Identify and study the hazards inside individual plants and within the factory

premises.

• Check safety system for its adequacy.

• Suggest modifications or additions in the operating practices and safety system, if

necessary.

Frequency of Third Party Safety Survey: Once in a year

6.4.1.3 PRESSURE VESSEL TESTING/ EXAMINATION

• To prepare list of pressure vessels in the plant with details of operating conditions

and manufacturing details.

• To carry out preventive maintenance of valves & fittings on all pressure vessels

(valves, pipelines, pressure gauge, temperature recorders and emergency vent lines)

• To arrange for testing and examination of all pressure vessels as per the rules of

Factories Act by govt. certified competent person on due date.

• To maintain record of testing and certificates issued by competent person and make

them available to Factory Inspector at the time of inspection.

Frequency of Pressure Vessel Testing / Examination: Twice in a year




6.4.1.4 NON-DESTRUCTIVE TESTING (NDT)

• To prepare list of equipment and pipelines in the plant which require NDT as per the

rules of Factories Act.

• To arrange for Non-Destructive Testing (NDT) as per the rules under Factories Act by

govt. certified competent person on due dates.

• To maintain record of testing and certificates issued by competent person and make

them available to Factory Inspector at the time of inspection.

Frequency of Non-Destructive Testing : Once in a year

6.4.1.5 SAFETY RELIEF VALVES TESTING

• To prepare list of Safety Relief Valves installed on various equipment and pipelines in

the unit alongwith detailed specifications.

• To prepare schedule for testing and calibration as per the rules under Factories Act

by govt. certified agencies on due dates.

• To maintain record of testing and certificates and mark dates of testing and

calibration on the valves.

• To carry out repairs/replacement as suggesting by the testing authority.

Frequency : Twice in a year

6.4.1.6 FIRE SYSTEM TESTING

• To prepare list of various fire-fighting equipment (Fire Extinguishers, etc.) installed at

various locations in the unit along with detailed specifications.

• To prepare schedule for testing of all these equipment and check operability

• To maintain record of testing and mark dates of testing on the equipment.

• To carry out repairs/replacement of defective equipment

Frequency: Once in a month

6.4.1.7 MUTUAL AID SCHEME

• To prepare Mutual Aid Scheme and enter into agreement with the neighboring units

for getting or extending help during emergency




• To appoint coordinator for follow-up under mutual Aid Scheme

• To review the scheme once in a year with coordinators of neighboring units w.r.t.

scope of help, type of aid, contact persons, etc.

• To include the scheme in mock drills

6.4.1.8 MOCK-DRILLS

• To conduct minor mock drills to train employees about their role / duties during

emergency

• To refresh training to the employees for fire fighting, spill control, use of personal

protective equipments etc.

• To check whether various members of emergency control committee remember

their role / duties properly and to find out the faults and points of improvement in

their performance.

• To check whether the various equipment for emergency control are operating

satisfactorily and find and rectify the draw-backs if any.

• To conduct major mock-drills with permission from the authorities

Mock drills shall be regularly conducted in our unit by our Emergency Control Organization

and the findings are compiled to analyze whether employees are familiarized with the

emergency control procedures and what sort of training is required to be given.

6.4.1.9 SAFETY TRAINING

To organize regular training for the employees for handling of safety equipment, use of

personal protective equipment, first-aid, etc. by internal/external faculty, as well as by

sending persons outside to attend safety programs etc. The topics covered in safety

training will be –

• Training on fire fighting

• Training on spill control

• Training on toxic release control

• Training on good housekeeping




• Training on use of PPE

The records of the training programs shall be maintained by the Safety Committee. New

topics will be included in the safety training programs year by year to upgrade safety

knowledge among the workers.

Frequency: Once in a year

6.4.1.10 PERSONAL PROTECTIVE EQUIPMENT

• To procure adequate number of personal protective equipment (aprons, hand gloves,

safety goggles, helmets, nose masks, safety belts, gas cartridges, self-breathing

apparatus, safety shoes etc.) suitable for plant operations and maintain records of use.

• To have proper system for issuing the PPE and disposal of used PPE

• To train the workers about proper use of PPE.

• To check the fresh air blowers provided at confined spaces for fresh air to workers.

6.4.1.11 COMMUNICATION

• To maintain internal/external telephones in working order

• To check alarms / siren / loudspeakers for workability

• To provide manual emergency bells at various location for use during power failure

• To periodically check wind cock for wind direction

• To check lightning arrestors installed at different locations for physical condition and

proper earthing connection.

6.4.1.12 EMERGENCY LIGHTS

• To keep sufficient number of emergency torch/ batteries in ECC as well as at the

production site

• To maintain the three DG sets available in the factory as stand-by for power failure.

The D.G. sets are set to start functioning within two minutes of failure of electricity.




6.4.1.13 EMERGENCY CONTROL ROOM

It is necessary to maintain the Emergency Control Room and keep it equipped with all

necessary items, documents, telecommunication systems, PPE etc. required in case of an

emergency.

6.4.1.14 ASSEMBLY POINTS

• To fix assembly points in the factory for non-essential workers

• To fix assembly points for plant emergency staff and coordinators

• To maintain record of no. of workers gathered at the assembly points at the time of

emergency. The Safety Committee shall nominate a person for this duty.

6.4.1.15 LIAISON WITH STATE AUTHORITIES

• To liaison with civil authorities, local hospitals, Fire-Brigade, Collector, factories

Inspector, Police, etc regarding emergency activities and need for external aid.

• To keep the details regarding name, address & telephone numbers of various govt.

authorities and neighboring units available and update the details from time to time.

• To inform about Mock-drill in advance and if required conduct mock-drill in presence

of any of these authorities.

• To submit report of Mock-drill conducted and the out comings with photograph to

Factories Inspector.

6.4.1.16 HOSPITAL FACILITIES

• To equip Occupational Health Centre with First-Aid and medicines

• To keep Health records (esp. blood-group records) of all employees

• To liaison with hospitals in the area of the unit

• To keep list of blood donors ready for reference

• To update arrangements with neighboring units for emergency first aid.




6.4.1.17 OUTSIDE SHELTER

• To reserve space in nearby schools/hospitals/buildings for temporary shelter during

emergency

• To arrange for clothing, food, medicine in temporary shelter

6.4.1.18 STATUTORY INFORMATION

Statutory Information about chemicals handled in the unit, manufacturing process, the

hazards in the unit, methods of prevention and control, first aid measures etc. shall be given

to

- Workers

- Public and Neighboring units

- Government authorities & outside emergency services

6.4.1.19 PROTECTIVE DEVICES & ENGINEERING MAINTENANCE

• Installation of safety valve and pressure gauges on vessels used for high pressure

operations.

• Installation of temperature indicators on reactors, temperature switch or alarm at

critical reactors

• Maintenance of cooling water systems and pumps. To keep standby pump at cooling

tower.

• Installation of overhead water tank for emergency. To keep it filled and regular

cleaning of the same

• Periodic cleaning of heat transfer surfaces (jacket, reactors, shell & tube heat

exchangers, boilers)

• To keep minimum inventory of hazardous materials with records

• To maintain good housekeeping and ensure safety compliance




6.4.1.20 LIST OF SUPPLIERS OF SAFETY EQUIPMENT

• To prepare and preserve list of suppliers of safety equipment e.g. first aid box,

medicines, fire extinguishers, PPE, communication, self breathing apparatus, chlorine

kit, etc.

• To check all supplies every three months

• To update the list and keep it ready-to-refer location in the plant as well as at ECC

6.4.1.21 FIRE PREVENTION PLAN

• List of major work-place fire hazards

• Potential ignition sources

Sparks from electrical fitting / motors

Sparks from welding operations

Ignition system of boiler house

Sparks from static electricity

• Fire prevention & control measures

• Use of flameproof electrical fittings and electric motors wherever necessary

• No welding shall be done anywhere in the plant without prior permission from safety

officer and necessary precautions from in charge of the area.

• Ignition system of boiler should be provided with guard

• All vessels and pipeline should be properly earthed to prevent static electricity

• The vent lines of all vessels and tanks holding flammable materials should be

provided with flame arrestors

• Fire extinguishers shall be provided at all critical locations in the unit

6.4.2 POST EMERGENCY ACTIVITIES

These activities are to be carried out after an emergency is over so as to establish the cause

of the emergency and decide the measures to be taken to prevent its re-occurrence. These

activities are –

1. Collection of records of accident, injury, damage to property, buildings, equipment,

material and loss of production




2. Conducting enquiries and concluding preventive measures

3. Making insurance claim for the materialistic loss / damage

4. Implementation of enquiry report’s recommendations

5. Rehabilitation of affected persons within and outside the plant

6. Restarting the plant and normalizing the operations.

6.4.3 EMERGENCY TIME ACTIVITIES

The probable emergency situation that can arise in the unit and the corresponding control

actions are describes below.

6.4.3.1 FLAMMABLE RELEASES

Source / Incident – Fire involving spilled combustible material near or in flammable storage

areas

Control action –

1. Any one who notices fire shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation.

For fire due to spillage of combustible material, he activates the on-site plan as -

• He cuts off electric supply to that area and evacuates all the persons to safe

assembly points.

• He calls in DIC (if DIC is not present there) and asks essential workers to fight fire

with dry chemical / CO2 fire extinguisher or sand.

• He inform fire brigade telling them in briefly about kind of fire and type of

extinguishers required

• He informs mutual aid teams and asks for necessary help.

• He arranges first-aid / hospitalization for the affected persons.

• Fire officer on reaching the site, takes charge of the fire-fighting operations

• Mutual aid teams shall be asked for help in the form of first-aid, transport etc.

• If fire is growing, fire officer informs IC who alerts neighboring units and through

SMC gets more fire-fighting help.

• Fire fighting shall be continued till fire is fully overcome




• After extinguishing fire, fire officer cools the entire area with water spray and checks

that no re-ignition shall be likely. After that, he declares the area safe.

• IC tells essential workers to sound all clear

• The incident shall be recorded

• SMC arranges to inform families / relatives of injured / dead.

• SMC issues authorized statement to press / media.

• SMC informs Factories Inspector about the incident and related information

6.4.3.2 TOXIC RELEASES

Source / Incident – Pressure release due to failure of

- Stuffing box gland packing

- Pressure release valve

- Vessel / pipeline failure

Control action –

1. Any one who notices the release shall sound emergency alarm.

2. SMC/IC who is at site, shall immediately rush to the scene and assess the situation.

For toxic release from a reactor, he activates the on-site plan as -

• He evacuates all the persons to safe assembly point.

• He calls in DIC (if DIC is not present there) and asks essential workers to wear self-

breathing apparatus and if the reaction is exothermic, start cooling water flow in the

reactor jacket and cool the reactor as soon as possible.

• The essential workers stop all the charging pumps of that reactor and the nearby

reactors.

• He informs mutual aid teams and asks for necessary help.

• He arranges first-aid / hospitalization for the affected persons.

• Mutual aid teams shall be asked for help in the form of first-aid, transport etc.

• When the leak stops and the air shall clear of toxic release, IC tells essential workers

to sound all clear.

• The vessel / rupture disc/gland packing will be attended by maintenance

department.




• The incident shall be recorded

• SMC arranges to inform families / relatives of injured / dead.

• SMC issues authorized statement to press / media.

• SMC informs Factories Inspector about the incident and related information

6.4.3.3 CHEMICAL SPILL

Most of the storage tanks shall be located in Storage Tank Yards. Dyke walls of sufficient size

will be connected around the tank yard. Neutralizing material shall be kept nearby. For

dilution, water connection will be provided on all sides of tank farms. Sand buckets shall be

provided for covering spillage of flammable / corrosive materials.

6.4.4 EVACUATION & TRANSPORTATION

All non-essential workers shall be evacuated from incident area and adjacent areas to safe

assembly points. Assembly points shall be clearly marked and assembly point in-charge will

also be designated. The assembly point in-charge will be a well-trained supervisor who shall

keep record of persons arriving at the assembly point and direct them for proper gathering.

He shall also inform the ECC about the persons gathered at the assembly point. Those in

need of medical treatment shall be transported to first-aid center / hospital as the case may

be. In case of major emergency all non-essential workers shall be transported to temporary

shelter.

6.4.5 SAFE CLOSE-DOWN

As per the instructions from IC or SMC, some parts or full of the plant shall be closed down

by the essential workers. The procedure for safe shut-down and start-up will be given in

safety manual given to all workers.

6.4.6 USE OF MUTUAL AID

Mutual aid from neighboring units shall be called up as and when required. The aid shall be

taken under the supervision of SMC.




6.4.7 HELP OF EXTERNAL AUTHORIES

Outside authorities such as Police, District Emergency Authority (DEA), Factory Inspector,

Disaster Management Centre, GIDC officer, Industries Association, Regional Pollution

Control Board, nearby hospitals etc. shall be informed of the on-site and off-site emergency

plans and called in as per need.

6.4.8 MEDICAL TREATMENT

Injured workers shall be located and given prompt first-aid by essential workers and key

personnel. Those requiring medical treatment shall be taken to the hospital / outside

medical center.

6.4.9 ACCOUNTING FOR PERSONNEL

Through daily muster rolls and with the help of shift-in-charge the head count shall be

undertaken to find out whether persons are missing and if so immediate search shall be

carried out to locate them. The list shall include company employees, contract workers as

well as visitors. Help from local authority or fire-brigade shall be taken if required. This list

shall be kept with time keeper / security officer at any time and shall be used to account for

personnel. Injured shall be taken to hospitals and their families/relatives shall be informed

Casualties would be identified, their families and local authority shall be informed.

6.4.10 ACCESS TO RECORDS

In order to inform families/relatives of injured/dead, a up-to-date list of names and

addresses of all the workers is maintained in addition to the muster roll where shift-wise

attendance is marked. Such list includes health records. This list will be available at the ECC

and one such copy shall be available at our head office.

6.4.11 PUBLIC RELATIONS

Our General Manager shall be the only nominated person to issue administrative statement

about the accident or emergency to news/media. No other person shall divulge any

information to any news / media person.




6.4.12 REHABILITATION

In case of Toxic release or chemical spillage, Senior Fire Brigade Officer would ensure that

the incident area shall be safe and cleaned up of all mess. Then only, he would allow people

to re-enter the location. In case of fire, the Senior Fire-Brigade Officer shall ensure that the

area is cooled down and there are no chances of re-ignition. IC shall arrange for clean-up of

the area and then only people shall be allowed to re-enter the area for work. Even when all

clear has been given, great care shall be taken when re-entering affected areas and no work

in connection with the salvage, collection of evidence or start up shall be taken up until a

thorough examination of the area has been carried out. The statutory powers of the

Factory Inspector shall be kept in mind before any evidence is disturbed. Particular care

shall be taken to avoid the introduction of possible sources of ignition, such as diesel

engines, hand or power operated tools, flame cutting equipment, etc. until it has been

established that no flammable materials are present where they could be ignited.

6.5 OFF – SITE EMERGENCY PLAN

6.5.1 NEED OF THE OFF – SITE EMERGENCY PLAN

An off-site emergency plan is prepared to deal with those incidents which have the potential

to harm persons or the environment outside the boundary of the factory premises. A major

accident, major emergency and disaster may affect areas outside the plant. An explosion

can scatter debris over wide areas and its effects of blasts can cover considerable distances.

Wind can spread burning fumes of toxic gases. Thus the events like these described above

can affect outside areas and combating them needs an Off-site Emergency plan.

Envisaging such a rare incident, an off-site emergency plan should be drawn up for the

following purpose.

1. To provide basic information about the risk and environmental impact assessment

related to the unit to local / district authorities, police, fire-brigade, surrounding

units, and the general public. To appraise them of consequences and the protection

/ prevention measures and control actions and to seek their help to communicate

with public in case of a major emergency. The information from all industries shall




enable district authorities to educate public about what could go wrong, and to train

them of measures to be taken as an individual.

2. To enable district authorities to prepare the off-site emergency plan (contingency)

for the district or particular area and to organize rehearsals and initiate actions

learnt from these incidents.

Our Emergency Plan shall be made after considering the all possible effects of incidents on

the neighboring population and the remedial measures will be devised in consultation with

the local authorities and emergency services.

6.5.2 STRUCTURE OF THE OFF-SITE EMERGENCY PLAN

IC District Authorities Mutual Aid teams, outside

SMC (Collector, Factory services, voluntary

Essential Workers Inspector, Police) organizations

(Implementing Information, Evacuation (Fire-fighting, Gas leak

Action plan, control, First-aid, Shelter,

Informing nearby Hospitalization,

Public) Transportation)

6.5.3 ROLE OF FACTORY MANAGEMENT

The Off-Site emergency Plans are dovetail so that the emergency services shall be

summoned at the appropriate time and shall be provided with accurate information and a

correct assessment of the situation. The responsibility for this is with the Site Main

Controller. The Site Main Controller shall provide a copy of our On-Site and Off-Site

Emergency Plan to the District authorities, the Factories Inspectorate and the Emergency

Services, so that on the basis of information and such authorities can make their emergency

preparedness plan to formulate and execute the District / Area off Site Emergency Plan.

Further on the advice of the authorities we can also modify our plan to make our plan more

effective and perfect.




6.5.4 ROLE OF EMERGENCY CO-ORDINATION OFFICER (ECO)

The various emergency services will be co-ordinated by the Emergency Co-ordination officer

(ECO), who will likely to be a Collector. The ECO will liaise closely with the Site Main

Controller. The Emergency Control Centre of the factory can be utilized by the ECO to keep

liaison with the Site Main Controller.

6.5.5 ROLE OF THE FIRE AUTHORITIES

The control of fire is normally the responsibility of the senior fire officer who would take

over the handling of fire from the IC on arrival at the site.

• The senior fire brigade officer may also have similar responsibility for other events

such as explosion and toxic releases. Fire authority having major hazard units in the

area shall- Familiarize themselves with the location and site of all stages of

flammable materials, water and foam supply points, fire fighting equipment.

• Act as observer of an on-site exercise involving only site personnel

6.5.6 ROLE OF THE HEALTH AUTHORITIES

Health authorities, including Doctors, Surgeons, Hospitals, and Ambulances so on, have a

vital part to play following a Major Accident and they should form an integral part of any

emergency plan. In case of major fires, injuries will be the result of the effects of thermal

radiation to a varying degree, and the knowledge and experience to handle this type of

injuries cases may be generally available in most of the hospitals. But in case of major toxic

releases, the effects vary according to the chemical, which has leaked, and it is important for

health authorities that might be involved in dealing with the aftermath of a toxic release to

be familiar with the treatment appropriate to such casualties. Major Off-Site incidents are

likely to require medical equipment and facilities additional to those available locally and a

Medical 'Mutual Aid' scheme should exist to enable the assistance of neighboring

authorities to be obtained in the event of an emergency.




6.5.7 ROLE OF TELEPHONE DEPARTMENT

The communication system between the factory and the various above role-playing

authorities must be effective. The ineffective public telephone system will not be useful in

emergency. Therefore, telephone department should maintain the phones and if required

temporary telephone connection may be provided to various above authorities to deal the

emergency.

6.5.8 ROLE OF POLICE AND EVACUATION AUTHORITIES

• To protect life and property

• To control traffic movement

• To inform people to remain indoors or evacuate

• To carry-out evacuation

• To identify dead, deal with casualties and inform relatives of dead or injured.

For evacuation, the following criteria are useful:

a) In case of major fire, only houses close to fire and in the direction of smoke need

evacuation

b) If fire is escalating and in turn threatening a store of hazardous material, it is

necessary to evacuate people nearby if time is available; otherwise they should be

informed to keep themselves indoor and shield from the fire.

c) For release of toxic gases, limited evacuation may be appropriate in downwind

direction with windows closed and provides good protection. Toxic gases which are

hazardous down to much lower concentration cover a long distance. This factor

must be considered while deciding upon the need and extent of evacuation.

6.5.9 ROLE OF THE MUTUAL-AID AGENCIES

Mutual-aid arrangements shall be made in areas of fire & toxicity control, medical and

transport & evacuation. All partners of mutual-aid shall extend all possible help in these

areas.




6.6 OCCUPATIONAL HEALTH AND SAFETY

For large industries, where multifarious activities are involved during construction, erection,

testing, commissioning, operation and maintenance; the men, materials and machines are

the basic inputs. Along with the boons, industrialization generally brings several problems

like occupational health and safety. The industrial planner, therefore, has to properly plan

and take steps to minimize the impacts of industrialization and to ensure appropriate

occupational health and safety including fire plans. All these activities again may be

classified under construction and erection, and operation and maintenance.

6.6.1 OCCUPATIONAL HEALTH

Occupational health needs attention both during construction & erection and operation &

maintenance phases. However, the problem varies both in magnitude and variety in the

above phases.

6.6.1.1 CONSTRUCTION AND ERECTION

The occupational health problems envisaged at this stage can mainly be due to

constructional accident and noise. To overcome these hazards, in addition to arrangements

to reduce it within TLV's, necessary protective equipments shall be supplied to workers.

6.6.1.2 OPERATION AND MAINTENANCE

The problem of occupational health, in the operation and maintenance phase is primarily

due to noise which could affect consultation. The necessary personal protective equipments

will be given to all the workers. The working personnel shall be given the following

appropriate personnel protective equipments.

• Industrial Safety Helmet;

• Face shield

• Zero power plain goggles with cut type filters on both ends;

• Zero power goggles with cut type filters on both sides and blue color glasses;

• Welders equipment for eye and face protection;




• Cylindrical type earplug;

• Ear muffs;

• Canister Gas mask;

• Self contained breathing apparatus;

• Leather apron;

• Aluminized fiber glass fix proximity suit with hood and gloves;

• Boiler suit;

• Safety belt/line man's safety belt;

• Leather hand gloves;

• Asbestos hand gloves;

• Acid/Alkali proof rubberized hand gloves;

• Canvas cum leather hand gloves with leather palm;

• Lead hand glove;

• Electrically tested electrical resistance hand gloves; and

• Industrial safety shoes with steel toe.

6.6.1.3 HOSPITAL FACILITIES

It is proposed that client will make formal agreements with nearby hospital having facilities

to attend fire and toxic effect cases for attending the affected persons in the emergency

arising out of accidents, if any.

6.6.1.4 FACTORY MEDICAL OFFICER

A qualified doctor will be appointed as FMO on retainer ship basis. Apart from him,

Paramedical Staff will be employed.

6.6.1.5 PROPOSED FACILITY TO BE MADE AVAILABLE AT OHC

One Room is proposed to be provided to be operated as OHC. The centre will be equipped

with following medical equipments:—

1. Examination Table




2 . Dressing Tables For performing Dressing

3. Glucometer For measurement of Blood Sugar

4 . Vision chart To evaluate vision acuity

5. Nebuliser For relieving coughs & Breathing Difficulty

6. Infra red light for relieving muscular pain

7. Suction machine For cleaning airway

8. Autoclave machine For sterilizing cotton &dressing material

9. Weighing Machine For measuring body weight

10. Medical Oxygen Cylinder kit

11. Sphygmomanometer To measure blood pressure

12. Refrigerator To preserve medicines

13. Thermometer

6.6.1.6 AMBULANCE VAN

An ambulance van is proposed to be made available 24 hours at Fire Station.

6.6.1.6 FIRST AID BOX

First Aid Boxes are proposed to be made available at the different location in the plant,

Training to be given to employees for First Aid.

6.6.1.7 PERIODIC MEDICAL EXAMINATION

It is proposed that client will ensure that…

(1) Workers employed shall be medically examined by a qualified medical practitioner/

Factory Medical Officer, in the following manner:

(a) Once in a period of 6 months, to ascertain physical fitness of the person to do the

particular job;

(b) Once in a period of 6 months, to ascertain the health status of all the workers in

respect of occupational health hazards to which they are exposed and in cases where

in the opinion of the Factory Medical Officer it is necessary to do so at a shorter

interval in respect of any workers;




© In periodic and pre-medical examinations, various parameters will be checked. Viz.,

LIVER FUNCRION TESTS, Chest X-rays, Audiometry, Spirometry, Vision testing (Far &

Near vision, color vision and any other ocular defect) ECG and other parameters as will

be found necessary as per the opinion of Factory Medical officer.

(2) No person shall be employed for the first time without a certificate of granted by the

Factory Medical Officer.

6.6.1.8 EMP FOR THE OCCUPATIONAL SAFETY & HEALTH HAZARDS SO THAT SUCH

EXPOSURE CAN BE KEPT WITHIN PERMISSIBLE EXPOSURE LEVEL (PEL)/THRESHOLD

LEVEL VALUE (TLV) SO AS TO PROTECT HEALTH OF WORKERS

1.It is proposed to formulate and implement an EMP for Occupational Safety and Health

with following aims…

• To keep air-borne concentration of toxic and hazardous chemicals below PEL

and TLV.

• Protect general health of workers likely to be exposed to such chemicals

• Providing training, guidelines, resources and facilities to concerned

department for occupational health hazards.

• Permanent changes to workplace procedures or work location to be done if it is

found necessary on the basis of findings from workplace Monitoring Plan.

2.It is proposed that this EMP be formulated on the guidelines issued by Bureau of

Indian Standards on OH&S Management Systems: IS 18001:2000 Occupational

Health and Safety Management Systems

3. Proposed EMP will be incorporated in Standard Operating Procedure also.

4. The proposed EMP will also include measure to keep air-born concentration of toxic

and hazardous chemicals below its PEL and TLV, like…

a.Leak Surveys

b. Separate storage for toxic chemicals

c.Exhaust Ventilation

d. Proper illumination

e. On-line detectors toxic chemicals like Chlorine and Bromine

f.Close processes to avoid spills and exposures

g. Atomization of process operations to hazards of manual handling of chemicals




h. Supply of proper PPEs like Air mask, Berating canisters, SCBA sets, On-line

breathing apparatus at the places where there is possibility of presence of

toxic chemicals

i. Decontamination procedure for empty drums and carboys.

j. Regular maintenance program for pumps, equipment, instruments handling

toxic and corrosive chemicals

k. Display of warning boards

l. Training to persons handling toxic and corrosive chemicals

5. Workplace Monitoring Plan

• It is proposed that a Workplace Monitoring Plan to be prepared & implemented in

consultation with FMO and industrial hygienists.

• Each workplace must be evaluated to identify potential hazards from toxic substances

or harmful physical agents. Air-borne concentration of toxic chemicals will be

measured and record will be kept.

• The current state-of-the-art exposure measurement model is as follows: For purposes

of measuring worker exposure across a single shift it is sufficient t o place a

reasonably accurate exposure measuring device on the worker , within t he worker ’s

breathing zone, and have it operate for nearly the full shift. Client has been proposed

to study the exposure data when the plant is operative.

6. Health Evaluation of Workers

1. It is proposed that management will device a plan to check and evaluate the exposure

specific health status evaluation of workers

2. Workers will be checked for physical fitness with special reference to the possible

health hazards likely to be present where he/she is being expected to work before

being employed for that purpose. Basic examinations like Liver Function tests, chest

x ray, Audiometry, Spirometry Vision testing (Far & Near vision, color vision and any

other ocular defect) ECG, etc. will be carried out. However, the parameters and

frequency of such examination will be decided in consultation with Factory Medical

Officer and Industrial Hygienists.

3. While in work, all the workers will be periodically examined for the health with

specific reference to the hazards which they are likely to be exposed to during work.

Health evaluation will be carried out considering the bodily functions likely to be

affected during work. The parameters and frequency of such examination will be




decided in consultation with Factory Medical Officer and Industrial Hygienists. Plan

of monthly and yearly report of the health status of workers with special reference to

Occupational Health and Safety.

6.6.1.9 MEDICAL SURVEILLANCE PROGRAM

Pre-employment Medical Check Up

1. Chest X-ray

2. Cardiogram

3. Audiometry

4. Hematological Examination:- CBC, SGOT, SGPT, Cholesterol, Blood Sugar etc

5. Urine Examination

6. Vision test

7. Colour blindness test

8. Lung function test- Spirometry

Periodical Medical Check up

1. Lung Function test

2. Cardiogram

3. Audiometry

4. Hematological Examination

5. Urine examination

6. Vision test

7. Colour blindness test

8. Biomarker in Blood & Urine

TABLE-6.7 Occupational health impact on employees, control measures, action plan if

accident occur

Sr.

No.

Chemical Occupational health

impact on

employees

EMP/Measures to

keep

exposure below

TLV/ PEL

EMP for STEL & IDLH

1 Acetic Acid

Chronic respiratory

disease due to long

term exposure

inhalation Skin

disease due to skin

contact

Process enclosure,

Local exhaust, General

dilution ventilation,

Personal protective

equipments

Remove victim from the spillage

location into fresh air area. Small

spillage control absorb on paper

towel. Large spillage – Evacuate

area and stop source of ignition.

Dilute with water and collect

washed out water in tank and

neutralize it in safe manner.

2 Bromine May be fatal if

inhaled. Highly toxic

by inhalation,

ingestion or skin

contact. Causes

Provide exhaust

ventilation or other

engineering controls to

keep the airborne

concentrations of

Small Spill: Absorb with an inert

material and put the spilled

material in an appropriate waste

disposal.

Large Spill: Corrosive liquid.




severe burns.

Lachrymator. Typical

TLV 0.1 ppm. Typical

STEL 0.3 ppm. The

substance is toxic to

mucous membranes.

The substance may

be toxic to kidneys,

liver, cardiovascular

system, central

nervous system

(CNS), thyroid

vapors below their

respective threshold

limit value. Ensure that

eyewash stations and

safety showers are

proximal to the work-

station location.

Personal Protection:

Face shield. Full suit.

Vapor respirator. Be

sure to use an

approved/certified

respirator or

equivalent. Gloves.

Boots.

Poisonous liquid. Stop leak if

without risk. Absorb with DRY

earth, sand or other non-

combustible material. Do not get

water inside container. Do not

touch spilled material. Use water

spray curtain to divert vapor drift.

Use water spray to reduce

vapors. Prevent entry into

sewers, basements or confined

areas; dyke if needed. Call for

assistance on disposal. Be careful

that the product is not present at

a concentration level above TLV.

3 Dimethyl

formamide(DMF)

The substance is

toxic to kidneys,

liver, central nervous

system (CNS). The

substance may be

toxic to blood, the

nervous system.

Repeated or

prolonged exposure

to the substance can

produce target

organs damage.

Provide exhaust

ventilation or

other engineering

controls to

Keep the airborne

concentrations of

vapors below their




safety showers are


station location.

Flammable liquid. Keep away

from heat. Keep away from

sources of ignition. Stop leak if



combustible material. Do not

touch spilled material. Prevent

entry into sewers, basements or

confined areas; dyke if needed.

4 Ethyl Alcohol The substance is

toxic to blood, the

reproductive system,

liver, upper

respiratory tract,

skin, central nervous

Provide close process Flammable liquid. Keep away









5 Hydrochloric

Acid

Very hazardous in

case of skin contact

(corrosive, irritant,

permeator), of eye

contact (irritant,

corrosive), of

ingestion, Slightly

hazardous in case of

inhalation (lung

sensitizer). Non-

corrosive for lungs.

Liquid or spray mist

may produce tissue

damage particularly

on mucous

membranes of eyes,

mouth and

Provide close process

and scrubber on

process vent and

storage vent

Corrosive liquid. Poisonous liquid.

Stop leak if without risk. Absorb

with DRY earth, sand or other

non-combustible material. Do not

get water inside container. Do

not touch spilled material. Use

water spray curtain to divert

vapor drift.




respiratory tract. Skin

contact may produce

burns. Inhalation of

the spray mist may

produce severe

irritation of

respiratory tract,

characterized by

coughing, choking, or

shortness of breath.

Severe over-

exposure can result

in death.

6 Hexane The substance is

toxic to blood, the


liver, upper

respiratory tract,











7 Isopropyl alcohol The substance is

toxic to blood, the


liver, upper

respiratory tract,











8 Methanol The substance is

toxic to blood, the


liver, upper

respiratory tract,











9 Liq. Ammonia Very hazardous in

case of skin contact

(corrosive, irritant,

permeator),

Inhalation of the

spray mist may

produce severe

irritation

of respiratory tract,

characterized by

coughing, choking, or

shortness of breath.

Severe overexposure

can result in death.

Provide exhaust



keep the airborne

concentrations of

vapors below their




safety showers are


station location.

Dilute with water and mop up, or

absorb with an inert dry material

and place in an appropriate waste

disposal container. If necessary:

Neutralize the residue with a

dilute solution of acetic acid.

Corrosive liquid. Poisonous liquid.

Stop leak if without risk. Absorb

with DRY earth, sand or other

non-combustible material.

Do not get water inside

container. Do not touch spilled

material. Use water spray curtain

to divert vapor drift. Use water




The substance is

toxic to upper

respiratory tract

spray to reduce vapors. Prevent



Call for assistance on disposal.

Neutralize the residue with a

dilute solution of acetic acid.

10 ethylene

Chloride

CARCINOGENIC

EFFECTS: Classified +

(Proven.) by OSHA.

The substance is

toxic to lungs, the

nervous system,

liver, mucous

membranes, central

nervous system

(CNS).

Provide exhaust



keep the airborne

concentrations of

vapors below their




safety showers are

proximal to the

workstation location.

Personal Protection:

Absorb with an inert material and

put the spilled material in an

appropriate waste disposal. Be

careful that the product is not

present at a concentration level

above TLV

11 Pyridine Target organs: Liver,

kidneys, nerves,

Bone Marrow.

Persons with pre-

existing disorders

may be more

susceptible. This

Product has been

reported to be a

possible carcinogen.

Long-term exposure

may cause liver,

kidney or CNS

damage. Typical STEL

10 ppm. Typical PEL

15 ppm.

Use process enclosure,

local exhaust

ventilation, or other


control airborne levels

below recommended

exposure limits.

Facilities storing or

utilizing this material

should be equipped

with an eyewash

facility and a safety

shower. Ventilation

fans and other

electrical service must

be non-sparking and

have an explosion

proof design.

Absorb spill with inert material

(e.g. vermiculite, sand or earth),

then place in

Suitable container. Clean up spills

immediately, observing

precautions in the Protective

Equipment section. Remove all

sources of ignition. Use a spark-

proof tool. Provide ventilation.

Prevent spreading of vapors

through sewers, ventilation

systems and confined areas.

Evacuate unnecessary personnel.

Approach spill from upwind. Use

water spray to cool and disperse

vapors, protect personnel, and

dilute spills to form

nonflammable mixtures. Control

runoff and isolate discharged

material for proper disposal.

12 Thionyl Chloride Corrosive. Extremely

destructive to tissues

of the mucous

membranes and

upper respiratory

tract. Symptoms may

include burning

sensation, coughing,

wheezing, and

laryngitis, shortness

of breath, headache,

nausea and vomiting.

Inhalation may be

fatal as a result of

spasm inflammation

Use process enclosure,

local exhaust

ventilation, or other


control airborne levels

below recommended

exposure limits.



should be equipped

with an eyewash


shower. Use only under

a chemical fume hood.

Do not contact with water.

Ventilate area of leak or spill.

Wear appropriate personal

protective equipment as specified

in Section 8. Isolate hazard area.

Keep unnecessary and

unprotected personnel from

entering. Contain and recover

liquid when possible. Neutralize

with alkaline material (soda ash,

lime), then absorb with an inert

material (e. g., vermiculite, dry

sand, earth), and place in a

chemical waste container. Do not

use combustible materials, such




and edema of the

larynx and bronchi,

chemical

pneumonitis and

pulmonary edema.

as saw dust. Do not flush to

sewer.

14 Toluene The substance is

toxic to blood, the


liver, upper

respiratory tract,











15 Sulfuric Acid Prolonged or

repeated skin

contact may cause

dermatitis.

Prolonged or

repeated inhalation

may cause

nosebleeds, nasal

congestion, erosion

of the teeth,

perforation of the

nasal septum, chest

pain and bronchitis



should be equipped

with an eyewash


shower. Use adequate

general or local

exhaust ventilation to

keep airborne

concentrations below

the permissible

exposure limits. Use a

corrosion-resistant

ventilation system.

Clean up spills immediately,

observing precautions in the

Protective Equipment section.

Carefully scoop up and place into

appropriate disposal container.

Provide ventilation. Do not get

water inside containers. Cover

with dry earth, dry sand, or other

noncombustible material

followed with plastic sheet to

minimize spreading and contact

with water.

16 Aluminum

chloride

The substance is

toxic to lungs,

mucous membranes.

Repeated or

prolonged exposure


produce target

organs damage.

Repeated exposure

of the eyes to a low

level of dust can

produce eye

irritation. Repeated

skin exposure can

produce local skin

destruction, or

dermatitis. Repeated

inhalation of dust can

produce varying

degree of respiratory

irritation or lung

damage. Repeated

exposure to a highly

toxic material may

Produce general

deterioration of

Use process

enclosures, local

exhaust ventilation, or

other engineering

controls to keep

airborne levels below

recommended

exposure limits. If user

operations generate

dust, fume or mist, use

ventilation to keep

exposure to airborne

contaminants below

the exposure limit.

Corrosive solid. Poisonous solid.

Stop leak if without risk. Do not

get water inside container. Do

not touch spilled material. Use

water spray to reduce vapors.

Prevent entry into sewers,

basements or confined areas;

dyke if needed. Call for assistance

on disposal.




health by an

accumulation in one

or many human

organs.

17 EDC/ (1,2-

Dichloroethane)

The substance is

toxic to lungs, the

nervous system,

liver, mucous

membranes.

Repeated or

prolonged exposure


produce target

organs damage.

Repeated or

prolonged contact

with spray mist may

produce chronic eye

irritation and severe

skin

Irritation. Repeated

or prolonged

exposure to spray

mist may produce

respiratory tract

irritation leading to

frequent attacks of

bronchial infection.

Provide exhaust



keep the airborne

concentrations of

vapors below their




safety showers are


station location.

Flammable liquid. Corrosive

liquid. Keep away from heat.

Keep away from sources of

ignition. Stop leak if without risk.

Absorb with DRY earth, sand or

other non-combustible material.

Do not get water inside

container. Do not touch spilled

material. Use water spray curtain

to divert vapor drift. Prevent



Eliminate all ignition sources. Call

for assistance on disposal. Be



above TLV.

18 Nitric acid The substance may

be toxic to lungs,

mucous membranes,

upper respiratory p.

2 tract, skin, eyes,

and teeth. Repeated

or prolonged

exposure to the

substance can

produce target

organs damage.

Repeated or

prolonged contact

with spray mist may

produce chronic eye

irritation and severe

skin irritation.

Repeated or

prolonged exposure

to spray mist may

produce respiratory

tract irritation

leading to frequent

attacks of bronchial

infection.

Provide exhaust



keep the airborne

concentrations of

vapors below their




safety showers are


station location.

Corrosive liquid. Oxidizing

material. Poisonous liquid. Stop

leak if without risk. Absorb with

DRY earth, sand or other

noncombustible material. Do not

get water inside container. Avoid

contact with a combustible

material (wood, paper, oil,

clothing...). Keep substances

damp using water spray. Do not

touch spilled material. Use water

spray curtain to divert vapor drift.

Use water spray to reduce

vapors. Prevent entry into

sewers, basements or confined

areas; dyke if needed. Call for

assistance on disposal. Neutralize

the residue with a dilute solution

of sodium carbonate. Be careful

that the product is not present at

a concentration level above TLV.

19 Phenol The substance may Use process Corrosive solid. Stop leak if




be toxic to kidneys,

liver, central nervous

system (CNS).

Repeated or

prolonged exposure


produce target

organs damage.

Repeated p. 2

exposure of the eyes

to a low level of dust

can produce eye

irritation. Repeated

skin exposure can

produce local skin

destruction, or

dermatitis. Repeated

inhalation of dust can

produce varying

degree of respiratory

irritation or lung

damage. Repeated

exposure to a highly

toxic material may

produce general

deterioration of

health by an

accumulation in one

or many human

organs.

enclosures, local

exhaust ventilation, or

other engineering

controls to keep

airborne levels below

recommended

exposure limits. If user

operations generate

dust, fume or mist, use

ventilation to keep

exposure to airborne

contaminants below

the exposure limit.

without risk. Do not get water

inside container. Do not touch

spilled material. Use water spray

to reduce vapors. Prevent entry

into sewers, basements or


Eliminate all ignition sources. Call

for assistance on disposal. Be



above TLV.

20 Chlorine Toxic by inhalation.

Irritating to eyes,

respiratory system

and skin. Very toxic

to aquatic organisms.

Use only with adequate

ventilation. Use

process enclosures,

local exhaust



keep worker exposure

to airborne

contaminants below

any recommended or

statutory limits.

Immediately contact emergency

personnel. Keep unnecessary

personnel away. Use suitable

protective equipment. Eliminate

all ignition sources if safe to do

so. Do not touch or walk through

spilled material. Shut off gas

supply if this can be done safely.

Isolate area until gas has

dispersed.

6.6.2 SAFETY PLAN

Safety of both men and materials during construction and operation phases is of concern.

Safety plan shall be prepared and implemented in the proposed project activity. The

preparedness of an industry for the occurrence of possible disasters is known as emergency

plan. The disaster in the plant is possible due to collapse of structures and fire/explosion etc.




• The proposed project would formulate safety policy keeping in view the safety

requirement during construction, operation, maintenance phases, with the following

regulations:

• To allocate sufficient resources to maintain safe and healthy conditions of work;

• To take steps to ensure that all known safety factors are taken into account in the

design, construction, operation and maintenance of plants, machinery and equipment;

• To ensure that adequate safety instructions are given to all employees;

• To provide wherever necessary protective equipment, safety appliances and clothing

and to ensure their proper use;

• To inform employees about materials, equipment or processes used in their work

which are known to be potentially hazardous to health or safety;

• To keep all operations and methods of work under regular review for making

necessary changes from the point of view of safety in the light of experience and up to

date knowledge;

• To provide appropriate facilities for first aid and prompt treatment of injuries and

illness at work;

• To provide appropriate instruction, training, retraining and supervision to employees in

health and safety, first aid and to ensure that adequate publicity is given to these

matters;

• To ensure proper implementation of fire prevention methods and an appropriate fire

fighting service together with training facilities for personnel involved in this service;

• To organize collection, analysis and presentation of data on accident, sickness and

incident involving people injury or injury to health with a view to taking corrective,

remedial and preventive action;

• To promote through the established machinery, joint consultation in health and safety

matters to ensure effective participation by all employees;

• To publish/notify regulations, instructions and notices in the common language of

employees;

• To prepare separate safety rules for each type of occupation/processes involved in a

plant; and

• To ensure regular safety inspection by a competent person at suitable intervals of all

buildings, equipments, work places and operations.




6.6.3 SAFETY ORGANIZATION

Construction and Erection Phase

A qualified and experienced safety officer shall be appointed. The responsibilities of the

safety officer include identification of the hazardous conditions and unsafe acts of workers

and advice on corrective actions, conduct safety audit, organize training programs and

provide professional expert advice on various issues related to occupational safety and

health. He is also responsible to ensure compliance of Safety Rules/ Statutory Provisions.

Operation and Maintenance Phase

When the construction is completed the posting of safety officers shall be in accordance

with the requirement of Factories Act and their duties and responsibilities shall be as

defined there of.

6.6.4 SAFETY CIRCLE

In order to fully develop the capabilities of the employees in identification of hazardous

processes and improving safety and health, safety circles would be constituted in each area

of work. The circle would consist of about five to six employees from that area. The circle

normally shall meet for about an hour every week.

6.6.5 SAFETY TRAINING

Safety training shall be provided by the Safety Officers with the assistance of faculty

members called from Professional Safety Institutions and Universities. In addition to regular

employees, limited contractor labors shall also be provided safety training. To create safety

awareness safety films shall be shown to workers and leaflets shall be distributed.

Some precautions and remedial measures proposed to be adopted to prevent fires are:

• Compartmentalization of cable galleries, use of proper sealing techniques of cable

passages and crevices in all directions would help in localizing and identifying the area

of occurrence of fire as well as ensure effective automatic and manual fire fighting

operations;

• Spread of fire in horizontal direction would be checked by providing fire stops for cable

shafts;




• Reliable and dependable type of fire detection system with proper zoning and

interlocks for alarms are effective protection methods for conveyor galleries;

• Housekeeping of high standard helps in eliminating the causes of fire and regular fire

watching system strengthens fire prevention and fire fighting; and

• Proper fire watching by all concerned would be ensured.

6.6.6 HEALTH AND SAFETY MONITORING PLAN

The health of all employees shall be periodically monitored for early detection of any

ailment due to exposure to heat and noise.

6.7 TRAINING, REHERASAL & RECORDS

6.7.1 NEED OF TRAINNING & REHEARASAL

Training is important in order to –

• Teach worker’s how to handle chemicals safely, how to act as a runner/messenger, how

to use PPE, how to start and shut down the plant, how to carry out emergency repairs

etc.

• Teach one to be a safe and alert worker.

Rehearsal is essential for -

• Explaining and making key personnel and essential workers aware of their role in

case of an emergency.

• Testing the emergency procedure, emergency arrangements and ability of all

involved with it to grasp the procedure and implement the same.

• Testing the effectiveness of communication system including the alternative

arrangement in case of failure.

• Testing the speed of mobilization of resources, search, rescue and treatment of

casualties, emergency isolation and shut down.

• Detecting the shortcomings in the emergency plan and incorporating remedial

measures.




• Allowing professional emergency services to test their parts of the plan and testing

co-ordination.

• Building confidence in workers which is helpful in facing real situations.

Training shall be given to regular employees and contract personnel also. Effective and

latest teaching aids will be used to train workers and supervisory staff. Such training courses

shall be conducted once in a year and co-ordination with offsite personnel shall be sought

during such training. Records will be maintained for training.

6.7.2 SOME CHECK POINTS

Following points can be checked at the time of training/assessing the adequacy of the

Emergency Plan.

� Does the plan cover the range of incidents that can realistically be anticipated?

� Have the consequences of the various incidents considered been adequately assessed?

� Are there sufficient resources in terms of personnel and equipment on the site to carry

out the Emergency Plan for the various incidents in conjunction with the public

emergency services?

� Have the time scales been assesses correctly?

� Is there a logical sequence of actions for each person given a role in the plan? Whether

key personnel, especially the nominated incident controllers, consulted in the

preparation of the plan?

� Is there 24 hours cover, to take account of absences due to sickness and holidays,

minimum shift manning, operator only periods, silent hours, shutdown periods, only

security personnel being present, or for unmanned sites etc.?

� Is there satisfactory co-operation with the local emergency services and district

emergency planning officers?

� At sites where an off-site plan to protect people and the environment outside the site in

the event of an incident is appropriate what is the procedure for initiating the off-site

plan and is this satisfactory?




6.7.3 RECORDS AND UPDATING THE PLAN

All records of On-Site and Off-Site Emergency Plan and modifications by experience and

suggestion, the rehearsals and conclusions of such plans and the enquiries shall be well

maintained and preserved. The necessary data bank shall be also maintained for the utility

of industries and others. New information and the deficiencies identified during the

rehearsal is reviewed and incorporated in the document for continual up dating of the plan

and such information shall be communicated to the concerned authorities.

6.8 HAZOP STUDY

6.8.1 OBJECTIVE

For identifying cause and the consequences of perceived mal operations of equipment and

associated operator interfaces in the context of the complete system. It accommodates the

status of recognized design standards and codes of practice but rightly questions the

relevance of these in specific circumstances where hazards may remain undetected.

6.8.2 PURPOSE OF HAZOP

It emphasizes upon the operating integrity of a system, thereby leading methodically to

most potential and detectable deviations which could conceivably arise in the course of

normal operating routine

- including "start-up” and "shut-down" procedures

- as well as steady-state operations.

It is important to remember at all times that HAZOP is an identifying technique and not

intended as a means of solving problems nor is the method intended to be used solely as an

undisciplined means of searching for hazardous scenarios.




Subsystems of interest line and valve, etc

Equipment, Vessels

Modes of operation Normal operation

Start -up mode

Shutdown mode

Maintenance /construction / inspection mode

Trigger events Human failure

Equipment /instrument/component failure

Supply failure

Emergency environment event

Other causes of abnormal operation, including

instrument disturbance

Effects within plant Changes in chemical conditions

Changes in inventory

Change in chemical physical conditions

Hazardous conditions Release of material

Changes in material hazard characteristics

Operating limit reached

Energy source exposed etc.

Corrective actions Change of process design

Change of operating limits

Change of system reliability

Improvement of material containment

Change control system

Add/remove materials

How would hazardous During normal operation

Conditions detected? Upon human failure

Upon component failure

In other circumstances

Contingency actions Improve isolation

Improve protection

6.8.3 FEATURES OF HAZOP STUDY

6.8.4 HAZOP STUDY PROCEDURE

• Procedure in HAZOP study consists of examining the process and instrumentation (P&I)

line diagram, process line by process line.

• A list of guide words is used to generate deviations from normal operation

corresponding to all conceivable possibilities.

• Guide words covering every parameter relevant to the system under review i.e. flow

rate and quality, pressure, temperature, viscosity, components etc.

• Flowchart for application of HAZOP is shown in figure.




FIG. 6.4 HAZOP STUDY PROCEDURE




FIG.6.5 HAZOP STUDY FLOW CHART




GUIDE WORDS

NONE No forward flow when there should be

MORE More of any parameter than there should be, e.g. more

flow, more pressure, more temperature, etc.

LESS As above, but "less of" in each instance

PART System composition difference from what it should be

MORE THAN More "components" present than there should be for

example, extra phase, impurities

OTHER What needs to happen other than normal operation, e.g.

start up, shutdown, maintenance?

NONE e.g., NO FLOW caused by blockage; pump failure; valve

closed or jammed: leak: valve open; suction vessel empty;

delivery side over - pressurized: vapor lock; control failure

REVERSE e.g., REVERSE FLOW caused by pump failure: NRV failure or

wrongly inserted; wrong routing; delivery over pressured;

back- siphoning; pump reversed

MORE OF e.g., MORE FLOW caused by reduced delivery head ; surging

; suction pressurized ; controller failure ; valve stuck open

leak ; incorrect instrument reading.

MORE OF MORE TEMPERATURE, pressure caused by external fires;

blockage ; shot spots; loss of control ; foaming; gas release;

reaction; explosion; valve closed; loss of level in heater; sun.

LESS OF e.g., LESS FLOW caused by pump failure; leak; scale in

delivery; partial blockage ; sediments ; poor suction head;

process turndown.

LESS e.g., low temperature, pressure caused by Heat loss;

vaporization; ambient conditions; rain; imbalance of input

and output; sealing; blocked vent.

PART OF Change in composition high or low concentration of mixture;

additional reactions in reactor or other location; feed

change.

MORE THAN Impurities or extra phase Ingress of contaminants such as

air, water, lube oils; corrosion products; presence of other

process materials due to internal leakage ; failure of

isolation ; start-up features.

OTHER Activities other than normal operation start-up and

shutdown of plant ; testing and inspection ; sampling ;

maintenance; activating catalyst; removing blockage or scale

; corrosion; process emergency ; safety procedures activated

; failure of power, fuel, steam , air, water or inert gas;

emissions and lack of compatibility with other emission and

effluents.




6.8.5 PROCESS HAZARD AND ITS CONTROL

Parameter Guide

Word

Name of

hazardous

process

and

operation

Possible causes Possible

consequences

Measures

safeguard

Action Require

Distillation

Temp. More Distillation Good Heating 1. No process hazards.

It is part of the

requirement.

2. It will accelerate the

distillation process.

1. Temperature

gauge &

pressure

gauge

provided.

2. Sight glass

provided.

3. Safety valve

provided .

4. Cooling &

chilling

arrangement

with

alternative

provided.

1. Non return Valve to be provided.

2. Arrow indicator to be provided on

pipeline.

3. Stand by pump to be provided.

4. Pump, storage tank & pipe line

identification to be done.

5. Color code to be provided.

6. Periodic checking of the condenser

to be followed.

Less Poor Heating No distillation will

take place. Process

delayed.

Pressure More Not Possible --

Less Not Possible --

Flow More Not Possible --

Power

Failure

No GEB Supply Distillation will not

achieve.

D.G.Set

provided.

Raw material to the storage tank ( Day Tank ) - Transferring

Flow

Pressure

No Transferrin

g of Raw

material to

the Storage

Tank

1. No material

in the

storage tank.

2. Pump

tripped.

3. Pump

discharge

valve closed.

4. Heavy

leakage in

pipe line or

chocking the

pipeline.

No material to service

tank.

Pressure gauge

provided on the

pump discharge

valve.

pipeline

arrangement

with alternative

provided.

1. Non-returnable Valve to be

provided.

2. Arrow indicator to be provided on

pipeline.

3. Stand by pump to be provided.

4. Pump, storage tank & pipe line

identification to be done.

5. Color code to be provided.

6. Work permit procedure to be

followed for handling of

hazardous chemicals.

7. PPE compliance to be followed

during handling of acid.

More 1. Valve opened

more than

set value

2. Human Error.

More material to the

service tank.

Reverse Not possible

Less SOP to be prepared.




Transferring of Raw material from storage tank to Process vessel

Temp. More Transferri

ng of Raw

material

from the

Storage

Tank to

Process

Vessel

1. Seasonal effect

2. Poor insulation of

pipeline.

3. Falling of hot

water on

uninsulated

line.

4. Incoming

material from

storage tank

itself has high

temperature.

1. More pressure in the

pipeline may give rise

to leakage.

2. From poor flange joints,

valve. Fire & health

hazards.

Insulation on

pipeline &

batch tank

provided.

1. Considering this sufficient

quantity of water shall

be ensured.

2. All flange joints shall be

checked regularly.

Less 1. Seasonal effect

2. Leakage of chilled

water from

tank.

No workplace Hazards. Safety valve

provided on

batch tank.

Pressure More 1. N2 pressures

more.

2. Valve failure

3. FIC mal function.

4. Human error.

1. Pressure rise in batch

tank.

2. Leakage in flange joint.

3. Safety valve of batch tank

may popup.

4. Tank filling operation

completed in less

time.

Pressure gauge shall be

provided on batch tank.

Less 1. Low pressure of N2

itself.

No safety hazards but it will

take more time for filling

operation.

Flow More Same as

Pressure

Same as Pressure Same as Pressure

Less 1. Choking in the

excess flow

valve. (Holes are

choked.)

2. Low pressure of N2

itself.

3. Valve choked.

No safety hazards but it will

take more time for filling

operation.

Reverse No chances 1. NRV

provided.

2.Auto shut

off valve

provided.




Transferring of Raw material from storage tank to Process vessel

Temp. More Transferri

ng of Raw

material

from the

Storage

Tank to

Process

Vessel

5. Seasonal

effect

6. Poor

insulation of

pipeline.

7. Falling of hot

water on

uninsulated

line.

8. Incoming

material

from storage

tank itself

has high

temperature

.

3. More pressure in

the pipeline may

give rise to

leakage.

4. From poor flange

joints, valve. Fire

& health

hazards.

Insulation on

pipeline & batch

tank provided.

3. Considering this sufficient quantity

of water shall be ensured.

4. All flange joints shall be checked

regularly.

Less 3. Seasonal effect

4. Leakage of

chilled water

from tank.

No workplace

Hazards.

Safety valve

provided on

batch tank.

Pressure More 5. N2 pressures

more.

6. Valve failure

7. FIC mal

function.

8. Human error.

5. Pressure rise in

batch tank.

6. Leakage in flange

joint.

7. Safety valve of

batch tank may

popup.

8. Tank filling

operation

completed in less

time.

Pressure gauge shall be provided on

batch tank.

Less 2. Low pressure of

N2 itself.

No safety hazards but

it will take more time

for filling operation.

Flow More Same as

Pressure

Same as Pressure Same as Pressure

Less 4. Choking in the

excess flow

valve. (Holes

are choked.)

5. Low pressure of

N2 itself.

6. Valve choked.

No safety hazards but

it will take more time

for filling operation.

Reverse No chances 3. NRV provided.

4.Auto shut off

valve

provided.




6.8.6 PLANNING FOR HAZOP

• Safety procedures documents

• Relief/venting philosophy

• Chemical involved

• Piping specifications

• Carry out the study

• Record the results

• Follow-up of actions noted

1. Final report contains resolution of all recommended actions.

2. Must appoint someone as leader to check progress of action.

3. Team may meet again if answers to questions do not simply lead to an action.

Team may meet again if significant design changes in interim report.




CHAPTER – 7:

ENVIRONMENTAL MANAGEMENT PLAN

7.1 BACKGROUND

The industry has adopted a comprehensive Environmental Management Plan (EMP) which

covers several environmental protection measures, not only for abatement of

environmental pollution resulting from the project, but also for the improvement in the

ambient environment. The various components of the EMP are outlined in subsequent

sections. An EMP is a site-specific plan developed to ensure that all necessary measures are

identified and implemented in order to protect the environment and comply with

environmental legislation.

7.2 OBJECTIVES OF ENVIRONMENTAL MANAGEMENT PLAN

The Environment Management area is handled by a Qualified Manager with adequate

training and experience in operation of ETP and management of other pollution control

measures. He is assisted by a Qualified Executive and one operator (in each shift) to run ETP

and other pollution control system.

All the necessary controls w.r.t. management of Liquid / Hazardous / Gaseous pollutants are

exercised.

For all liquid effluents, full fledged effluent treatment plant consisting of primary, secondary

and tertiary treatment will be installed to ensure adequate treatment.

Process stacks will be equipped at safe height with scrubbers where required to ensure

emissions within prescribed limits.

To handle hazardous waste as per Hazardous and other Wastes (Management and

Transboundary Movement) Rules, 2016 by MoEFCC. Hazardous waste will be disposed off

to/at registered re-processor / registered vendor / cement industries / common Incinerator

/ common secured land fill facility.

• Fixed gas detection system will be installed in the workplace area.




• Work place monitoring will be carried out regularly through continuous 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.

7.3 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, M/s. Nutraplus India Ltd. (Unit-2) will assign responsibilities

to officers from various disciplines to co-ordinate the activities concerned with management

and implementation of environment control measures. An organogram of Environment

management cell is shown in Figure 7.1. This department will undertake the monitoring of

environment pollution level by measuring stack emissions, Ambient air quality, water and

effluent quality, Noise level, etc. either departmentally or by appointing external agency

whenever necessary. M/s. Nutraplus India Ltd. (Unit-2) will have its own laboratory

equipped with different equipment for environmental monitoring.

M/s. Nutraplus India Ltd. (Unit-2) 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 will be

taken through the concerned plant authorities. The actual operation and maintenance of

pollution control equipment of each department will be under respective department

heads.

The environmental department will also look after preparation and submission of Water

Cess Return, Environmental statement and Consolidated Consents & Authorization




application/ renewal under water (Prevention and Control of Pollution) Act, 1974, Air

(Prevention and Control of Pollution) Act, 1981, Ambient Air Quality as per NAAQS

Standards, 2009 and Hazardous & Other Wastes (Management and Transboundary

Movement) Rules, 2016 under Environment Protection Act, 1986.

FIGURE - 7.1

ORGANOGRAM OF ENVIRONMENT MANAGEMENT CELL

DIRECTOR / CEO

GENERAL MANAGER

MANAGER / ASST. MANAGER

EXECTUTIVES / OFFICERS

OPERATORS




7.3.1 ENVIRONMENT POLICY

FIG.7.2




7.3.2 CORPORATE ENVIRONMENT RESPONSIBILITY

• To develop & to promote the technology having minimum pollution of Air, Water &

Land.

• Educating & promoting staff & workers for creating safe working atmosphere.

• More & more tree plantation in the surrounding open area within site.

7.3.3 MANAGEMENT RESPONSIBILITY

• CEO will be overall responsible for effective implementation of Occupational Health,

Safety & Environment Management System (HSEMS).

• Core Committee will conduct management review every Six months to assess the

effectiveness of HSE Management System. If necessary the committee will allocate

resources for taking Corrective and Preventive action on Non-Conformance.

• The Core Committee will advise and monitor the establishment and implementation

of HSEMS

• HODs, Dept. in-charges, Supervisors, are responsible for implementing HSE

Management Programs. Safety Officer to lead the programme. All the employees are

responsible for implementing and maintaining HSE Management System.

• HODs are responsible to define and monitor the key characteristics for measure of

performance in HSE. HODs are responsible for control of all the documents and data

as per the requirement of ISO-14001 and OHSAS 18001

• Verification activities, including internal HSE Audits, are carried out at the direction of

Core committee and team of Internal Auditors.

The organization structure of M/s. Nutraplus India Ltd. (Unit-2), Plot No. C-198, Saykha

Industrail Estate, TAL: Vagra, DIST. Bharuch will be as per Organization Chart. The Roles,

responsibilities, accountabilities and authorities of key personnel is defined in the

following paragraphs:




ROLE – 1: GENERAL MANAGER (OPERATION HEAD)

RESPONSIBILITIES:

• He is responsible for entire activities of Unit.

• He is responsible to define HSE policy and ensure that this policy is understood,

implemented and maintained at all levels in the organization.

• He is also responsible to provide adequate resources for achieving improved

Occupational Health Safety and environmental performance

• He is responsible for setting organizational HSE objectives and targets.

• He is also responsible to review HSE management system at appropriate intervals, to

ensure its continuing and effectiveness. Monitoring of effectiveness of the system shall

be done through Management Reviews

• He is also responsible to appoint Management Representative and extend support and

resources in implementing HSE management system.

• He is responsible for procurement of raw material (Indigenous & Imported) and

engineering goods as per the specifications

• He is overall responsible to ensure that legal requirements are met as per the legal

register.

• Review the implementation of HSE Management System and its effectiveness, at

appropriate intervals, to ensure continual improvement of the organization’s overall

performance

In absence of General Manager, other unit’s Operations Head oversees his functions. CEO

also may look into the delegation of authority, during his absence.

ACCOUNTABILITY

He is accountable for all operations being carried out in the organization. His scope of

accountability in terms of HSE is as follows




1. Establishment, operation and maintenance of ISO 14001 and OHSAS 18001 systems

in all spheres of manufacturing site.

2. Review of performance and progress of the management systems by periodic

review through Management review.

3. To ensure availability of resources essential to establish, implement, maintain and

improve the HSE management system.

MRM INCLUDES

1. The AMR shall obtain the findings of statutory inspection and testing reports from

concerned departments and present in the management review meeting for

discussion and action

2. The minutes of the Management Review Meeting are recorded and circulated to all

members of the HSE Apex Committee.

Assistant MR shall prepare minutes of meeting within two days after the meeting. He shall

ensure that the review outputs are recorded in the “Action decided” column of format of

Minutes of Management review meeting.

7.4 ENVIRONMENT MANAGEMENT PLAN

The Environment Management plan is meant for mitigation/ management of the adverse

impacts and the strengthening positive impacts during proposed project. Environment

Management Plan is tabulated in Table:-7.1

7.4.1 CONSTRUCTION PHASE

During Construction Phase sanitation facilities will be required. Temporary facilities shall be

made available to construction personnel. Necessary PPE’s shall also be provided.

• Sanitation




The site should be provided with adequate and suitable sanitary facilities to maintain proper

standard of hygiene for construction workers. These facilities should include water supply,

sanitary toilets, rest room, etc.

• Noise Environment

Noise effect on the nearly habitation during construction activities will be negligible as the

nearest habitat is more than 3 km from the plant. However, construction labor would be

provided with noise protection devises like ear muffs and occupational safety ware, as per

requirement. And noise generating equipment shall be stopped during night hours.

• Construction Equipment & Waste

The waste oil generated by construction equipment, if any, would be disposed through

authorized recyclers and unauthorized dumping of waste oil shall be avoided. Other wastes

shall be disposed-off by adopting environmentally compatible methodology.

• Storage of Hazardous Materials

The hazardous material such as lubricating oils, compressed gases (for welding), paints,

varnishes, etc. are required to be stored at the site during construction phase. Since, these

materials are hazardous in nature; they shall be stored as per the prescribed / accepted

safety norms.

• Solid / Hazardous Waste Disposal

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

specified under Hazardous and Other Wastes (Management and Transboundary Movement)

Rules, 2016 by MoEFCC. 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. Rags could be laundered for reuse.

� Vehicle maintenance area to be selected properly, to prevent contamination of soil

and ground water by accidental spillage of oil, and other wastes

TABLE:-7.1

ENVIRONMENT 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, incineration

facility, re-cyclers, re-processors.

Effluent generation and

treatment

Effluent treatment plant will be provided for treatment of

wastewater.

Emission from stack Adequate pollution control systems will be provided for

control of gaseous emission.

• Adequate stack height for better dispersion of

pollutants

• Scrubbers at Process Vents

Noise Acoustic enclosure on DG 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 32% of the plant area will be developed as greenbelt.

Information and awareness

about hazardous chemicals

plant

Awareness and information will be provided within 10 km

of the study area about the hazardous situations.

Preparedness to handle onsite Onsite & Offsite Emergency Management Plan is prepared




& offsite emergency

Monitoring of Environmental

parameters

Regular monitoring of various environmental parameters

will be carried out to check the effectiveness of the control

system.

7.4.2 WATER ENVIRONMENT

Water requirement will be met through GIDC Water supply. However, record of water

consumption for different usages should be maintained.

Water Pollution and Its Mitigation Plan

Total water requirement will be 154 m3/day (57 Fresh + 97 Recycled) which will be met

through GIDC water supply.

The wastewater generation will be 102 m3/day.

High COD stream (27.0 m3/day) from process will be treated in MEE plant with solvent

stripper.

Low COD stream from, Process, Boiler, Cooling, Washing/ & Domestic effluent (74 m3/day)

will be sent to proposed ETP consists of primary, secondary & tertiary treatments. To

achieve the Zero Liquid Discharge, Treated effluent from ETP (74.0 m3/day) shall be treated

in R.O. plant. Then R.O. permeate (52.0 m3/day) shall be reused in Boiler and Cooling while,

R.O. reject (21 m3/day) shall be treated in MEE Plant & salt will be sent to TSDF site for

disposal. MEE Condensate 44.0 KLD will be reuse in Industrial Purpose.

Domestic wastewater will be added in biological treatment of ETP.

Scrubbing media will be reuse in plant premises and sent to end users having Rule-9

permission.

Construction Phase

• The drinking water and sanitation facilities at the project site will be available to the

construction work force. This is necessary to reduce pollution of any receiving water

body and also to prevent hazards due to water borne vectors.

Operation Phase

• Annual environmental audit will be carried out every year from recognized

environmental auditor.




• Records of analysis results of treated and untreated wastewater along with MLVSS in

aeration tanks will be maintained.

• Adequate spares for effluent collection, handling, treatment and disposal system will be

maintained.

• Proper housekeeping will be adopted to prevent spillages and contaminated surface

runoff going to storm water drains.

• The following measures will be taken to minimize the water usage in the operational

phase:

� Endeavor to reduce the actual process water consumption by way of improvement

in operation of processing units.

� Water saving by shower head flow controls, spray taps and faucet aerators and

photo-sensitive taps.

7.4.3 AIR ENVIRONMENT

M/s. Nutraplus India Ltd. (Unit-2) proposes Bulk Drugs And Bulk Drug Intermediates Plant at

Plot No. C-198, Saykha Industrail Estate, TAL: Vagra, DIST. Bharuch, Gujarat. The source of

air pollution due to the project is Flue gas & Process Emissions. There will be emission from

Boiler (2 Nos.), Thermopack Bioler (1 no.), D.G. sets (1 Nos.) and Process vents (3 Nos.). To

control the emission from stack & process vents, adequate air pollution control equipments

are installed i.e. Cylcone separator with bag filter and scrubber, Two Stage Scrubber (Water

+ Alkali), Two Stage Alkali Scrubber & Two Stage Ammonia Scrubber. The baseline ambient

air quality monitoring is carried out during study period (March, 2017 to May, 2017) around

Project site (within the study area), clearly reveals that the concentrations of PM10, PM2.5,

SO2, NOX, HCl, Cl2, O3, Pb, CO, NH3, C6H6, Benzo (a) Pyrene (BaP), Arsenic (As), Nickel (Ni) &

VOCs are well within the prescribed limits as per the National Ambient Air Quality Standards

for residential & Industrial.

• The major sources of air emission from the proposed project are:

1. Non point sources emissions

2. Point source emissions

3. Fugitive emissions




7.4.3.1 ACTION PLAN TO CONTROL AMBIENT AIR QUALITY AS PER NAAQES STANDARDS:

Control Measures:

The design stage endeavors to mitigate the problems related to environment and health at

the process technology/ source level itself. Besides standards, emphasis would be given to

comply with all design standards/ regulatory norms as specified by CPCB/MoEFCC/GPCB,

etc. Following measures would be taken right from the design stage to ensure compliance

with applicable regulatory standards:

• Under normal circumstances, there will be no continuous release of volatile hydrocarbon

streams. However, if during start-up/ shut down or an emergency situation any hydrocarbon

stream is released, the same will be directed to an elevated flare for complete combustion.

This will eliminate the possibility of forming an explosive mixture due to sudden release of

un-burnt hydrocarbons to the atmosphere.

Construction Phase (Non point sources emissions)

Generation of suspended particulate matter is a common phenomenon due to

transportation of constructions materials. This will be mitigated by allowing the vehicles

entering the premises under cover. Emission of fugitive dust due to movement of heavy

vehicles etc. will be controlled by spraying water in the affected zone. Hosing down the

wheels of the vehicles with water and providing washing troughs for them further mitigates

the amount of dust generated. In addition, emission of other pollutants from construction

machinery using diesel driven prime movers will be controlled by proper maintenance.

Operation Phase (Point sources emissions)

In-plant Control Measures: Some of the mitigation measures, which reduce the impact on

air environment, are as follows:

• Ensuring the operations of various process units as per specified operating guidelines/

operating manuals.




• Strict adherence to maintenance schedule including lubrication for various machinery/

equipment.

Emission at M/s. Nutraplus India Ltd. (Unit-2) is in the form of the gas emission from

Boiler (2 Nos.), Thermopack Boiler (1 no.), D.G. sets (1 Nos.) and Process vents (3 Nos.).

To control the emission from stack & process vents, adequate air pollution control

equipments are installed i.e. Cylcone separator with bag filter and scrubber, Two Stage

Scrubber (Water + Alkali), Two Stage Alkali Scrubber & Two Stage Ammonia Scrubber.

Moreover, regular monitoring of stacks will be carried out to check the emissions.

Record will be maintained for changing of scrubbing media on printed logbook. In case

emissions exceed, the corrective measures should immediately be taken and records of

the same should be maintained.

• Regular ambient air quality monitoring will be carried out within premises and will also

carried out in the nearby area for PM10, PM2.5, SO2, NOx & VOCs.

• A greenbelt around the factory will be developed for reducing the air pollution and

attenuation of noise.

• Adoption of good house-keeping.

7.4.3.2 INFORMATION FOR CONTROL OF FUGITIVE EMISSIONS

The emissions are normally defined as emissions to the atmosphere resulting from leaking

piping sources and equipments 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 will be

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. will be the

major sources of fugitive emissions of organic chemicals and VOCs. Excess use of solvent

may also results fugitive emission from the process vessels.




The above will be controlled by having proper scrubbing system, boiler stacks will be

provided with cyclones/bag filters to take care of particulate matter, Condenser to trap

VOC, solid raw material charging will be done through closed system. Proper maintenance

schedule will be adhered to avoid emissions through flange joints, pump seals etc. Proper

gland packing will always be maintained for pumps and valves and to the extent possible

pumps are with mechanical seal.

M/s. Nutraplus India Ltd. (Unit-2) will have fully closed system. Adequate dust collector will

be installed for control of fugitive emission during loading of raw material and product.

Condenser will be provided to trap VOC. All the Flange joints of the pipe lines which carry

solvents will be covered with flange guards. All the rotating equipments like pumps will be

installed with Mechanical Seals to arrest any sort of emissions. VOC detectors will be

installed at various places to identify any fugitive emissions. A regular preventive

maintenance schedule will in place to replace or rectify all gaskets and joints etc as a part of

ISO systems to ensure no fugitive emissions will take place.

Following measures will be adopted to prevent and control fugitive emissions:

1. Airborne dust at all transfers operations/ points will be controlled either by spraying

water or providing enclosures.

2. Care will be taken to store construction material properly to prevent fugitive

emissions, if any.

3. Adequate ventilation will be provided.

4. Regular maintenance of valves, pumps, flanges, joints and other equipment will be

done to prevent leakages and thus minimizing the fugitive emissions of VOCs.

5. Entire process will be carried out in the closed reactors with proper maintenance of

pressure and temperature.

6. Periodic monitoring of work area will be carried out to check the fugitive emission.

7. Breather valves will be provided on solvent tanks.

8. Solvent tank vents will be connected to vent chillers.

9. To eliminate chances of leakages from glands of pumps, mechanical seal will be

provided at all solvent pumps.




10. Stand by pumps will be provided on all scrubbers. Besides, scrubbers will be

equipped with on-line pH meter with hooter system for better operational control.

11. Close feeding system will be provided for centrifuges. Centrifuge and filtrate tank

vents will be connected to vent chillers.

12. Minimum number of flanges, joints and valves in pipelines.

13. Regular inspection of floating roof seals and proper preventive maintenance of roofs

and seals for tanks

14. Fugitive emission over reactors, formulation areas, centrifuges, chemical loading,

transfer area, are collected through hoods and ducts by induced draft and

controlled by scrubber/ dust collector.

15. Dedicated scrubbers will be provided for fugitive emissions control

16. For dust emissions, cyclones / bag filter will be provided.

17. Emphasis will be given to solvent management / solvent loss prevention.

18. Enclosures to chemical storage area, collection of emission from loading of raw

materials in particular solvents through hoods and ducts by induced draft, and

control by scrubber / dust collector to be ensured.

19. Nitrogen blanketing will be provided besides special care needs to be taken for

control in respect of odorous chemicals.

7.4.4 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 is given for implementing noise control

measures. Comprehensive measures are taken at design stage for noise from proposed unit.

The measures are as under:

• The noise level at the plant boundary will be restricted to 75 dB(A) during day time and

70 dB(A) during night time.




• Noise level will be specified for various rotating equipment as per Occupational Safety

and Health Association (OSHA) standards.

• Erection of suitable enclosure, if required, to minimize the impact of high noise

generating sources.

• There may be small addition to the ambient noise level, due to the increased

transportation activities. This will create a slight adverse impact on the sound

environment.

• Regular oiling, lubrication and maintenance of the equipment will be carried out to

minimize noise generation.

During Construction Phase

Following measures will be taken for abatement of noise during construction phase:

• Noise emissions from construction equipment will be kept to a minimum by regular

maintenance.

• Heavy and noisy construction jobs will be avoided during night hours.

Following measures will be adopted for abatement of noise during operation phase:

• Acoustic laggings, enclosures and silencers will be provided wherever necessary for high

noise generating equipment.

• Sound proof glass paneling will 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 will be done.

• Use of personal protective devices such as ear-muffs and ear-plugs will be strictly

enforced.

• Acoustic barriers / shelter will be developed in noisy workplaces.

• Noise generating sources in the plant areas will be monitored regularly. Monitoring of

ambient noise levels should also be carried out regularly both inside the premises as well

as outside the greenbelt.

During Operation Phase




The volume of transport vehicles to be handled is very low. The company will develop a

green belt around the periphery of the premises, which acts as a barrier to the propagation

of noise from the factory premises. This shall further reduce the noise levels appreciably.

• It is recommended to measure and maintain records of noise level at various places

within and outside factory premises.

• Manufacturers/ suppliers of major noise generating equipment/ machines like

compressors, turbines, generators will be asked to take required measures for

minimizing the noise levels generated by machines by using noise absorbing material

for various enclosures or using appropriate design/ technology for fabricating/

assembling the machines.

• Audiometric tests will be conducted periodically for the employees working close to

the high noise sources.

7.4.5 LAND ENVIRONMENT

7.4.5.1 HAZARDOUS WASTE MANAGEMENT

Twenty Five types of hazardous wastes will be generated from the Proposed Project.

Treatment, Storage & Disposal mode for the same will be followed as per Hazardous and

Other Wastes (Management and Transboundary Movement) Rules, 2016 by MoEFCC.

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.

Storage of Hazardous Waste:

• Hazardous waste will not be stored for a period more than 90 days and records will be

maintained.

• Will be Stored at a designated Onsite-secured area with impervious floor that affords

protection from sun & rain fall, spreading of leachate, mixing of wastes etc.

Transportation of Hazardous Waste:

• Properly packed & labeled waste transport through dedicated vehicle to a captive

facility/ authorized TSDF facility.




Disposal of Hazardous Waste:

Twenty Five types of Hazardous/Solid Wastes shall be generated from this Unit.

• Used Lube Oil will be Collected, Stored, Transported & Disposed by selling to GPCB

Authorized Recyclers.

• Discarded Drums, Containers, Discarded Liners & Cardboards will be Collected,

Stored, Decontaminated & Transported back to the supplier for reuse or sold to

GPCB authorized vendor.

• Spent catalysts will be Collected, Stored, Transported & send back for regeneration

or return to suppliers or sent to common incineration facility.

• Process/ Distillation Residue, Spent Carbon will be Collected, Stored, Transported &

Disposed by co-processing or sent to common incineration facility.

• ETP Sludge, Spray Dryer Salt will be Collected, Stored, Transported & Disposed at

TSDF Site.




FIG.7.3 HAZARDOUS WASTE PREMISES

Solid Waste Contaminated with

Hazardous Material:

Use Proper Decontamination

Process treatment separately and

recycle/reuse/sell only

Hazardous Wastes (HWs) generated from the Premises

Properly Segregate, Label and store in Roofed

Designated secured storage area with impervious

Flooring & Leachate Management System as per

the Guidelines

Leachate to ETP for

further treatment

Use proper safety and

personal protective

equipment while

handling HWs

Disposable HWs of

Secured TSDF:

ETP Sludge, Waste Residue

Containing Oil, Flue gas

cleaning residue, Scrubber

sludge, Spray Dryer Salt,

Incinerable HWs:

Process Waste, Distillation

Residues, Spent Carbon,

Spent Catalyst

Reusable,

Recyclable,

Recoverable HWs:

Used Oil, Discarded

drum/ Containers of

PP/HDPE bags/Liners

TSDF Site

Common Incinerator

Site Reuse/recycle within the plant premises offer necessary

treatment (if required)

OR

Sell to the authorized reprocessor/ recyclers/ end users




7.4.5.2 IDENTIFICATION OF RECYCLE/REUSE, CLEANER PRODUCTION AND CO-PROCESSING

OPTION OF HAZARDOUS WASTE

• It is recommended to analyze each hazardous waste periodically and maintain records.

• Check the calorific value of the ETP Sludge, Process/ Distillation Residue, Spent Carbon ,

Spent Catalyst and then explore possibilities of Co-Processing in Cement Industry as

Primary fuel. Waste materials used for co-processing are referred to as alternative fuels

and raw materials (AFR).

1. On-site recovery of solvent in distillation column. Recovered solvent will be recycled

back for re-use and residue will be sent for incineration.

2. Second wash of plant/ equipment will be re-used as first wash in the same equipment/

reactor to reduce fresh water consumption.

3. Reduce water consumption by proper housekeeping, utilizing low-flow, drip or

micro-spray irrigation systems and technologies that reduce water loss.

4. Repairing leaks to pipes, glands, seals and gaskets can significantly reduce energy

costs.

7.4.5.3 PLAN FOR MANAGEMENT OF LEAKAGE, SPILLAGE, SCRUBBING MEDIA &

OCCASSIONAL REACTOR WASHING


• Do not touch damaged containers or spilled material unless wearing appropriate

protective clothing.


• As per Haz Chem code information material will be contained or diluted.

• The diluted material will be collected/ stored separately/treated in ETP

• Contained material will be collected /Stored/ disposed at TSDF site.

• Scrubbing Media/occasional reactor washing will be collected/treated in ETP.




7.5 GREEN BELT DEVELOPMENT

Tree plantation is known for improving the aesthetic and climatological environment of an

area and properly designed green belt can help in ameliorating air pollution to a very

significant degree. It should be borne in mind that the green belt will be most effective as a

sink for particulate matter and gaseous emissions from ground level sources, such as,

fugitive emissions. Effectiveness of green belt for the elevated sources is rather limited but

its action as a green lung greatly helps in improving the air quality of the area. However,

considerable scope exists for strengthening the existing green belt and developing the same

in future.

BREAK UP OF DIFFERENT LAND USE OF FACTORY

Total 16067 sq. meter land area is available at site; out of this area about 5300.36 sq. meter

(33 %) area will be developed as greenbelt and other forms of greenery.

A green belt with width of min. 1 meter shall be developed within the site boundary and

across the premises inside roads. Trees like Asopalav, Neem, Gulmohar, Champa, Gauva,

Babul, Palm Trees, Nariyal, Ghaneri, Shevga, Jangli badam, Sag, Jamun, Mango, Rain tree

etc. shall be planted in and around the site.

Green Belt to Trap and Absorb Pollutants

A green belt traps and absorbs pollutants without altering the biogeochemical cycle of

water and nutrients. Absorption and trapping capacity of trees depend on height of plant,

canopy structure, physiognomy and morphological character of leaf. Once fully developed,

such tree plantations can serve as buffer and shock absorber against transient and

accidental release of pollutants caused by power, equipment and human failures. Green belt

is usually designed in such a way that the first few rows in a green belt have a shorter height

and dense canopy. Plants native to an area are generally used to suit the prevailing

ecosystem and biogeochemical cycle. Native plants are more tolerant to disease, grow at a

faster rate and result in better attenuation of pollutants.

Plantation Design




In view of the different functional requirements of the plant in an industrial area, the

pattern of plantation within plant is discussed as below:

A. Curtain Plantation

To help in restrict the movement of pollutants from inside to outside and from outside to

inside, a thick green belt shall be developed at the peripheral limits of the plant along the

boundary walls whenever feasible. The curtain will be an effective buffer against gases, dust

and noise.

B. Avenue Plantation

Linear plantations along road-sides help reduce air and noise pollution from automobiles as

well as general emissions from the industrial units. To combine bio-aesthetic and pollution

abatement needs, parallel rows of trees (inner and outer rows) shall be planted on the roads

and boundary.

C. Field Plantation

Plantation on the open stretches of land helps improve the general ecological conditions of

the habitat by adding greenery to the landscape and by providing a vast canopy of foliage

for sink of pollutants generated in the area. The open land spaces, not used for industrial

purposes, shall be filled with plant species.

D. Ornamental Plantation

The immediate area of each building shall be arranged into a lawn, fringed by flower beds.

In some strategic corners flowering climbers been used to highlight the visual effect.

Plantation Details

Actual Status of Plantation/Green Belt

Trees species to be planted at plant are in line with trees species recommended in CPCB’s

guidelines for developing Greenbelts. For plantation at the plant in future, it is suggested




that these guidelines should also be followed for selecting pollutants tolerant and absorbent

species.

(a.) Species of tree planted

Green Belt Avenue Trees Shrubs

Above 3m height Below 3m height

Jamun Alstonia Bamboo Pentas var.

Gulmohar Pinkcaassia Bahunia Galphemia

Peltophorum Spethodia Large stomia Miniature bamboo

Kasid Paras, papal Cordia Jestropha

Gultora Pendula Karen Hibiscus var.

Karen Gulmohar Gulltora Braya

Kapop Jackranda Tecoma var. Palmbago capensis

Neem Bignonia Tagari Acalypha var.

Arjun Largestomia Russolia

Sisoo Cadamba Duranta var.

Australian babul Lantana var.

Babul Cassia biflora

Pangara Ixora var.

Cassia fistula Cana

(b.) Co-relation of Trees with pollution control

Trees Air pollution Dust Noise Salt

Trees Pangara Karen Pendula Neem Neem

Babool Pendulla Bahunia Peltophorum Gulmohar

Cadamba Neem Paras pipal Jamun

Tecoma var. Bogunvelia Cassia fistula Pendula

Alstonia Spethodia

Jackranda Gulmohar

Places: Green-Belt Plant Area Plant Area Plant Area Plant Area




And green

belt

GREEN BELT DEVELOPMENT PROGRAMME

YEAR NO. OF TREES/PLANTS TO BE

PLANTED IN PLANT AREA

2016-2017 200

2017-2018 200

2018-2019 100

2019-2020 25

2020-2021 25

7.6 OCCUPTIONAL HEALTH AND SAFETY

Health hazards associated with the occupation are called occupational hazards. Due to

handling of toxic and hazardous chemicals there are possibilities of developing occupational

diseases. M/s. Nutraplus India Ltd. (Unit-2) shall carry out the following checks to curb the

problem:

i) Pre - employment medical check up at the time of employment.

ii) Annual medical check up shall be done for all employees.

iii) First aid training shall be given to the employees.

iv) Monitoring of occupational hazards like noise, ventilation, chemical exposure shall

be carried out at frequent intervals, the records of which shall be documented.

OHC Room will be provided at Security building. Professional doctor will be called every

week at factory. And routine checkup of all employees will be carried out annually for all

standard tests needed as per Factory Inspector Office. Employees will be trained frequently

through special master faculties on various points related to occupational health to create

more awareness on the subject. All precautions shall be taken to avoid foreseeable

accidents like spillage, fire and explosion hazards and to minimize the effect of any such

accident and to combat any emergency at site level. Some of the preventive safety




measures shall be taken to minimize the risk of accident with respect to Technical Safety,

Organizational Safety and Personal Safety are listed below:

• Company shall take all reasonably practicable measures to minimize the risk of such

accident in compliance with the legal obligation under the relevant safety.

• All building plans and installations shall be as per relevant acts and duly approved by

competent government authorities.

• Process and Equipment shall be designed by qualified and experienced professionals

and fabricated to applicable national / international codes with stage wise

inspection.

• Pressure Relief Valves and rupture disks shall be installed on the reactor and jackets

wherever required.

• Hazardous processes shall be operated by trained workers and shall be looked after

by qualified & experienced supervisors.

• Safety features such as fire extinguishers, fire hydrant system and suitable Personal

Protective Equipment (PPE) shall be provided. Regular operations and testing of fire

hydrant system and fire extinguishers shall be carried out.

• Suitable provisions for control of critical process / storage parameters within

specified safe limits (use of pressure relief valves, rupture discs, safety valves, trip

circuits, wherever necessary) shall be done.

• Use of flameproof electrical equipment, flame arresters and breather valves shall be

done.

• Provision of Earthing and lighting arrestor to prevent electrical fires and explosions in

flammable / explosive chemicals storage / processing areas shall be done.

• Tanks storing hazardous liquid chemicals shall be provided with dyke wall to confine

any spillage and facilitate easy collection. Necessary separation distance shall be

maintained.

Personal Protective Equipment (PPE) like goggles, safety shoes, helmet, apron, earplugs,

facemask & clothing shall be provided to employees as per the job requirements. The




company shall prepare a comprehensive on-site emergency plan with well-defined

responsibilities to face any eventuality caused under adverse circumstances and unforeseen

reason.

7.7 MEASURES FOR CONSERVATION OF ENERGY

M/s. Nutraplus India Ltd. (Unit-2) shall adopt various measures for energy conservation:

• Energy efficient machineries will be used during operation phase.

• Installation of economizer & high efficiency burner on steam boilers

• Enough care will be taken to prevent/minimize energy losses at each stage.

• Energy audit will be used as a tool for monitoring purpose.

• External lights will be controlled through timers for auto on/off function based on

timings.

• The cable size will be selected so as to minimize the power losses.

• The power factor improvement capacitors will be provided individually for AC loads.

• Using water cooled chillers, variable frequency drives for secondary pumps and

public area and building management system for HVAC equipments with non-CFC

and non-HCFC based refrigerants.

• Use of VFDs for various utilities in variable load application to optimize pump and air

handling unit performance, wherever required.

• Automated day light control.

• Efficient lamps and ballasts.

• Automated control for external lighting (Astronomical/Sensor)

• Occupancy Sensors.

• Phase-wise implementation of Advance Process Control (APC) in the process plants

• Replacement of conventional lighting fixture by more energy efficient fittings.

• Installation of improved insulation over the High Pressure (HP) steam line to reduce

the heat loss.

• Use of FRP blade on Cooling Tower

Company shall explore possibility of use of solar energy for various infrastructure

operations. Also use of Energy Efficient Lighting, Transformers, Use of Energy Efficient




Motors, electrical appliances to minimize the energy consumption in addition to Process

Planning.

7.8 NATURAL RESOURCES CONSERVATION

The substances that are found in nature and are used by the man for his welfare directly or

indirectly are called as natural resources. Sun, wind, soil, fossil fuels, wood, forest, flora and

fauna are some of the examples of natural resources. The judicious or wise use of natural

resources in such a way that the present generations make use of natural resources without

compromising the needs of the natural resources for the future generation is called

as conservation of natural resources.

Conservation of Natural Resources

As natural resources are beneficial to human beings, maintain ecological balance and at the

same time are in a threat of getting depleted due to its indiscriminate over exploitation,

there is an urgent need for conservation of natural resources. This can be accomplished by

the following ways:

• Alternative forms of energy such as solar energy etc. shall use more in comparison to

fossil fuels. Alternative forms of energy are eco-friendly, do not cause pollution and are

renewable.

• Avoid using plastics, synthetic materials etc as these materials cause damage to the soil.

• Water is precious natural resources and hence avoids wasting water. Taps shall be

closed when not in use.

• Adopt 3 R's for conservation viz, Re-use, Reduce and Re-cycle.

• Trees shall be planted along roadsides, railway tracks and waste lands and deforestation

should be avoided.

• Don't waste electricity. Fans and lights shall be switched off when not in use.

7.9 SKILLED AND TRAINED MANPOWER

Employment would be as per prevailing norms of state government for skilled and trained

people for the proposed project. M/s. Nutraplus India Ltd. (Unit-2) will give employment to

about 100 Employees (Including Contract Workers).




7.10 SOCIO-ECONOMIC DEVELOPMENTAL ACTIVITIES

Apart from business, M/s. Nutraplus India Ltd. (Unit-2) shall be devoted to social

commitments and will continue to do the same as per the needs of nearby village people.

For Corporate Social Responsibility, Various Programs/ Projects related to Social & Economic

development of surrounded area has been planned, which are as follows, Planned for

providing Water purifier for Village people, conducting medical camps for Cataract

operation, pregnant women check up & Senior Citizen Check-up, deputing teacher for

literacy development to Senior Citizens. Other such activities as stated as below:

A) Natural Resource Management – The main focus of this program will be to maximize the

yield returns of the farmers through efficient management of existing resources & extension

of new agricultural practices.

1) Integrated Agricultural Growth Project – For improvement and use of the modern

techniques and thereby would certainly contribute to prosperity in the agriculture

sector and reduce the rural poverty by programs like Farmers Training, Nursery

Growing Trainings, Modern agriculture equipment distribution programs etc.

2) Animal Husbandry Projects – Various programs like health checkups & treatment,

vaccination program, Anti sterility camps, breed improvement etc. will be carried

out.

B) Income Generation Program -

1) Establishment of Self help groups

2) Rural Entrepreneurship Development Program

3) Handcrafts Development Program

4) Vocational Training

5) Business process outsourcing

C) Health, Education & Infrastructure

1) Aids Awareness Program

2) General Health Camps

3) Innovative Teaching Methods

4) Adult Education

5) Sanitation




6) Infrastructure Development Projects

TABLE :7.2

FUND FOR CSR ACTIVITIES

Activities: 2020 2021 2022 2023 2024 TOTAL

Education/

Vocational skills /

livelihood

enhancement in

Government School

150000 160000 200000 200000 250000 960000

Eradicating Hunger,

Poverty & Health

Care in Keshrol

Village, Juned Village,

Bhersam Village,

Kothia Village

50000 50000 65000 75000 85000 325000

Plantation of trees in

Saykha Industrial

Estate around

Roadside

600000 600000 600000 600000 750000 3150000

Donation of Trusts

(Sri. Uma Vikas &

Charitable Trust

300000 400000 550000 550000 600000 2400000

Eye camp and eye

surgeries in the poor

class at Keshrol

Village, Juned Village,

Bhersam Village,

Kothia Village

400000 400000 400000 400000 400000 2000000

Total CSR Spending

1500000 1610000 1815000 1825000 2085000 129670000

7.11 SOLVENT RECOVERY PLAN

Name of Solvent Total Solvent

Input Kg

Qty of Solvent

Recycled Kg

Qty of Losses

Kg

%

Recov

ery

%

Loss

Hexane 1.26 1.2 0.06 95 5




IPA 7.73 7.11 0.62 92 8

EDC/MDC 2.43 2.38 0.05 98 2

Methanol 61.32 58.37 2.95 95.2 4.8

Acetone 11.12 10.27 0.85 92.5 7.5

Toluene 37.1 35.808 1.292 96.51 3.48

SOLVENT MANAGEMENT PLAN

• All the solvents shall be directly distilled from high COD effluent with the help of

Solvent Stripper and Distillation.

• Pure solvent, crude solvent and distilled (recovered) solvent shall be stored only in

storage tanks.

• Wherever required, the solvents shall be directly pumped into day tanks from the

storage tanks and shall be charged into the reactors without involving any manual

handling.

• All the pumps shall be mechanical seal type to avoid any leakage of solvent.

• All necessary fire fighting systems shall be provided with alarm system. Flame proof

wiring and flame proof electrical accessories shall be provided to avoid any mishap.

• All the storage tank and day tank shall be connected to a vent system through

cooling water and chilled brine condensers to prevent loss of solvents in the

atmosphere.

• All the distillation column vents are also connected to cooling water/ chilled brine

condensers for maximum possible recovery of the solvents.

• All the vents will be connected to a common carbon Adsorber for removing traces of

solvent from vent gases.

• Residue generated from the distillation will be incinerated in-house or sent to BEIL

incinerator site.




• Coolant to be used




Solvent

Main

Storage

Tank

Addition

Tank

Reaction

Mass

With

Solvent

Receiver

Distilled

Solvent

Solvent

Distillation

System

Recycle

Organic

Layer/spent

solvent to recovery

System


CHW

in

CHB. In

C.W. Out

CHB. Out

CHB. Chilled Brine

CHW Chilled Water

Distillation

Column




7.12 VOC MONITORING PLAN

FIG. 7.4 VOC Control Mechanism




Atmospheric distillation of Solvents:

Primary Condenser HE-01 Cooling Tower water will be used to condense

the solvents and the non condensed vapors

will be condensed in a Secondary Condenser

Secondary Condenser HE-02 Chilled water at 6 0C will be used to condense

the non condensed vapors in the Secondary

Condenser

VOC Trap Condenser HE-03 Chilled Brine at -35 0C will be used to trap any

traces of Solvent which is slipped from

Secondary condenser

Vacuum distillation of Sol vents:

Primary Condenser HE-01 Cooling Tower water or Chilled water will be

used to condense the solvents depend on the

vapor pressure at its operating conditions and

the non condensed vapors will be condensed in

a Secondary Condenser

Secondary Condenser HE-02 Chilled Brine at -17 0C will be used to condense

the non condensed vapors in the Secondary

Condenser

VOC Trap Condenser HE-03 Chilled Brine at -35 0C will be used to trap any

traces of Solvent which is slipped from

Secondary condenser

Notes 1 Normal Operating pressure for all vacuum

distillations for solvents is 100 mmHg (Hence

No Solvent escapes from the VOC vent Trap)




Notes 2 A TIC (Temperature Indicator and Controller) is

placed at the outlet of Secondary Condenser

vent gasses line and a set point (just above

room temperature) will be put to control

heating of the Reactor. If Vapor temperature at

TIC is more than set point automatically the

Heating media Valve to the reactor will be shut.

Hence the system itself will ensure no vapor is

escaping without condensing.

FIG. 7.5 PROCESS VENTS CONTROL MECHANISM




Gasses like HCl and SO2 evolve during Reactions. All such gasses will go to Scrubbing system.

Before going to Scrubbing system these gasses will pass through a Primary and Secondary

Condensers to remove Solvents and put it back into the reactor. Then the gasses free of

solvents will go to a VOC trap where traces of VOC will be recovered and then go to

Scrubbing system.

Scrubbing system will consist of Primary Scrubber (water) and secondary Scrubber (Caustic).

And a Tertiary Scrubber consists of Lean Caustic solution (This solution will be used in

Secondary Scrubber for the next batch). The final process vent will be from tertiary

scrubber.

7.13 ODOUR CONTROL PLAN

Measures for Control of Odour Nuisance

The chemicals used or manufactured at M/s. Nutraplus India Ltd. (Unit-2) at Saykha

Industrail Estate do not release any disagreeable Odour. However if any spillage or leakage

of such chemicals are taken place then following material handling procedures will be

followed to reduce the ODOUR and release of chemical vapors in atmosphere.

Procedure for Unloading Chemicals from Tankers

When a liquid is transferred from one container to another the air from the receiving

container is displaced to atmosphere and the air from atmosphere is sucked into the

container from which the material is transferred.

The air released from receiving container is contaminated with vapours of the liquid being

transferred. To avoid this release of vapors into atmosphere, the contaminated air from

receiving tank is let into the tanker from where the material is transferred with help of a

designated pipe line called as pressure equalization line or vent equalization line. The

system has been depicted in the following drawing




FIG. 7.6

Procedure for transferring chemicals from one tank to another tank or reactor.

The same technique of pressure equalization is used for transfer of liquid from one tank to

another tank or reactor to reduce the release of vapors to atmosphere. The system has

been depicted in the following drawing

Spill control measures

The accidental spills of chemicals are handled in a systematic manner to reduce the Odour:




1. The area where the chemical spillage can take place is covered with appropriate

adsorbent material like soda ash, saw dust or even an earth using all necessary

Personal Protective equipment (PPE).

2. The adsorbent spread is carefully collected in closed container and transferred to

incinerator for destruction.

3. Contaminated area is then cleaned with soap and water and the water used is

transferred to ETP.

4. Masking agents (e.g. PIION, ECOPEARL) spray is then used to reduce the impact of

lingering odours.

7.14 METHODOLOGY OF DE-CONTAMINATION AND DISPOSAL OF DISCARDED

CONTAINERS AND ITS RECORD KEEPING

Decontamination & Disposal of Discarded Containers: The proper disposal of empty

chemical containers is more important for hazardous chemicals as it can contain residual

amounts of chemicals. There can be no more than 1 inch of material left in the container not

more than 3% by weight of the containers capacity. In an effort to ensure that this residue is

handled properly and to be able to recycle or properly dispose of these containers, the

following procedure is to be followed. The below guidelines are useful for non hazardous

chemicals also.

Rinse Procedure: An empty chemical container that contains hazardous chemicals (liquid or

solid), must be rinsed 3 times with water (or appropriate rinsing agent) before being

discarded. The first rinse should be collected as chemical waste, it can be put into any waste

container of compatible chemicals, the second & third rinses can then go down to drain. If

the chemical is on the list of acutely hazardous waste, then all three rinses must be

collected. For solvents or other volatile liquids like benzene, toluene, etc. (not in the list of

acutely hazardous waste) should not be rinsed with water. They are to be placed into an

operating fume hood overnight without the cap to allow the vapors to disperse. After the

containers are rinsed, they can be discarded appropriately as described below. All caps

should be let off of the discarded containers. Containers should be labeled with “Empty”




labels and the chemical name should be crossed or blacked out prior to being discarded.

Caps may be discarded to regular trash.

Reuse /Recycle/ Disposal of cleaned containers:

• All chemicals must follow the above rinse except the volatile Solvents & before being

discarded in any form.

• Metal containers or any plastic containers, plastic tubing or plastic beakers that do not

meet the recycling criteria can be discarded into regular trash.

• Glass containers, glass tubing that do not meet the recycling criteria should be placed into

trash can for disposal.

• Plastic & glass containers that meet the recycling criteria must be placed in appropriate

recycling containers.

• Empty compressed gas cylinders should be returned to vendor.

7.15 TECHNICAL DETAILS OF THE PLANT/S ALONG WITH DETAILS ON BEST AVAILABLE

TECHNOLOGIES (BAT)

We have vast experience of adopting technology which is available in the market by the

following procedure.

1) On the basis of our past experience of this industry we propose to go ahead with the API

which we can manufacture & sale comfortably with our existing Infrastructure.

2) Once we decide to go ahead with particular API manufacturing we search the technology

availability from market from various companies either by the way of purchase or procure

by our professional contacts.

We procure the technology from 2 to 3 sources which is manufacturing the same product

and start laboratory trial in our laboratory.

3) We take nearly 10 to 20 batches in lab in combination of process what we have received

and standardize the process in lab and also being tested as per the international standard

norms.




4) We do the primary comparison of process & its discharge; yield & costing of 100 grams

batch of above API and take many batches.

5) Once it is through we proceed for the pilot trial (Kilo lab) having all infrastructure in our

available company units.

6) After establishing process in pilot plant we do the techno-economic viability of the

product and its capacity to manufacturing the product.

7) Firstly we procure 2-3 MT Raw material for the commercial batches; we take commercial

batch in our spare capacity in existing plant.

8) On completion of commercial trials we again do the process comparison in terms of yield

costing, discharges, By-products recoveries & quality of the products as per IP, BP & USP.

9) After studying techno economic viability, safe operating parameters, total minimized

effluent load and the require capital investment with respect to viable qty of the project

considering the Indian requirement as we are not concentrating on export as there is big

potential in our country.

10) Normally for FDA license for the addition of product take max 1 month so we complete

the formality before we procure the commercial batch.

11) Since we are already marketing many APIs so we exist in a almost all formulation

companies in India so it is easy for us to enter in the market with new product with viable

qty.

12) The recent development in API slides small scale is not getting viable because of many

reasons like

I) Volume of Operation and capital investment requirement as per required guideline.

II) Process Development infrastructure in terms of process, establishment, operating

viable qty, pollution load and safety analysis.

III) The industry trend is that all formulation companies come for the audit of the API

mfg facility as per the current guideline and small scale to face this audit by

providing SCH M, GMP, WHO compliance and safety audit.

IV) The Biggest advantage of API industry is by introducing GST because there were so

many small. API industry in the country where mfg, Selling , Formulation and




payment of API being done in Black Market . This business is stopped after

introducing GST. After GST the price raise in the API market by 15-25% of all APIs, so

being medium scale we have given the project is having excellent potential with

regulatory compliance.

Company is also planning to project the products in regulatory market of Europe and

America & and by taking necessary regulatory compliance as per above countries so the

plant what we are planning is as per the international standard.

Example-BAT and Competition

Product -1 Nimesulide

- We enter into this product in year 2011 when there were 7 manufacturers of this product.

- We did many process modifications by permutation & combination of various processes &

Parameters & develop in C-2 process which reduces time cycle, less effluent & better

Yields.

- We use mainly ANFD in the process so that product handling becomes very easy which is

very specialized Equipment develops by our in-house Facility. In our all process we use

ANFD.

- By adopting developed best available technology of Nimesulide we have become so

competitive that for six months we sold the material at lowest cost in the market and that

is how only two manufacturer remain in the market and other scale companies had to

discontinue the product .

- Conclusion is by adopting combination of process and in C-2 process development and by

using ANFD in the process time cycle is reduced, effluent is reduced man power handling

is reduced, power cost reduced, contamination of foreign particle reduced and since all

API consumed flammable solvent the use of ANFD increases the almost safety and Health

Hazard during the process.




Following are our API portfolio of products where we are strong and have adopted the

above procedure successfully in launching all products.

Sr.

No.

PRODUCTS MFG SINCE YEARS PROCESSS MODIFIED BY BAT

1 NIMESULIDE 06 YES

2 ACECLOFENAC 03 YES

3 MAFENAMIC ACID 02 YES

4 ALBENDAZOLE 01 YES

5 SATRANIDAZOLE 17 YES

6 TRAMADOL HCL 03 YES

7 M- BROMO ANISOLE 10 YES

8 DOXOPHYLLINE 05 YES

9 DICLOFENAC SODIUM 03 YES

10 LUMEFANTRINE 03 YES

7.16 CAPITAL COST FOR ENVIRONMENTAL MANGEMENT

Total Project Cost for proposed project activity is Rs. 55 Crores. Capital cost of air & water

pollution control system and environmental monitoring equipments will be Rs. 6 Crores.



EIA Report prepared by: M/s. Aqua-Air Environmental Engineers Pvt. Ltd 546

CHAPTER – 8:

EXECUTIVE SUMMARY & CONCLUSION

8.1 Project Description

M/s. Nutraplus India Ltd. (Unit-2) proposes Bulk Drugs And Bulk Drug Intermediates

Plant at Plot No:C-198, Saykha Industrail Estate, Tal: Vagra, Dist: Bharuch, Gujarat. The

total area of the premises is 16,067 m2 only. Total cost of the Project will be Rs. 55

Crore.

LIST OF PRODUCTS ALONG WITH PRODUCTION CAPACITY

SR.

NO

.


CAPACITY

(MT/MONTH)

END USE

1 IBUPROFEN 15867-27-1

400

Anti-Inflammatory

2 DICLOFENAC SODIUM 15307-79-6 ''

3 ACECLOFENAC 89796-99-6 ''

4 NIMESULIDE 51803-78-2 ''

5 CHLORZOXASONE 95-25-0 ''

6 MEFENAMIC ACID 61-68-7 ''

7 MESALAMINE 89-57-6 ''

8 ALBENDAZOLE 54965-21-8 Anti-Worm medication

9 FEBENDAZOLE 43210-67-9 Anti-Trematode therapeutic

10 MEBENDAZOLE 31431-39-7 Anti-Worm medication

11 METRONIDAZOLE 443-48-1 Antibiotics

12 METRONIDAZOLE

BENZOATE

22916-47-8 ''

13 TINIDAZOLE 19387-91-8 ''

14 ORNIDAZOLE 16773-42-5 ''

15 OXYCLOZANIDE 2277-92-1 Anthelmintic

16 ROXARSONE 121-19-7

17 CHLORPHENIRAMINE

MALEATE (C.P.

MALEATE)


18 BROMHEXINE HCL 611-75-6 Antioxident/Expectorant

19 AMBROXOL HCL 23828-92-4 Secretolytic

20 PHENYLEFFRINE HCL 61-76-7 Decongestant

21 DEXO METHERPHAN HBR 6700-34-1 Antihistamines




22 SALBUTEMOL SULPHATE 51022-70-9

23 THEOPHYLLIN 58-55-9 Xanthines

24 CAFFEIN 58-08-2 Ergotamine

25 THEOBROMINE 83-67-0 Vasodilator

26 CIPROFLOXACIN 85721-33-1 Antibiotics

27 OFLAXACIN 82419-36-1 ''

28 ENROFLOXACIN 93106-60-6 ''

29 SILDINAFIL CITRATE 171599-83-

0

pulmonary arterial

hypertension

30 TRAMADOL HCL 27203-92-5 Analgesic

31 LUMEFANTRINE 82186-77-4 Antimalarial

32 ALUMINIUM HYDROXIDE

GEL/POWDER

21645-51-2 Antacid

33 AMPICILLIN 69-53-4 Antibiotics

34 AMOXICILLIN 26787-78-0 ''

35 CLOXACILLON 61-72-3 ''

36 CEPHALEXIN 15686-71-2 ''

TOTAL 400

MT/MONTH

8.2 Description of the Environment

BASELINE ENVIRONMENTAL STATUS

AIR ENVIRONMENT

Several meteorological parameters effect the dispersion of pollutants in the

atmosphere, some are enlisted here

• Temperature

• Inversion Level

• Wind speed & Direction

• Mixing Depth

Collected ambient air samples are analyzed for Respirable Suspended Particulate Matter

(RSPM-PM2.5), Suspended Particulate Matter, Nitrogen Dioxide (NO2), Respirable

Suspended Particulate Matter (RSPM-PM10), Ammonia (NH3), Sulphur Dioxide (SO2),

Ozone (O3), Lead (Pb), Arsenic (As), Nickel (Ni), Benzene (C6H6), Beznzo (a) Pyrene

(BaP), Carbon Monoxide (CO) were monitored at site and nearby villages for




identification, prediction, evaluation and assessment of potential impact on ambient air

environment.

� The PM10 and PM2.5 concentrations at all the AAQM locations were primarily

caused by local phenomena including vehicular activities and natural dust

getting air borne due to manmade activities and blowing wind. The values of

PM10 at all the locations in residential/rural areas ranged between 60-84

µg/m3 in pre-monsoon season. Similarly, the values of PM2.5 varied in the

range of 38-45 µg/m3.

� The values of SO2 at all the locations in residential/rural areas ranged between

11-17 µg/m3. The values of NOx at all the locations in residential/rural areas

were observed in the range of 14-19 µg/m3. The values of O3 at all the

locations in residential/rural areas ranged between 119-144 µg/m3. At all the

air quality monitoring locations in residential/rural areas, the values of NOx,

SO2 & O3 were observed within limits.

� The values of CO at all the locations in residential/rural areas were observed

between 1.11-1.17 mg/m3. At all the air quality monitoring locations in

residential/rural areas, the values of CO, C6H6 & HC were observed within

limits.

� The values of VOCs at all the locations in residential/rural areas ranged

between 0.2-0.6 ppm. At all the AAQM locations (Industrial as well as

residential) Pb, NH3, BaP, As, Ni values were below detectable limit.




WATER ENVIRONMENT

GROUND WATER QUALITY

SR NO. PEARAMETER RESULTS

1 pH 7.10 – 7.67

2 Turbidity 0.2 – 0.3

3 TDS 214 – 282 mg/L

4 TSS 2 – 18 mg/L

5 D.O. 6.86 – 7.62 mg/L

6 COD BDL – 4.08 mg/L

7 BOD3 BDL

8 Total hardness (as CaCO3) 109 – 147 mg/L

9 Calcium hardness (as CaCO3) 39.34 – 82.78 mg/L

10 Total Alkalinity 121 – 164 mg/L

11 Chlorides 27.84 – 44.62 mg/L

12 Sulfates 18.76 – 48.55 mg/L

13 Copper BDL

14 Sodium 16.52 – 39.09 mg/L

15 Potassium 1.64 – 12.54 mg/L

16 Lead 0.005 - 0.015




SURFACE WATER QUALITY

SR NO. PEARAMETER RESULTS

1 pH 7.03 – 7.46

2 Turbidity 0.1 – 0.2 NTU

3 TDS 372.0 – 802.0 mg/L

4 TSS 8.0 -14.0 mg/L

5 D.O. 6.74 – 7.02 mg/L

6 COD 4.96 – 8.19 mg/L

7 BOD3 BDL

8 Total hardness (as CaCO3) 156 – 159 mg/L

9 Calcium hardness (as CaCO3) 72.16 – 82.66 mg/L

10 Total Alkalinity 107 – 214 mg/L

11 Chlorides 25.44 – 62.34 mg/L

12 Sulfates 24.32 – 50.16 mg/L

13 Copper BDL

14 Nickel BDL

15 Zinc 0.087 – 0.29 mg/L

16 Sodium 84.12 – 267.4 mg/L

17 Potassium 10.76 – 41.8 mg/L

NOISE ENVIRONMENT

The objective of the noise pollution survey around the project site was to identify

existing noise sources and to measure background noise levels. The study was carried

out in the following steps:

• Reconnaissance

• Identification of noise sources and measurement of noise levels




• Measurement of noise levels due to transportation

• Community noise levels

LAND ENVIRONMENT

Soil quality monitoring has been carried during pre-monsoon season at seven locations.

BASELINE STATUS

pH varies from 7.10 – 7.95. Water Holding Capacity (WHC) varies from 46.53 % - 69.16

%. Bulk Density varies from 1.11 – 1.25 g/cm3. Sulphates are found in the range 109.1 –

495.2 mg/kg. Total Hardness varies from 498.16 – 775.2 mg/kg. Calcium are found in the

range of 108.0 – 168.5 mg/kg. Sodium varies from 526.0 – 2452.0 mg/kg. Potassium is

found in the range of 526 - 6416 mg/kg. Lead is found Below the Detectible Limit. (BDL)

8.3 Anticipated Environmental impacts and mitigation measures

Water Requirement, Waste Water Generation and Treatment:

Total water requirement will be 154 m3/day (57 Fresh + 97 Recycled) which will be met

through GIDC water supply.

The wastewater generation will be 102 m3/day.

High COD stream (27.0 m3/day) from process will be treated in MEE plant with solvent

stripper.

Low COD stream from, Process, Boiler, Cooling, Washing/ & Domestic effluent (74

m3/day) will be sent to proposed ETP consists of primary, secondary & tertiary

treatments. To achieve the Zero Liquid Discharge, Treated effluent from ETP (74.0

m3/day) shall be treated in R.O. plant. Then R.O. permeate (52.0 m

3/day) shall be reused

in Boiler and Cooling while, R.O. reject (21 m3/day) shall be treated in MEE Plant & salt

will be sent to TSDF site for disposal. MEE Condensate 44.0 KLD will be reuse in

Industrial Purpose.

Domestic wastewater will be added in biological treatment of ETP.

Scrubbing media will be reuse in plant premises and sent to end users having Rule-9

permission.

Air Pollution Source and Control Management:




There will be emission from Boiler (2 Nos.), Thermopack Boiler (1 no.), D.G. sets (1

Nos.) and Process vents (3 Nos.). To control the emission from stack & process vents,

adequate air pollution control equipments are installed i.e. Cyclone followed by Bag

Filter, Two Stage Scrubber (Water + Alkali), Two Stage Alkali Scrubber & two stage

Ammonia scrubber.

Hazardous Waste:

Sr.

no.

Type/Name of

Hazardous

waste

Specific Source of

generation

(Name of the

Activity, Product

etc.)

Category

and

Schedule

as per

HW Rules.

Quantity

(MT/Annum)

Management of HW

1 ETP Sludge From ETP plant Sch-

I/35.3

636

MT/Year


Transportation &

sent for co-

processing in cement

industries or disposal

at nearest TSDF Site.

2 Discarded

Container/

Bags/Drums

From raw material Sch-

I/33.1

36.0

MT/Year


Transportation,

Decontamination &

Sell to authorized

vendors

3 HDPE Bags From raw material Sch-

I/33.1

12.0

MT/Year


Transportation,

Decontamination &

Sell to authorized

vendors

4 Distillation

Residue

From Solvent

Recovery plan

Sch-

I/33.1

360.0

MT/Year


Transportation &

sent for co-

processing in

cement industries

or disposal at

common

incineration site

5 Spent From mfg. Process Sch- 12000.0 Collection, Storage,




Solvent I/36.1 MT/Year and in-house

solvent recovery

plan & Reuse in

plant premises.


machinery

Sch-

I/5.1

6.0

MT/Year


Transportation &

Reuse or sale to

registered re-

processors

7 Process

Waste

From plant

machinery

Sch-

I/28.1

480.0

MT/Year


Transportation &

sent for co-

processing in

cement industries

or disposal at

common

incineration site

8 Spent Carbon From mfg. process

Product

no.02,04,10-

16,18,19,21,25,26-

30,36

Sch-

I/28.3

192

MT/Year

9 Iron Sludge From mfg. process

Product

no.04,18,23,24,29

Sch-

I/28.1

1200

MT/Year


Transportation &

sent for co-

processing in

cement industries

10 Spent Catalyst From mfg. process

Product no.09,22

Sch-

I/28.2

24.0

MT/Year


Transportation &

return back to

supplier for re-

generation or Sent

to nearest common

Incineration Site.

11 MEE Salt From waste water

treatment MEE

Sch-

I/35.3

430

MT/Year


Transportation &

sent for co-

processing in

cement industries

or disposal at

nearest TSDF Site.

12 HCl (32%) From mfg. process

Product no.07,08 &

Scrubber

Sch-

I/28.1

4800.0

MT/Year


Transportation And

Reuse in Roxarsone

(Require Quantity

of HCL (32%)–5400




MT/Annum)

13 H2SO4 (70%) From mfg. process

Product no.09,22

Sch-

I/28.1

3840.0

MT/Year


Transportation And

Reuse in Sildinafil

Citrate (Require

Quantity of H2SO4

(70%)–5328.0

MT/Annum).

14 Sodium

Sulphite

From mfg. process

Product no.15,10 &

Scrubber

Sch-

I/28.1

360.0

MT/Year


Transportation &

sell to end user

having Rule-9

Permission.

15 Sodium

hypochlorite

From mfg. process

Product no.15,10 &

Scrubber

Sch-

I/28.1

180.0

MT/Year


Transportation &

sell to end user

having Rule-9

Permission. 16 Ammonium

Chloride

From mfg. process

Product no.08,22

Sch-

I/28.1

672.0

MT/Year

17 Sodium

Sulphate

From mfg. process

Product no.17,23

Sch-

I/28.1

1800.0

MT/Year

18 Sodium

Bromide

From mfg. process

Product no.08 &

Scrubber

Sch-

I/28.1

816.0

MT/Year

19 KCl Salt From mfg. process

Product no.04

Sch-

I/28.1

288.0

MT/Year

20 Sodium

Carbonate

From mfg. process

Product no.07,22

Sch-

I/28.1

1200

MT/Year


Transportation And

Reuse in

MESALMINE

(Require Quantity

of Sodium

Carbonate (1200.0

MT/Annum) or

SALBUTAMOL

SULPHATE (Require

Quantity of Sodium

Carbonate (144.0




MT/Annum) Send to

End users having

Rule 9 permission.

21 AlCl2 From mfg. process

Product no.22,26

Sch-

I/28.1

660.0

MT/Year


Transportation And

Send to End users

having Rule 9

permission.

22 Al(OH)3 From mfg. process

Product

no.01,02,10,32

Sch-

I/28.1

2760.0

MT/Year


Transportation &

sell to end user

having Rule-9

Permission.

23 NaOH From mfg. process

Product no.07

Sch-

I/28.1

768.0

MT/Year


Transportation And

Reuse in

MESALMINE

(Require Quantity

of Sodium

Hydroxide (864.0

MT/Annum) or Send

to End users having

Rule 9 permission.

24 MnO2 From mfg. process

Product no.19

Sch-

I/28.1

1920.0

MT/Year


Transportation &

sell to end user

having Rule-9

Permission.

25 Methane

Sulfonic Acid

From mfg. process

Product no.21

Sch-

I/28.1

2160.0

MT/Year

26 Methyl

Sodium

Sulphate

From mfg. process

Product no.24

Sch-

I/28.1

3060.0

MT/Year

27 MMA Solution From mfg. process

Product no.25

Sch-

I/28.1

624.0

MT/Year

28 Ether From mfg. process

Product no.26

Sch-

I/28.1

2400.0

MT/Year

Non-Hazardous Waste





MT/Year


Transportation and

sell to brick

manufacturer

Green Belt:

Total 16,067 sq. meter land area is available at site; out of this area about 5,300.36 sq.

meters (33 %) area will be developed as greenbelt and other forms of greenery.

POWER & FUEL REQUIREMENTS:

Energy:

SR. NO. REQUIREMENT SOURCE

1. 1200 MW DGVCL

Note: 3 No. of 1000 KVA Capacity of DG sets will be kept for emergency power back up.

Fuel:

Sr. No. Fuel Requirement

1 Diesel 2000 Lit/ Day

2 Coal/

Briquettes of Bio-

Coal

24 MT/Day

or

15 MT/Day




CUMULATIVE IMPACT CHART

ENVIRONMENTAL

PARAMETER

TOTAL CUMULATIVE

SCORE

Air Quality 13

Noise and Odour 10

Water Quality 8

Land Requirement 9

Infrastructure 13

Service 12

Environmental Hazards 14

Housing 2

Terrestrial Ecology/ Land use 11

Socio Economic Status 6

Aquatic Ecology 1

8.4 ENVIRONMENTAL MONITORING PROGRAM

Environmental

Component

Parameters Standards Frequency

Air Environment

AAQM at plant site As prescribed by GPCB

including PM2.5, PM10,

SO2, NOx, HCl, Cl2, HC

& VOCs

Prescribed

by CPCB

Once in a month in upwind

and downwind direction.

Stack emission

monitoring of

emissions sources


by GPCB

In stack

Prescribed

by GPCB

Once In a Month

Fugitive emissions/

work place

monitoring within

the plant side

VOC Prescribed

by GPCB

Regular

Water Environment




Analysis of treated

effluent


by GPCB

Prescribed

by GPCB

Once a day by Company,

Once a month by NABL Lab.

Ground water

quality

Colour, pH, TDS, TSS,

Sulphates, Chlorides,

BOD3, COD, oil and

grease, etc.

Water

quality

Standards

Once a Season

Noise Environment

Ambient Noise at

plant site

Noise level in dB(A) As per

National

Noise

Standards

Once In a Month

Soil Environment

At plant site Analysis of pH,

conductivity,

Sulphates, calcium,

magnesium, Cl-

-- Pre and post monsoon

season by Company

8.5 Additional Studies

STORAGE DETAILS OF HAZARDOUS CHEMICALS

SR.

NO

NAME OF THE MATERIAL TYPE OF

HAZARD

SIZE

(KL)

NO.

TANK STORAGE

1 N-HEXANE FLAMMABLE 30 1

2 TOLUENE FLAMMABLE 30 6

3 METHANOL FLAMMABLE 30 4

4 BENZENE FLAMMABLE 30 1

5 METHYLENE CHLORIDE FLAMMABLE 30 2

6 MONO CHLORO BENZENE FLAMMABLE 30 2

7 ETHYL ACETATE FLAMMABLE 30 3

8 EDC FLAMMABLE 30 1

9 HCL CORROSIVE 30 2

10 PHENOL CORROSIVE 25 1

11 LIQ . BROMINE CORROSIVE 30 1

12 H2SO4 CORROSIVE 30 1

13 CAUSTIC SODA LYE TOXIC 30 1

14 NITRIC ACID (98%) TOXIC 30 1

15 LIQ NITROGEN TOXIC 30 1

16 ACETONE FLAMMABLE 30 2




CYLINDER

23 CHLORINE GAS TOXIC 10 1

24 MMA GAS TOXIC 5 1

25 AMMONIA GAS TOXIC 2 1

DRUM STORAGE

FORMALDEHYDE PCBA H2O

2 (50 %)

MIBK 3, 5, 6 TRI CHLORO SALICYLIC ACID THIONYL CHLORIDE

HYDROSO 6-AMINO PENICILLANIC ACID(6-APA) PARA CHLORO ANILINE

MONO METHYL CHLORO

ACETIC ACID

MIBK THF

ANILINE DIBROMO DIMETHYL HYDANTOIN CHLOROFORM

CHLORO ACETYL CHLORIDE AZOBISISOBUTYRONITRILE PIVALOYL CHLORIDE

DI METHYL ANILINE SODIUM BIO-CARBONATE SOLN MCA

CYAANAMIDE SOLUTION (L-

500)

METHYL ANTHRANILATE ACETONE

5 CHLORO 2 NITRO ANILINE

TRANS 4-AMINO CYCLOHEXANOL DMF

BUTYL ACETATE IPA HCL AMMONIUM THIOCYNATE

2 METHYL 5

NITROMIDAZOLE

L(+)TARTARIC ACID N- PROPANOL

ACETIC ANHYDRIDE ETHYLENE OXIDE ISO BUTYL BENZENE

ONCB BUTYL ACETATE PARA CHLORO ANILINE

PHOSPHORIC ACID FORMALDEHYDE DIMETHYL SULPHOXIDE

ORTHO NITRO TOLUENE N-PROPYL BROMIDE N-BUTANOL

FORMIC ACID H2O2

BAG STORAGE

RANEY NICKEL IRON POWDER SODIUM HYDROSULPHITE

SODIUM HYDROXIDE ARSENIC TRIOXIDE SODIUM BORO HYDRIDE

MANGANESE DIOXIDE PHOSPHOROUS OXY CHLORIDE N-METHYL PIPERAZINE

PIPERAZINE DANE SALT 2, 4 –DI CHLORO – 6-

AMINO PHENOL

RESORCINOL HYFLOSUPERCEL 3 HYDROXY

ACETOPHENONE

BETA PICOLINE ALUMINIUM CHLORIDE 2 ETHYL HEXANOIC ACID

PALLADIUM CHARCOAL

CATALYST

POTASSIUM CARBONATE SODA ASH

SODIUM SALT KOH THIOPHENOL

DIMETHYL CARBONATE 4-CHLORO-2- AMINO PHENOL (4CAP) SODIUM SULPHATE

SODIUM NITRITE




8.6 Project Benefits

It can be seen that the proposed project is beneficial in the interest of common man,

the society, the state and as the country as a whole. The benefits can be summarized as

below:

� The proposed project will provide quality product at lower cost to the users.

� There should be positive impact on the socio-economic condition of the area in

terms of direct and indirect employment due to the proposed expansion project.

� Numbers of local trained persons are likely to find jobs.

� Country will save valuable foreign exchange as import of these products will

reduce by corresponding amount.

� These products also have export potential. Hence, possibility of earning foreign

exchange.

Adequate pollution control measures will be taken to check any kind of contamination

or pollution from the company. Due to coming up of project many changes are expected

to occur in the socio – economic setup of the surrounding region. The socio- economic

changes may be beneficial or detrimental. General trend of socio – economic

environment due to the project industry is that it increases the population density

within the area and in a few of the surrounding villages. This can be attributed to more

job opportunities, direct and indirect, provided by the industry. Considering the

pollution control measures taken by the company environment management system

adopted there is no significant adverse impact on environment.




8.7 Environment 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, incineration facility, re-

cyclers, re-processors.

Effluent generation and

treatment

Effluent treatment plant will be provided for treatment of

wastewater.

Emission from stack Adequate pollution control systems will be provided for control

of gaseous emission.

• Adequate stack height for better dispersion of pollutants

• Scrubbers at Process Vents

Noise Acoustic enclosure on DG 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 32% of the plant area will be developed as greenbelt.

Information and awareness about

hazardous chemicals plant

Awareness and information will be provided within 10 km of the

study area about the hazardous situations.

Preparedness to handle onsite &

offsite emergency

Onsite & Offsite Emergency Management Plan is prepared

Monitoring of Environmental

parameters

Regular monitoring of various environmental parameters will be

carried out to check the effectiveness of the control system.




8.8 Conclusion

The EIA study of M/s. Nutraplus India Ltd. (Unit-2) has been carried out with respect to

the TORs awarded by SEAC, Gandhinagar. All the impacts likely to have an effect on the

environment have been identified and efficient/adequate mitigation measures have

been proposed for the same.

• Considering the probability of likely impacts, M/s. Nutraplus India Ltd. (Unit-2)

has planned adequate mitigation measures and EMP.

• Further, M/s. Nutraplus India Ltd. (Unit-2) shall also undertake CSR activities

which shall have beneficial impacts on the socio-economic environment.

• Measures like energy conservation and greenbelt development are also

noteworthy.

• Looking to the overall project scenario, employment potential and allied

development plans; it has been noticed that the proposed project would

significantly help in the improvement of the society and nation at large.

• M/s. Nutraplus India Ltd. (Unit-2) has committed to implement all the pollution

control measures to protect surrounding environment. Also this project can

definitely improve the regional, state and national economy. Industrial growth is

an indication of socio economic development.

• The implementation of this project will definitely improve the physical and social

infrastructure of the area.

• The unit has already acquired membership of M/s. Saurashtra Enviro Projects P.

Ltd.

• Domestic effluent will be added in aeration tank of ETP.

• Only fresh water will be used for gardening & drinking purpose.

• Overall, direct & indirect employment opportunities will take place.

• It can be concluded that on positive implementation of mitigation measures and

Environmental management plan during the construction and operational phase,

there will be negligible impact on the environment.

M/S. AQUA – AIR ENVIRONMENTAL ENGINEERS PVT. LTD.

403, CENTER POINT, NR. KADIWALA SCHOOL,

RING ROAD, SURAT – 395002 (GUJARAT)

TEL: +91 (261) 2460854/2461241/3987173/3048586

TELEFAX: +91 (261) 2707273/3987273

EMAIL: [email protected]

WEBSITE: WWW.AQUA-AIR.CO.IN

561

CHAPTER - 9

DISCLOSURE OF CONSULTANTS ENGAGED

Aqua-Air Environmental Engineers Pvt. Ltd.

(Pollution Control Consultants & Engineers)






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562

COMPANY PROFILE

Aqua-Air Environmental Engineers Pvt. Ltd. is a Surat based company; one of the leading and

multidiscipline Environmental Management Consulting firms of the region.

Aqua-Air Environmental Engineers Pvt. Ltd. was founded by Mr. Jayesh S. Patel & Mrs. Archana J. Patel

on May 7, 2008 and Aqua-Air Environmental Engineers Pvt. Ltd. was registered under the companies

Act on May 7, 2008.

Office having 6756 Sq. Ft. of area covering EC/EIA Department, R & D Centre (Environmental

Laboratory), Consent (NOC/CC&A) Department, ETP/Civil Department and Account Department,

Library, Conference room and Administration Department, etc. with experienced and qualified staff to

render services in the field of Environmental Management of various types of industries.

Aqua-Air Environmental Engineers Pvt. Ltd. has a well-established track record in monitoring legislation

and developing and implementing strategies for organizations that enable them to manage the impact

of environmental issues on their business.

The company has built a reputation for delivering innovative and practical solutions to environment

related business issues. These solutions help our clients to achieve successful business outcomes and

make sustainable environment serving improvements within their business operations.

Aqua-Air Environmental Engineers Pvt. Ltd. started the process for ISO/IEC 17025:2005 Accrediation by

NABL, New Delhi for the Competence Testing & Calibration Laboratories on June 24, 2008 and

submitted the application (Version No. 10) to NABL, New Delhi for ISO/IEC 17025:2005 registration on

October 7, 2008. After final assessment and Non-Conformances resolved and corrective actions taken

against the Non-Conformances, Laboratory Department - Aqua-Air Environmental Engineers Pvt. Ltd.

was accredited with the certification of ISO/IEC 17025:2005 on October 19, 2010.

Aqua-Air Environmental Engineers Pvt. Ltd. started the process for ISO 9001:2008 registration for

Quality Management System on December 1, 2009 and submitted the application for ISO 9001:2008




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563

registration on March 4, 2010. After final assessment, Aqua-Air Environmental Engineers Pvt. Ltd. was

certified from ANAB by M/s. Intertek System Certification on May 4, 2010.

Aqua-Air Environmental Engineers Pvt. Ltd. started the process for “EIA Consultant Organization”

accreditation under National Accreditation Board for Education And Training (NABET)/Quality Council

of India (QCI), New Delhi on January 7, 2010 and submitted the application (Rev. 06) for “EIA

Consultant Organization” accreditation under NABET, New Delhi on April 8, 2010. Office assessment

was done by external NABET/QCI auditors [Dr. L. Ramakrishnan & Mr. A. K. Gupta (B.Sc. Mechanical

Engg.)] on Feb. 3 & 4, 2011. NABET/QCI closed the application of Aqua-Air Environmental Engineers

Pvt. Ltd. on March 15, 2011. Aqua-Air Environmental Engineers Pvt. Ltd. filed SCA in Hon’ble High Court

of Gujarat against MoEF, QCI & NABET, New Delhi on April 13, 2012. Hon’ble High Court of Gujarat

issued stay order against operation of all OMs (related to NABET/QCI Scheme) of MoEF, New Delhi for

the company on Jan. 24, 2013. MoEFCC, New Delhi published Notification regarding mandatory

implementation accreditation scheme of NABET/QCI on March 3, 2016. Aqua-Air Environmental

Engineers P. Ltd. along with 11 EIA Consultants of Gujarat filed SCA No. 5312of 2016 in Hon'ble High

Court of Gujarat. Hon'ble High Court of Gujarat gave Stay Order on Apr. 5, 2016 against

implementation of Notification dated March 3, 2016 of MoEFCC, New Delhi till further orders.

Aqua-Air Environmental Engineers Pvt. Ltd. received the Certificate of Registration of Trade Mark,

Section 23 (2), Rule 62 (1) from Trade Marks Registry, Govt. of India on January 18, 2011.

The company’s work is spread all over Gujarat in India & Oman. Company have already prepared 340

Form-1, 198 EIA & EMP reports, 180 Risk Assessment & DMP reports, conducted 82 Public Hearings

and obtained 206 Environmental Clearances so far that includes Water related Projects / Pesticide

Industry Projects / Textile Industry Projects / Sugar Industry Projects / Chemical Industries / Specialty

Chemical Industry Projects / Bulk Drug (API) Industry Projects / Chemical Fertilizer Industry Projects /

Cement Plants / Thermal Power Plants / Mining Projects / Infrastructure Projects / Construction

Projects / Distilleries / Petrochemical Industry Projects/ SEZ Projects/ CRZ Projects, etc.




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564

Company's NABL Accredited Testing Laboratory has conducted Environmental Monitoring & Analysis

with Environmental Institute and Gujarat Pollution Control Board in Industrial Estates of Ankleshwar,

Panoli & Jhagadia. Company is also doing Turnkey/Consulting Projects for M/s. BASF (Detail

Engineering for Effluent Treatment Plant) & M/s. Reva Proteins Ltd. (Design of Effluent Treatment

Plant, supply of mechanical items, Commissioning and operation of Effluent Treatment Plant).




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565

2. ABOUT US

Aqua-Air Environmental Engineers Pvt. Ltd. has registered office in one of the top five fastest growing

cities of India – Surat. We are one of the most trusted and reliable environmental and engineering

consultancy service providers. With complete hold in the related domain and proficiency, we execute

our work all over Gujarat region.

In addition to engineering consultancy, we also execute turnkey projects for effluent treatment plants

at the client's site.

Aqua-Air Environmental Engineers Pvt. Ltd is:

• One of the leading companies in the region providing high quality services in environmental

engineering to the best of client's satisfaction.

• Posses a well - developed design office with Computer Center and Laboratory -cum- R&D Center to

carry out designing and analysis in the field of environmental engineering.

• Recognized as Schedule-II Environmental Auditor under the Environment Audit Scheme proposed

by the Hon'ble High Court of Gujarat.

• Listed with Gujarat Pollution Control Board as Consultants and proposing to get enlisted with GPCB

as Pollution Control Equipment Suppliers.

• Going to become a member of Consulting Engineers Association of India.

• Having well-developed library to render services in the field of environmental auditing, consulting,

monitoring and analysis.

3. ACHIEVEMENTS

1. Registered under the companies Act on May 7, 2008.

2. Gujarat Pollution Control Board Recognized Schedule – II Environmental Auditor on Dec. 24,

2008.

3. Certificate of ISO 9001:2008 received on May 4, 2010.

4. Import Export Licence received from Government of India on May 31, 2010.

5. Solvency Certificate of Rs. 1,40,00,000/- received from Bank of India, Gopipura branch, Surat on

Sept. 3, 2010.




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566

6. Certificate of National Accreditation Board for Testing and Calibration Laboratories (NABL)

received on Oct. 15, 2010.

7. Certificate of Registration of Trade Mark, Section 23 (2), Rule 62 (1) from Trade Marks Registry,

Govt. of India on Jan. 18, 2011.

8. Certificate of Authorization as dealer in India received from Spectrum Technologies, Inc., USA

on May 1, 2011.

9. Gujarat Pollution Control Board Recognized Schedule – II Environmental Auditor on May 6,

2011.

4. SERVICE PROVIDE

M/s. AQUA-AIR ENVIRONMENTAL ENGINEERS PVT. LTD. offers following specialized services in

Environmental Engineering, Water Supply Engineering and Civil Engineering.

4.1 TURN KEY/BOOT/BOO PROJECTS

4.1.1 ENVIRONMENTAL ENGINEERING

Detailed design Water Treatment Plants (WTPs)

Construction Common Effluent Treatment Plants (CETPs)

Fabrication Recycling Plants (RPs)

Piping Zero Discharge Plants (ZDPs)

Electrification Incineration System Plants (ISPs)

Supply Hazardous waste Storage areas (HWSAs)

Erection Secured/ Sanitary Landfill Facilities

Testing and Commissioning of Effluent

Treatment Plants (ETPs)

Bio–Medical Waste (BMW) Treatment Facilities on

a turnkey or BOOT/BOO basis.

Sewage Treatment Plants (STPs)

4.1.2 CIVIL ENGINEERING

Construction of

Water Treatment Plan Elevated Service Reservoirs (ESRs)

Sewage Treatment plant Underground Reservoirs (UGRs)

Industrial Wastewater Treatment plant Sewage Pumping Stations, etc.




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567

4.2 CONSULTING


1. Complete study of the Pollution Problem in industries from wastes generation to disposal and

providing necessary technical knowledge like–

How including design Zero Discharge Plants (ZDPs)

Basic engineering, detailed engineering Recycling plants (RPs) for reuse of water upto

maximum extent Water Treatment Plants (WTPs)

Tender preparation for Effluent Treatment

Plants (ETPs) for industrial wastewater

Incineration System Plants (ISPs) for various non-

biodegradable or toxic industrial wastes on

Consulting basis

Sewage Treatment Plants (STPs) for residential

wastewater

Design of Hazardous waste Storage area and

Consultancy Services for Secured/ Sanitary Landfill

Facilities

Common Effluent Treatment Plants (CETPs) for

more than two industries

Design and Consultancy Services for Bio – Medical

Waste Treatment Facilities.

2. Water Supply Distribution System

Analysis Tender preparation

Design

3. Laboratory Analysis of

Air Waste Water

Water Industrial Effluent

Sewage Industrial Sludge

4. Process Study

Reduce the pollution at source Reuse / Recycle effluent

5. Pollution Control Facility

Performance study of existing Suggesting scheme for the optimization of the

facility

6. Environment Management

Environmental Clearance from Environmental Impact Assessment Studies (EIAs)

• MoEF • Short term (Rapid)

• New Delhi or DoEF • Long term (Comprehensive)

• Gandhinagar

Environmental statements Environmental Auditing

7. Statutory Requirements under Factory Act

Safety Audit HAZOP study

On-site / Off-site Emergency Plan

8. For Various Energy Conservation Schemes

Energy Audit Design




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9. Environmental Management System

Preparing Adequacy Report Preparing Efficacy Report

10. Operation and Maintenance (O & M)

Effluent Treatment Plants (ETPs) Water Treatment Plants (WTPs)

Sewage Treatment Plants (STPs)

11. Air Monitoring

Ambient Air Stack

Vent

12. Design of Pollution Control Equipment

Cyclone Flash mixers

Scrubbers Reaction Vessels

Bag Filters, fume extraction systems Clariflocculators

Blowers Scrapper Mechanisms

Aerators Incinerators

Agitators Scrubbers, etc.

13. Pollution Control

Effluent Survey Feasibility Studies

Environmental review of Pollution control

equipment and systems

Laboratory bench scale Treatability studies

Pilot Plant studies etc.

14. Consulting Service

NOC Air Consent

Water Consent Hazardous Waste Authorization Application, etc.

15. As per requirements under Factory Act-1948 and Gujarat Factory Rules

Monitoring filling up Form-37

Analysis of Work Area Environment

16. Technical Consultation & assistance to ensure and assure compete Environ-Legal compliance

Liaison with statutory bodies in order to get the

required permits

Clearance

Consents

4.3 EQUIPMENT MFG. /TRADING


1. Manufacture and supply of Pollution Control Equipment such as

Incinerators With scrubbers Dissolved Air Flotation (DAF) units

Autoclaves Cyclone

Hydro-claves Scrubbers

Fixed Aerators Bag Filters

Floating Aerators Oil Skimmers

Submersible Aerators (EOLO2) Deoiler Pipes

Submersible Mixers (RIO or BRIO) API separators




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Cascade Aerators Vacuum Drum filters

Clarifier mechanisms Solid bowl centrifuges

Agitators Filter presses

Clariflocculator Belt filters

Clariflocculator mechanism Reaction vessels

Flash mixes Reverse Osmosis, etc.

Oil skimmers

570

LIST OF ANNEXURES

ANNEXURE

NO.

TITLE PAGE

NO.

1 National ambient air quality monitoring standards 571

2 Damage risk criteria for hearing loss occupational safety & health

administration (OSHA)

573

3 CPCB recommendations for community noise exposure 574

4 CPCB standards classification of inland surface water 575

5 Indian standards specifications for drinking water 576

6 Indian standards for industrial and sewage effluents discharge 579

7 Plot holding certificate obtained from GIDC Saykha. 581

8 GIDC Water supply letter /Undertaking stating that no bore well shall be

dug.

587

9 Undertaking stating that separate electric meter shall be provided. 588

10 Membership of Common Environmental Infrastructure 589

11 Copies of Agreement / MOU / Letter of intent 590

12 MSDS 592-

13 Do’s And Don’ts 647

14 Copy Of Hon'ble High Court Of Gujarat's Stay Order Against Notification

Dated March 3, 2016 Of Moefcc, New Delhi

650

15 Adequacy 655

571

ANNEXURE - 1

NATIONAL AMBIENT AIR QUALITY STANDARDS (NAAQS) (2009)

Sr.

No.

Pollutant Time

Weighted

Average

Concentration in Ambient Air

Industrial

Residential,

Rural and

Other Area

Ecologically

Sensitive Area

(notified by

Central

Government)

Methods of

Measurement

(1) (2) (3) (4) (5) (6)

1 Sulphur Dioxide

(SO2), µg/m3

Annual*

24 Hours**

50

80

20

80

• Improved West and

Geake

• Ultraviolet

fluorescence

2 Nitrogen Dioxide

(NOx), µg/m3

Annual*

24 Hours**

40

80

30

80

• Modified Jacob &

Hochheiser (Na-

Aresenite)

• Chemiluminescence

3 Particular Matter

(size less than 10

µm) or PM10 µg/m3

Annual*

24 Hours**

60

100

60

100

• Gravimetric

• TOEM

• Beta attenuation

4 Particular Matter

(size less than 2.5

µm) or PM2.5 µg/m3

Annual*

24 Hours**

40

60

40

60

• Gravimetric

• TOEM

• Beta attenuation

5 Ozone (O2) µg/m3 8 Hours**

1 Hour**

100

180

100

180

• UV photometric


• Chemical Method

6 Lead (Pb) µg/m3 Annual*

24 Hours**

0.50

1.0

0.50

1.0

• AAS/ICP method

after sampling on

EPM 2000 or

equivalent filter

paper

• ED-XRF using Teflon

filter

7 Carbon Monoxide

(CO) mg/m3

8 Hours**

1 Hour**

02

04

02

04

• Non Dispersive Infra

Red (NDIR)

Spectrology

8 Ammonia (NH3)

µg/m3

Annual*

24 Hours**

100

400

100

400


• Indophenol blue

method

572

* Annual arithmetic mean of minimum 104 measurements in a year at a particular site taken twice a

week 24 hours at uniform intervals

** 24 hourly or 08 hourly or 01 hourly monitored values, as applicable, shall be complied with 98%

of the time in a year. 2% of the time, they may exceed he limits but not on two consecutive days

of monitoring.

Note: Whenever and wherever monitoring results on two consecutive days of monitoring exceed the

limits specified above for the respective category, it shall be considered adequate reason to

institute regular or continuous monitoring and further investigation.

Sr.

No.

Pollutant Time

Weighted

Average

Concentration in Ambient Air

Industrial

Residential,

Rural and

Other Area

Ecologically

Sensitive Area

(notified by

Central

Government)

Methods of

Measurement

(1) (2) (3) (4) (5) (6)

9 Benzene (C6H6)

µg/m3

Annual* 05 05 • Gas chromatography

based continuous

analyzer

• Absorption and

Desorption followed

by GC analysis

10 Benzo (a) Pyrene

(BaP) particulate

phase only, mg/m3

Annual* 01 01 • Solvent extraction

followed by HPCL/GC

analysis

11 Arsenic (AS),

mg/m3

Annual* 06 06 • AAS/ICP method

after sampling on

EPM 2000 or

equivalent filter

paper

12 Nickel (Ni), mg/m3 Annual* 20 20 • AAS/ICP method

after sampling on

EPM 2000 or

equivalent filter

paper

573

ANNEXURE - 2

________________________________________________________________________

DAMAGE RISK CRITERIA FOR HEARING LOSS

OCCUPATIONAL SAFETY& HEALTH ADMINISTRATION (OSHA)

MAXIMUM ALLOWABLE

DURATION PER DAY

(HOURS)

NOISE LEVEL

(SLOW RESPONSE)

dB(A)

8 90

6 92

4 95

3 97

2 100

1.5 102

1 105

0.5 110

0.25 or Less 115

574

ANNEXURE - 3

________________________________________________________________________

CPCB RECOMMENDATIONS FOR COMMUNITY NOISE EXPOSURE (1989)

CATEGORY

OF AREA

Leq (dBA)

(DAYTIME)

(06:00 TO 21:00 HRS)

Ldn (dBA)

(NIGHT TIME)

(21:00 TO 06:00 HRS)

Industrial Area 75 70

Commercial Area 65 55

Residential Area 55 45

Silence Zone 50 40

Note:

1. Day time shall mean from 6.00 a.m. to 10.00 p.m.

2. Night time shall mean from 10.00 p.m. to 6.00 a.m.

3. Silence zone is an area comprising not less than 100 meters around hospitals, educational

institutions, courts, religious places or any other area which is declared as such by

competent authority.

4. Mixed categories of areas may be declared as one of the four above mentioned

categories by the competent authority.

*dB(A) Leq denotes the time weighted average of the level of sound in decibels on scale A

which is relatable to human hearing.

A "decibel" is a unit in which noise is measured.

"A", in dB(A) Leq, denotes the frequency weighting in the measurement of noise and

corresponds to frequency response characteristics of the human ear.

Leq: It is energy mean of the noise level, over a specified period.

575

ANNEXURE - 4 __________________________________________________________________________________________

CLASSIFICATION OF INLAND SURFACE WATER (CPCB STANDARDS)

SR

NO.

CHARACTERISTICS A@

B@

C@

D@

E@

1 Dissolved Oxygen

(mg/L), Min

6 5 4 4 -

2 Biochemical Oxygen

Demand (mg/L), Min

2 3 3 - -

3 Total Coliform

Organisms,

MPN/100 ml, Max.

50 500 5000 - -

4 Total Dissolved Solids

(mg/L), Max

500 - 1500 - 2100

5 Chlorides (as Cl-), mg/L,

Max.

250 - 600 - 600

6 Colour,

Hazen units, Max

10 300 300 - -

7 Sodium absorption

ratio, Max

- - - - 26

8 Boron (as B), mg/L, Max - - - - 2

9 Sulphates (as SO4-2

),

mg/L, Max.

400 - 400 - 1000

10 Nitrates (as NO3-), mg/L,

Max

20 - 50 - -

11 Free Ammonia

(as N), mg/L, Max

- - - 1.2 -

12 Conductivity at 25°C,

micromhos/cm, Max

- - - 1.0 2.25

13 pH value

6.5-8.5 6.5-8.5 6.5-8.5 6.5-8.5 6.0-8.0

14. Arsenic (as As), mg/L,

Max

0.05 0.2 0.2 - -

15 Iron (as Fe), mg/L, Max 0.3 - 50 - -

16 Fluorides (as F), mg/L,

Max

1.5 1.5 1.5 - -

17 Lead (as Pb), mg/L,

Max

0.1 - 0.1 - -

18 Copper (as Cu), mg/L,

Max

1.5 - 1.5 - -

19 Zinc (as Zn), mg/L,

Max

15 - 15 - -

*: If the Coliform count is found to be more than the prescribed tolerance limits, the criteria

for coliforms shall be satisfied if not more than 20 percent of samples show more than the

tolerance limits specified, and not more than 5 percent of samples show values more than 4

times the tolerance limit. Further, the feacal coliform should not be more than 20 percent of

the coliform.

576

ANNEXURE - 5

___________________________________________________________________________

INDIAN STANDARDS/SPECIFICATIONS FOR DRIINKING WATER IS: 10500-1991

SR

NO.

SUBSTANCES OR

CHARCTER-

ISTICS

MAX

REQUIREME-

NT

(DESIRABLE

LIMIT)

UNDESIRABLE

EFFECTS OUT-SIDE

THE DESIRABLE

LIMIT

PERMISSIBLE

LIMIT IN

ABSENCE OF

ALTERNATE

SOURCE

METHOD

OF TEST

CI REF OF

IS: 3025

REMARKS

ESSENTIAL CHARACTERISTICS

1 Colour, Hazen

unit

5 Above this,

consumer

acceptance

decreases

25 4 of 3025,

1983

Extended upto 25

only if toxic

substances are not

suspected in

absence of

alternate

Source.

2 Odour Unobjectionable - 5 of

3025,198

3

a. Test cold and

when heated

b. Test at several

dilutions

3 Taste Agreeable - - Test to be

conducted only

after safety has

been established

4 Turbidity, NTU 5 Above this,

consumer

acceptance

decreases

10 8 Test to be

conducted only

after safety has

been established

5 pH Value 6.5-8.5 Beyond this range

the water will affect

the mucous

membrane and/or

water supply

system

No relaxation 8 -

6 Total Hardness

mg/L (as CaCO3)

300 Encrustation on

water supply

structure and

adverse effects on

domestic use

600 - -

7 Iron (as Fe), mg/L 0.3 Beyond this limit,,

taste/appearance

are affected has

adverse effect on

domestic uses and

water supply

structures &

promotes iron

bacteria

1.0 32 of

3025,

1964

-

8 Chlorides

(as Cl-) mg/L

250 Beyond this limit

taste, corrosion and

palatability are

affected

1000 32 of

3025

-

9 Residual free

chlorine, mg/L

0.2 - - 26 of

3025,

1986

To be applicable

only when water is

chlorinated tested

at consumer end,

when protection

against viral

infection is required

it should be min 0.5

mg/L

577

ANNEXURE – 5 (Contd.)

DESIRABLE CHARACTERISTICS

10 Dissolved Solids,

mg/L

500 Beyond this

palatability

decrease and may

cause

gastrointestinal

irritation

2000 16 of

3025

11 Calcium (as Ca)

mg/L

75 - 200 40 of

3025,

1984

12 Copper (as Cu),

mg/L

0.05 Astringent, taste

discoloration of

pipes, fittings and

utensils will be

caused beyond this

1.5 36 of

3025,

1964

13 Manganese (as

Mn), mg/L

0.1 Astringent, taste

discoloration of

pipes, fittings and

utensils will be

caused beyond this

0.3 35 of

3025,196

4

14 Sulphate (as SO4-

2), mg/L

200 Beyond this causes

gastrointestinal

irritation when

magnesium or

sodium are present

400 24 of

3025,

1986

May be

extended upto

400 provided

(as Mg) does

not exceed 30

mg/l

15 Nitrate (as NO3-),

mg/L

45 Beyond this

methaemoglo-

binemia

100 - -

16 Fluoride (as F-),

mg/L

1.0 Fluoride may be

kept as low as

possible. High

fluoride may cause

fluorosis

1. 5 23 of

3025,

1964

-

17 Phenolic

substances mg/L

(as C6H5OH)

0.001 Beyond this, it may

cause objectionable

taste and odour

0.002 54 of

3025

18 Mercury (as Hg),

mg/L

0.01 Beyond this, the

water becomes

toxic

No relaxation See note

mercury

ion

analyzer

To be tested

when pollution

is suspected

19 Cadmium (as Cd),

mg/L

0.01 Beyond this the

water becomes

toxic


mercury

ion

analyser

To be tested

when pollution

is suspected

20 Selenium (as Se)

mg/L


water becomes

toxic

No relaxation 28 of

3025,

1964

To be tested

when pollution

is suspected

21 Arsenic (As),

mg/L


water becomes

toxic

No relaxation 37 of

3025,

1988

To be tested

when pollution

is suspected

22 Cyanide (CN-),

mg/L


water becomes

toxic

No relaxation 27 of

3025,

1986

To be tested

when pollution

is suspected

23 Lead (Pb), mg/L 0.05 Beyond this the

water becomes

toxic


86

To be tested

when pollution

plumb

solvency is

suspected

578


24 Zinc (as Zn), mg/L 5 Beyond this limit it

can cause

astringent taste and

an opalescence in

water

15 39 of

3025,196

4

To be

tested

when

pollution

is

suspected

25 Anionic

detergents mg/L

(as MBAS)

0.2 Beyond this limit

undesirable taste

and odour after

Chlorination takes

place

1.0 Methylen

e blue

extraction

method

To be

tested

when

pollution

is

suspected

26 Chromium (as

Cr+6

), mg/L

0.01 May be

carcinogenic above

this limit

0.05 28 0f

3025

To be

tested

when

pollution

is

suspected

27 Polynuclear

aromatic

hydrocarbons,

mg/L

- May be

carcinogenic

- 28 of

3025,196

4

To be

tested

when

pollution

is

suspected

28 Mineral Oil, mg/L 0.01 Beyond this limit

undesirable taste

and odour after

Chlorination takes

place

0.03 Gas

chromato

graphic

method

To be

tested

when

pollution

is

suspected

29 Pesticides

mg/L

Absent Toxic 0.001 58 of

3025,

1964

-

30 Radioactive

materials

a. Alpha emitters

Bq/L

b. Beta emitters

pci/L

-

-

-

-

0.1

1.0

-

-

-

-

31 Alkalinity (as

CaCO3), mg/L

200 Beyond this limit

taste becomes

unpleasant

600 13 of

3025,196

4

-

32 Aluminum (as Al),

mg/L

0.03 Cumulative effect is

reported to cause

dementia

0.2 31 0f

3025,196

4

-

33 Boron (as B),

mg/L

1 - 5 29 of

3025,196

4

-

Note: Atomic absorption spectrophotometric method may be used.

579

ANNEXURE - 6

________________________________________________________________________

INDIAN STANDARDS FOR INDUSTRIAL AND SEWAGE EFFLUENTS DISCHARGE IS: 2490-1982

SR

NO.

PARAMETERS INDUSTRIAL EFFLUENT

INTO INLAND

SURFACE

WATER

ON LAND FOR

IRRIGATION

INTO

MARINE

COASTAL

AREA

INTO PUBLIC

SEWERS

1 Colour / odour - - - -

2 Suspended Solids

(mg/L)

100 200 100(for

Process

Waste)

600

Particle Size

Suspended Solids

Shall pass

850 micron IS

sieve

- Floatable

Solids Max 3

mm

Settable

Solids

Max 850

micron

-

4 Dissolved Solids

(Inorganic),

mg/L

2100 2100 - 2100

5 pH Value 5.5-9.0 5.5-9.0 5.5-9.0 5.5-9.0

6 Temperature °C Shall not

exceed 40 in

any section

of the stream

within 15

mts. down

stream from

the effluent

outlet

- 45 at the

point of

discharge

-

7 Oil & Grease, mg/L,

Max.

10 10 20 20

8 Total Residual

Chlorine, mg/L, Max

1 - 1 -

9 Ammonical

Nitrogen (as N) mg/L

max

50 - 50 50

10 Total Kjeldahl

Nitrogen (as N), mg/L,

Max

100 - 100 -

11 Free Ammonia (as

NH3) mg/L, Max.

5 - 5 -

12 Biochemical Oxygen

Demand,

5 Days at 20 ° C

30 100 100 350

13 Chemical Oxygen

Demand, mg/L, Max.

250 - 250 -

14 Arsenic (as As), mg/L,

Max.

0.2 0.2 0.2 0.2

580


15 Mercury (as Hg)

mg/L

0.01 - 0.01 0.01

16 Lead (as Pb), mg/L,

Max

0.1 - 1.0 1.0

17 Cadmium (as Cd),

mg/L, Max

2 - 2 1

18 Hexavalent Chromium

(As Cr+6

), mg/L, Max.

0.1 - 1 2

19 Total Chromium (as

Cr) mg/L, Max

2 - 2 2

20 Copper (as Cu), mg/L,

Max

3 - 3 3

21 Zinc (as Zn), mg/L,

Max.

5 - 15 15

22 Selenium (as Se),

mg/L, Max

0.05 - 0.05 0.05

23 Nickel (as Ni), mg/L,

Max

3 - 5 3

24 Boron (as B), mg/L,

Max

2 2 - 2

25 Percent Sodium, Max - 60 60 -

26 Residual Sodium

Carbonate, mg/L,

Max

- 50 - -

27 Cyanide (as CN-),

mg/L, Max

0.2 0.2 0.2 0.2

28 Chloride (as Cl-), mg/L,

Max

1000 600 - 1000

29 Fluoride (as F-) mg/L,

Max

2 - 15 15

30 Dissolved Phosphate

(as P), mg/L, Max

5 - - -

31 Sulphate (as SO4-2

)

mg/L, Max

1000 1000 - 1000

32 Sulphide (as S-2

) mg/l,

Max

2 - 5 -

33 Phenolic Compounds

(as C6H5OH) Max

1 - 5 6

34 Radioactive materials

a.) Alpha emitters

µc/mL, Max

b.) Beta emitters

µc/mL, Max

10-7

10-6

10-8

10-7

10-7

10-6

10-7

10-6

35 Manganese (as Mn),

mg/L

2 2 - 2

36 Iron (as Fe), mg/L 3 3 - 3

37 Vanadium (as V), mg/L 0.2 - 0.2 0.2

38 Nitrate Nitrogen, mg/L 18 20 - 0.2

581

ANNEXURE-7

PLOT HOLDING/ALLOTMENT CERTIFICATE OBTAINED FROM SAYKHA GIDC INDUSTRAIL ESTATE.

587

ANNEXURE – 8

WATER SUPPLY LETTER /UNDERTAKING STATING THAT NO BORE WELL SHALL BE DUG.

588

ANNEXURE – 9

UNDERTAKING STATING THAT SEPARATE ELECRIC METER SHALL BE PROVIDED.

589

ANNEXURE – 10

MEMBERSHIP CERTIFICATE OF COMMON INFRASTRUCTUTRE

590

ANNEXURE – 11

COPIES OF AGREEMENT / MOU / LETTER OF INTENT

592

ANNEXURE – 12

MSDS

1. HCl

599

2. SULFURIC ACID

606

3. HYDROGEN PEROXIDE

613

4. METHANOL

619

5. BENZENE

625

6. Methylene chloride

630

7. Mono Chlorobenzene

635

8. Phenol

641

9. Acetone

647

ANNEXURE – 13

DO’s and DON’Ts for Safer Operation

Do’s:

• Store used oil at proper place as per plant guidelines.

• Use lubricating oil carefully to avoid spillage on ground.

• Use lubricating oil as per requirement.

• Use minimum amount of water wherever it is required as per plant guidelines.

• Waste disposal system for all plants should be separate.

• Avoid spillage of liquid, hand gloves, cotton waste on road, which will cause

pollution. Recycle or dispose that material.

• Use cleaning equipment carefully. (i.e. cotton waste, oil & chemicals)

• Place all the equipments (i.e. Fire Hose, Rubber Pipe and Chisel) at proper place.

• Handling of chemicals should be as per plant guidelines to avoid undesired chemical

reaction.

• Safety training and correct use of PPE’s must for all the employees.

• Environment guidelines should follow during cleaning of vessels, Tank, channels etc.

• Follow shift in charge’s instructions during loading or unloading of chemicals.

• In case of fire or any accident, immediately inform responsible person,

• In case of emergency, inform operator as well as control room.

• Area of work during excavation, radiography, sand blasting shall be cordoned with

warning tags of "work in progress”, “no entry”, “radiography” in progress' etc.

• Switch off lights and computers when not in use.

• Shut the water cock properly when not in use.

• Always follow safety rule during the plant operation.

Do’s during shut down:

• All equipment, vessels, lines where hot work is envisaged shall be purged, flushed

thoroughly and positively isolated. Similar precautions should be taken for vessel

entry also.

• Back flow of materials from sewers, drains should be avoided by proper isolations.

• In case of confined space entry and other cleaning jobs etc. which are to be carried

out by the process department, vessel entry permit should be issued to immediate

supervising officer/operator by shift in charge. This permit should be renewed by

incoming shift in charge during every shift.

• Hoist, Platform, cages used for lifting persons or to send persons inside vessels by

such means must be of sound construction with wire ropes slings, etc. to avoid

failure.

• All steam, condensate, hot water connections should be made tight with clamps.

• All underground sewers shall be flushed, protected from sparks.

• Full PPEs like PVC suits, gum boots, face shield & other required shall be used while

draining, flushing and other reclaiming activities to avoid burn, poisoning etc.

• Wet asbestos cloth/metallic plate should be used to collect flying sparks.

648

• Water, steam flushing, nitrogen blanketing shall be continued where spontaneous

combustion takes place. Precautions should be taken for pyrophoric nature of

material.

• Temporary electrical connections, cords, boards and other electrical fixtures should

be of sound material to prevent electrical shock.

• Proper approach like aluminum ladder should be provided to reach to the platforms

of scaffolding and ladder must be tied.

• All clumps of scaffolding should be tightened properly and planks should be tied at

both ends and supported at proper distances along span to avoid sagging and failure.

• Always use safety belt while working at height of more than 2 meters and ensure

tieing the life line of safety belt with firm support.

• Ensure area cordoning for hot work, X-ray, excavation, hazard material temporary

storage.

• Ensure proper tagging of valves, switches etc to prevent its use.

• Ensure proper guidance to workman and make him aware about local area hazards

before start of the job.

• All welding machines should be provided with power isolation switch of suitable

rating.

• Portable electrical appliances/tools earthing should be in good working condition.

Insulation portion should be free from damages.

• All electrical cables should be joints free and connection taken by using three pin

plugs.

• While inserting fuse all care should be taken so that no one touches conductor to

avoid the shock to the persons.

• During hydro jetting work workers should wear hand gloves, safety helmet goggles

and PVC suit.

Don’ts:

• Do not use fire hydrant water for washing/bath purpose.

• Do not use water for cleaning purpose, use broomstick if possible.

• Do not wash or clean trolley, tractor or trucks which are used for chemical/fertilizer’s

transportation. Wash them at proper place.

• Smoking & carrying matchbox, cigarettes, lighter, bidis etc. are prohibited.

• Photography & carrying cameras/Mobile phones are strictly prohibited in all areas.

• Do not spill liquid or chemicals in open atmosphere.

• The use of Radio Active Source within the plant shall not be allowed without

obtaining valid permission/work permit and intimation in the form of a circular to all

plant persons shall be given in advance.

• Unauthorized entry into any battery limit of plant is strictly prohibited.

• Sitting or walking on rail tracks, crossing between wagons, taking rest under stabled

wagons, crossing the rail through the openings underneath the stationary wagons

are strictly prohibited.

649

Don’ts during shut down:

• Do not use gasket or other blinds as it can fail during job. All blinds should be

metallic.

• No toxic/corrosive/irritating materials should remain plants or sections where hot

work is to be carried out.

• No hot work should be permitted in battery limits near sewers till areas have been

cleaned flushed properly.

• No hot work irrespective of place of area shall be done without valid permit.

• No combustible material shall be there in flare line for taking up of flare line job.

Isolations shall be ensured.

650

ANNEXURE – 14

COPY OF HON'BLE HIGH COURT OF GUJARAT'S STAY ORDER AGAINST NOTIFICATION

DATED MARCH 3, 2016 OF MoEFCC, NEW DELHI

655

ANNEXURE – 18

ADEQUECY

ENVIRONMENTAL MANAGEMENT SYSTEM ADEQUACY CERTIFICATE FOR PROPOSED EMS

The Environmental Audit Scheme was introduced by the Gujarat High

Court vide its orders dated 20/12/96 & 13/3/97 and modified vide order

dated 16/9/1999 & 22/04/2010 & 23/1/2015. We are recognised by the GPCB, Gandhinagar as Schedule – II Environmental Auditor for

compliance of the directions of the Hon’ble High Court in this matter and have carried out visit to check the adequacy of EMS proposed by:

A) M/S. NUTRAPLUS INDIA LTD. (UNIT-II)

PLOT NO. C-198, SAYKHA INDUSTRIAL ESTATE, TAL: VAGRA, DIST: BHARUCH, GUJARAT.

B) TO MANUFACTURE PRODUCTS AS UNDER:

SR.

NO.


CAPACITY (MT/MON

TH)

END USE

1 IBUPROFEN 15867-

27-1

400

Anti-Inflammatory

2 DICLOFENAC SODIUM

15307-79-6

Anti

3 ACECLOFENAC 89796-99-6

Anti

4 NIMESULIDE 51803-

78-2

Anti

5 CHLORZOXASONE 95-25-0 Anti

6 MEFENAMIC ACID 61-68-7 Anti

7 MESALAMINE 89-57-6 Anti

8 ALBENDAZOLE 54965-21-8

Anti-Worm medication

9 FEBENDAZOLE 43210-67-9

Anti-Trematode therapeutic

656

10 MEBENDAZOLE 31431-

39-7

Anti-Worm medication

11 METRONIDAZOLE 443-48-1 Antibiotics

12 METRONIDAZOLE BENZOATE

22916-47-8

Antibiotics

13 TINIDAZOLE 19387-

91-8

Antibiotics

14 ORNIDAZOLE 16773-

42-5

Antibiotics

15 OXYCLOZANIDE 2277-92-1

Anthelmintic

16 ROXARSONE 121-19-7 Anthelmintic

17 CHLORPHENIRAMINE

MALEATE (C.P. MALEATE)


18 BROMHEXINE HCL 611-75-6 Antioxident/Expectorant

19 AMBROXOL HCL 23828-

92-4

Secretolytic

20 PHENYLEFFRINE HCL 61-76-7 Decongestant

21 DEXO METHERPHAN

HBR

6700-34-

1

Antihistamines

22 SALBUTEMOL

SULPHATE

51022-

70-9

Antihistamines

23 THEOPHYLLIN 58-55-9 Xanthines

24 CAFFEIN 58-08-2 Ergotamine

25 THEOBROMINE 83-67-0 Vasodilator

26 CIPROFLOXACIN 85721-33-1

Antibiotics

27 OFLAXACIN 82419-36-1

Antibiotics

28 ENROFLOXACIN 93106-

60-6

Antibiotics

29 SILDINAFIL CITRATE 171599-83-0

pulmonary arterial hypertension

30 TRAMADOL HCL 27203-92-5

Analgesic

31 LUMEFANTRINE 82186-77-4

Antimalarial

32 ALUMINIUM

HYDROXIDE GEL/POWDER

21645-

51-2

Antacid

33 AMPICILLIN 69-53-4 Antibiotics

34 AMOXICILLIN 26787-

78-0

Antibiotics

35 CLOXACILLON 61-72-3 Antibiotics

36 CEPHALEXIN 15686- Antibiotics

657

71-2

TOTAL 400 MT/MONT

H

As per the directions of Hon’ble High Court in Environmental Audit Scheme and based on site visit & literature survey, we certify that the

Environmental Management System proposed by this industry for the products and capacity as stated above is adequate and efficacious to

achieve the quality of effluents (Wastewater) and management of

hazardous wastes as specified/required for Consents/Notifications by GPCB, Gandhinagar for following quantity of effluents.

c) Liquid effluent: 81 KL/DAY (INDUSTRIAL) + 21 KL/DAY

(DOMESTIC) WATER CONSUMPTION AND WASTE WATER GENERATION

SR.

NO.

CATEGORY WATER

CONSUMPTION

(m3/day)

WASTE WATER

GENERATION

(m3/day)

1. Domestic 21 21

2. Other

(Gardening)

3 -

3. Industrial

Process 50 60

Boiler 40 7

Cooling 30 5

Washing 10 10

Total Industrial 130 82

Grand Total 154 103

Water requirement = 154.0 KL/Day (Fresh: 57 KLD + Re use: 97 KLD)

(Source: GIDC Water Supply)

Wastewater Generation = 103.0 KL/Day

• Industrial = 82.0 KL/Day

658

• Domestic = 21.0 KL/Day

• High COD stream (27.0 m3/day) from process will be treated in MEE

plant with solvent stripper.

• Low COD stream from, Process, Boiler, Cooling, Washing/ &

Domestic effluent (74 m3/day) will be sent to proposed ETP consists

of primary, secondary & tertiary treatments. To achieve the Zero

Liquid Discharge, Treated effluent from ETP (74.0 m3/day) shall be

treated in R.O. plant. Then R.O. permeate (53.0 m3/day) shall be

reused in Boiler and Cooling while, R.O. reject (21 m3/day) shall be

treated in MEE Plant & salt will be sent to TSDF site for disposal.

MEE Condensate 44.0 KLD will be reuse in Industrial Purpose.

• Domestic wastewater will be added in biological treatment of ETP.

• Scrubbing media will be reuse in plant premises and sent to end

users having Rule-9 permission.

Please refer water balance diagram Please refer Annexure –I for details of Effluent Treatment Plant.

d) Details of air pollution control measures:

e) FUEL CONSUMPTION

f) DETAILS OF FLUE GAS EMISSIONS

Details Of Flue Gas Emission

Sr. No

.

Source of emission

With Capacity

Stack Height

(meter)

Type of Fuel

Quantity of

Fuel MT/Day

Type of emission

s i.e. Air Pollutant

s

Air Pollution

Control Measure

s

1 Steam Boiler 6 TPH *2

30. 0 M Coal/ Briquettes of Bio-

24 MT/Day or

Pm<150 Mg/Nm3 So2< 100

Multi -Cylcone separator

SR.

NO.

FUEL CONSUMPTION

PROPOSED

1. Coal/ Briquettes of Bio-Coal

24 MT/Day or

15 MT/Day

2. Diesel 2000 Lit/Day

659

Nos. Coal 15 MT/Day

ppm Nox< 50

ppm

with bag filter and

water scrubber

2 Thermopac

k Capacity

(4000 U)

30. 0 M Coal/

Briquettes of Bio-

Coal

24

MT/Day or

15 MT/Day

PM<150

Mg/Nm3 So2< 100

ppm Nox< 50

ppm

Multi -

Cylcone separator

with bag filter and

water scrubber

3 D. G Set 1000 KVA

11. 0 M Diesel 2000 Lit/Day

PM<150 Mg/Nm3 So2< 100 ppm

Nox< 50 ppm

Adequate Height Provided.

g) DETAILS OF PROCESS GAS EMISSIONS

Details Of Process Gas Emission

Particulars Height Emission Norms

APCM

Process Vent*-1

(Product :15 : Oxyclozanide)

(Product :10 : Mebendazole)

15 m HCl < 20

mg/Nm3

SO2 < 40 mg/Nm3

Two Stage

Scrubber

(Water + Alkali)

Process Vent*-2 (Product :10 : Mebendazole)

(Product :23 : Theophylline) (Product :24 : Caffein)

15 m CL2< 9.0 mg/Nm3

Two Stage Scrubber

(Water + Alkali)

Process Vent*-3 :

(Product :20 Phenylpherine) (Product :29 Sildinafil Citrate)

(Product :34 Amoxicillin

Trihydrate)

15 m NH3< 175.0

mg/Nm3

Two Stage

Acid Scrubber

Process Vent*-4 : (Product :21 Dexometherphan)

15 m HBR< 30.0 mg/Nm3

Two Stage Alkali

Scrubber

Proposed

h) HAZARDOUS WASTE:

660

Sr. no.

Type/Name of

Hazardous waste

Specific Source of generation

(Name of the Activity,

Product etc.)

Category and

Schedule as per

HW Rules.

Quantity (MT/Annu

m)

Management of HW

1 ETP

Sludge

From ETP plant Sch-

I/35.3

636

MT/Year

Collection,

Storage, Transportation

& sent for co-processing in

cement industries or disposal at

nearest TSDF Site.

2 Discarded

Container/ Bags/Dru

ms

From raw

material

Sch-

I/33.1

36.0

MT/Year

Collection,


, Decontaminati

on & Sell to authorized

vendors

3 HDPE

Bags

From raw

material

Sch-

I/33.1

12.0

MT/Year

Collection,


, Decontaminati

on & Sell to authorized

vendors

4 Distillation

Residue

From Solvent

Recovery plan

Sch-

I/33.1

360.0

MT/Year

Collection,



cement industries or disposal at common

incineration site

5 Spent

Solvent

From mfg.

Process

Sch-

I/36.1

12000.0

MT/Year

Collection,

Storage, and in-house

solvent

661

recovery plan & Reuse in

plant premises.


machinery

Sch-

I/5.1

6.0

MT/Year

Collection,


& Reuse or sale to

registered re-processors

7 Process Waste

From plant machinery

Sch-I/28.1

480.0 MT/Year

Collection, Storage, Transportation & sent for co-

processing in cement

industries or disposal at

common incineration

site

8 Spent Carbon

From mfg. process Product

no.02,04,10-16,18,19,21,25,

26-30,36

Sch-I/28.3

192 MT/Year

9 Iron Sludge From mfg.

process Product no.04,18,23,24,29

Sch-

I/28.1

1200

MT/Year

Collection,

Storage, Transportation & sent for co-processing in

cement industries

10

Spent Catalyst


no.09,22

Sch-I/28.2

24.0

MT/Year


Transportation & return back

to supplier for re-generation

or Sent to nearest

common Incineration

Site.

1

1

MEE Salt From waste

water treatment MEE

Sch-

I/35.3

430

MT/Year

Collection,




662

disposal at nearest TSDF

Site.

12

HCl (32%) From mfg. process Product

no.07,08 &

Scrubber

Sch-I/28.1

4800.0

MT/Year


Transportation

And Reuse in Roxarsone


HCL (32%)–5400

MT/Annum)

13

H2SO

4

(70%)


no.09,22

Sch-I/28.1

3840.0

MT/Year


Transportation

And Reuse in Sildinafil

Citrate (Require Quantity of H2SO4

(70%)–5328.0 MT/Annum).

1

4

Sodium

Sulphite

From mfg.

process Product

no.15,10 & Scrubber

Sch-

I/28.1

360.0

MT/Year

Collection,

Storage,

Transportation & sell to end

user having Rule-9

Permission.

15

Sodium hypochlorite


no.15,10 & Scrubber

Sch-I/28.1

180.0

MT/Year


Transportation & sell to end

user having

Rule-9 Permission.

16

Ammonium Chloride


no.08,22

Sch-I/28.1

672.0

MT/Year

17

Sodium Sulphate


no.17,23

Sch-I/28.1

1800.0

MT/Year

1

8

Sodium

Bromide

From mfg.

process Product no.08 & Scrubber

Sch-

I/28.1

816.0

MT/Year

663

19

KCl Salt From mfg. process Product

no.04

Sch-I/28.1

288.0

MT/Year

20

Sodium Carbonate


no.07,22

Sch-I/28.1

1200

MT/Year


Transportation

And Reuse in MESALMINE


Sodium Carbonate

(1200.0 MT/Annum) or

SALBUTAMOL SULPHATE


Sodium Carbonate (144.0

MT/Annum) Send to End

users having Rule 9

permission.

21

AlCl2 From mfg.

process Product

no.22,26

Sch-I/28.1

660.0

MT/Year


Transportation And Send to

End users having Rule 9 permission.

2

2

Al(OH)3 From mfg.

process Product no.01,02,10,32

Sch-

I/28.1

2760.0

MT/Year

Collection,


& sell to end user having

Rule-9 Permission.

23

NaOH From mfg. process Product

no.07

Sch-I/28.1

768.0

MT/Year


Transportation And Reuse in MESALMINE (Require

Quantity of

664

Sodium Hydroxide

(864.0 MT/Annum) or

Send to End users having

Rule 9 permission.

24

MnO2 From mfg.

process Product

no.19

Sch-I/28.1

1920.0

MT/Year


Transportation & sell to

end user having Rule-

9 Permission.

25

Methane Sulfonic

Acid


no.21

Sch-I/28.1

2160.0

MT/Year

2

6

Methyl

Sodium Sulphate

From mfg.

process Product no.24

Sch-

I/28.1

3060.0

MT/Year

2

7

MMA

Solution

From mfg.

process Product no.25

Sch-

I/28.1

624.0

MT/Year

28

Ether From mfg. process Product

no.26

Sch-I/28.1

2400.0

MT/Year

Non-Hazardous Waste


MT/Year

Collection,


and sell to brick

manufacturer

665

This certificate is subject to automatic cancellation in case of any

change in product profile/capacity, quality & quantity of effluents (Air + Water + Hazardous) and efficiency of EMS equipment then

what is stated above.

PLACE: SURAT

666

ANNEXURE – I

TOTAL PROPOSED WATER BALANCE DIAGRAM

667

ETP DETAILS

M/s. Nutraplus India Ltd. shall have a ZLD Effluent treatment plant

consisting of primary, secondary tertiary and advanced treatment units. The details of ETP are as follows.

Stream I (74 KLD Low COD + RO Reject 21.0 KLD)

First all non-toxic and biodegradable streams (low & medium COD) of wastewater shall pass through Screen Chamber (SC) where floating

material shall be removed with help of Screen (S-01). Then effluent shall be passed through Oil & Grease Removal Tank (OGRT). Automatic

mechanical Oil Skimmer shall be provided in the OGRT to remove floating oil and grease from the wastewater to Oil & Grease Collection Tank

(OGCT). Then effluent shall be collected in Collection cum Equalization

tank (CET). Pipe grid is provided at bottom of the CET to keep all suspended solids in suspension and to provide proper mixing. 2 nos. of Air

Blowers (1 stand-by) shall supply air through diffusers to pipe grid. Mother liquor Solvent Stripper shall be added in CET. Then after, equalized wastewater shall be pumped to Neutralization Tank

(NT) where the continuous addition and stirring of lime solution is done to maintain neutral pH of wastewater from Caustic Dosing Tanks (CDT) as

per requirement by gravity. Then after, neutralized wastewater shall go to Flash Mixer (FM) by gravity. Alum and Polyelectrolyte shall be dosed from

Flocculants Dosing Tank (FLDT) and Polyelectrolyte Dosing Tank (PEDT) respectively by gravity into FM-1 to carry out coagulation by using a Flash

Mixer.

Then after, coagulated wastewater shall be settled in Primary Tube Settler (PTS). Clear supernatant from PTS shall be passed in Aeration Tank (AT-1) Here, biodegradation of organic matter of the wastewater shall be

carried out by bacteria (suspended growth) in the AT-1 and for that oxygen shall be supplied by 2 nos. of air blowers (B-02) through diffusers.

Air blowers also keep MLSS in suspension.

Then after, wastewater shall go to Secondary Settling Tank-1 (SST-1) from AT. Here, the suspended solids shall be settled. Sludge shall

be removed from bottom of SST-1 and pumped to AT-1 to maintain MLSS and excess activated sludge shall be sent to Sludge Sump

(SS). Clear supernatant from SST-1 shall go to Aeration Tank-2 (AT-2). Here biodegradation of left out organic matter of the wastewater

shall be carried out by bacteria (suspended growth) and for that oxygen shall be supplied by two nos. of blowers (B-03) with help of

diffusers. Then after, wastewater shall go to Secondary Tube Settler-

2 (SST-2) from AT-2. Here, the suspended solids shall be settled.

668

Activated sludge shall be removed from bottom of SST-2 and

pumped to AT-2 to maintain MLSS and remaining will be sent to SS. Nutrients will be added from NDTs to Aeration Tank-2 for growth of

Bacteria. Clear effluent is the collected in of Intermediate Sump (IS) by gravity.

Thereafter, the wastewater shall be passed through Pressure Sand Filter

(PSF) to remove left out TSS and Activated Carbon Filter (ACF) for final effluent polishing. After tertiary treatment, Filter water is collected to RO

Feed Tank (RFT) and then pumped to RO Unit (large capacity) for further treatment. Permeate water from RO will be reuse in process. RO reject will

be sent to SD Feed Tank (SDFT) for further treatment. Then effluent shall be sent to Spray Dryer (SD). Solid from Spray Dryer shall be collected and

stored in HWSA for ultimate disposal to TSDF. Sludge settled in PTS-1 and excess sludge from SST-1 & 2 shall be

collected in Sludge Sump then sludge shall be pumped to Filter Press

(FP) where, dewatering shall be carried out before storage in HWSA and ultimate disposal to TSDF.

All high TDS streams of wastewater shall be collected in Solvent Feed Tank (SFT) then it will be sent to Solvent Stripper (STR) where solvent shall be removed from effluent and collected in Reactor (RE) before sent

to Distillation Unit. Mother liquid from Solvent Stripper shall be sent in CET for further treatment.

Stream II (27 KLD High COD )

All High COD streams of wastewater shall be collected in Collection cum Neutralization Tanks-2 (CNTs-02). Mixer is provided in Tank. where Lime

shall be added from Lime Dosing tank. Then after, effluent shall have sent to Flash Mixer-2 (FM-02) where Alum and poly shall be added from ADT and PDT-01 respectively. Then after, coagulated wastewater shall be

settled in Primary Clarifier-1 (PCL-01).

Clear effluent from PCL-01 shall be collected in Holding Tank (HT-01) before pumped to strippers (ST-01). Effluent from stripper collected in

MEE Feed Tank (MFT-01) where RO reject will be mixed with it. Then effluent shall be sent to Multiple Effect Evaporator (MEE-01) for further

treatment for solids dewatering. Condensate from MEE shall collect in Condensate Storage Tank (CST-01) before reuse in plant. Solids from

SD-01 shall be collected and stored in HWSA for disposal in TSDF.

Details of ETP Units

S.N. Name of unit Size (m x m x m)

L x B x (LD+FB) No. MOC/ Remark

669

Stream I (Low COD Stream) 73 KLD +21 KLD Ro Reject

1 Screen Chamber (SC-01)

1.5 m x 0.8 m (0.05 m+0.7 FB)

1 RCC M25+A/A Bk. Lining

2 Collection cum

Equalization Tank (CET-01)

4.0 m x3.0 m x

(3.0 m+1.0 FB)

1 RCC M25+A/A

Bk. Lining

3 Neutralization Tank

(NT-01)

1.0 m x 1.0 m x

(2.5 m +0.5 FB)

1 RCC M25+A/A

Bk. Lining

4 Flash Mixer (FM-01) 1.0 m x 1.0 m x

(2.3 m +0.7 FB)

1 RCC M25

5 Primary Tube Settler (PTS-01)

2.75 m x2.0 m x (2.0 m + 0.5 HB+0.5 FB)

1 RCC M25

6 Aeration Tank-1

(AT-01)

8.0 m x 7.5 m x

(4.0 m+0.7 m)

1 RCC M25

7 Secondary Settling Tank-1 (SST-01)

3.0 m x 2.0 m x (2.0 m + 0.5

HB+0.5 FB)

1 RCC M25

8 Aeration Tank-2 (AT-02)

7.5 m x 6.0 m x (4.0 m+0.7 m)

1 RCC M25

9 Secondary Settling

Tank-2 (SST-02)

2.5 m x 2.0 m x

(2.0 m + 0.5 HB+0.5 FB)

1 RCC M25

10 Intermediate Sump (IS-01)

2.0 m x 2.0 m x (2.5 m+0.5)

1 RCC M25

11 Pressure Sand Filter

(PSF-01)

5 m3/hr 1 FRP

12 Activated Carbon

Filter (ACF-01)

5 m3/hr 1 FRP

13 RO Feed Tank

(ROFT-01)

4.0 m x3.5 m x

(2.5 m+0.5 FB)

1 RCC M25

14 RO Unit 4.25 m3/hr 1 As per spec.

15 Sludge Sump(SS-01)

2.0 m x 2.0 m x (2.5 m + 0.5)

1 RCC M25

16 Filter Press(FP-01) 7 m3 / batch 1 PP

17 Drain Pit(DP-01) 1.0 m x1.0 m x (2.0 m+0.3 FB)

1 RCC M25

Stream II (High COD stream) 27 KLD

18 Collection Cum

Neutralization Tank (CNT-01)

4.0 m x3.5 m

x (2.5 m+0.5

FB)

1 RCC M25+A/A

Bk. Lining

670

19 Flash Mixer-2 (FM-02) 30 m3/D 1 RCC M25

20 Primary Settling Tank

(PST-01)

30 KLD 1 RCC M30

21 Holding Tank (HT-01) 50 KL 1 RCC M30

22 Stripper (ST-01) 30 KL 1 SS316

23 MEE Feed Tank (MFT-01) 50 KL 1 RCC M30

24 Multiple Effect Eveporator(MEE -01)

200 M3/hr 1 SS316L

25 Solid Dryer (SD-01) 25 M3/Day 1 RCC M30/HDPE

26 Condensate Storage Tank

(CST-01)

30 KL 1 RCC M30

• RCC M25 = REINFORCED CEMENT CONCRETE (M 25 GRADE)

• PCC = PLAIN CEMENT CONCRETE • PP = POLYPROPELENE

• MSEP = MILD STEEL EPOXY PAINTED SS = STAINLESS STEEL

DETAILS OF SOLVENT STRIPPER

• All the solvents shall be directly distilled from high COD effluent

with the help of Solvent Stripper and Distillation.

• The solvent distillation system shall be designed so as to achieve minimum 92.0 % recovery of solvent.

• Pure solvent, crude solvent and distilled (recovered) solvent shall be stored only in storage tanks.

• Wherever required, the solvents shall be directly pumped into day tanks from the storage tanks and shall be charged into the reactors

without involving any manual handling. • All the pumps shall be mechanical seal type to avoid any leakage of

solvent. • All necessary fire fighting systems shall be provided with alarm

system. Flame proof wiring and flame proof electrical accessories shall be provided to avoid any mishap.

• All the storage tank and day tank shall be connected to a vent system through cooling water and chilled brine condensers to prevent loss of solvents in the atmosphere.

• All the distillation column vents are also connected to cooling water/ chilled brine condensers for maximum possible recovery of the

solvents. • All the vents will be connected to a common carbon Adsorber for

removing traces of solvent from vent gases. • Residue generated from the distillation will be incinerated in-house

or sent to BEIL incinerator site. • Coolant to be used


671



Solvent

Main

Storage

Tank

Addition

Tank

Reaction

Mass

With

Solvent

Receiver

Distilled

Solvent

Solvent

Distillation

System

Recycle

Organic

Layer/spent

solvent to recovery

System


CHW

in

CHB. In

C.W.

CHB. Out

CHB. Chilled Brine

CHW Chilled Water

Distillation

Column

672

TECHNICAL DETAILS OF R.O.

673

Characteristics of Effluent:

Product No. Boiler Cooling Washing

pH 7.9 7.1 7.3

COD (mg/L) 60 170 2300

BOD3 (mg/L) <10 34 700

TDS (mg/L) 600 1350 1400

Expected Characteristics Of Wastewater Before & After

Treatment Low COD

Paramet

er

Untreat

ed (Dilute

Stream)

After

Primary Treatme

nt

After

First Stage

Aeration

After

Second

Stage Aerati

on

After

tertiary Treatme

nt

R.O

Permeate

pH 4 - 8 6 - 7.5 6-7.5 6 - 7.5

6 - 7.5 6 - 7.5

COD (mg/L)

3957 2690 1107 180 176 <10

BOD3

(mg/L)

1489 1042 560 48 25 <5

TDS

(mg/L)

3484 3208 3190 3180 2898 <150

674

Expected Characteristics Of Wastewater Before & After

Treatment High COD

SR. NO.

PARAMETER CHARACTERISTICS(MG/L)

Untreated After Solvent

Stripper

MEE

Condensate

1 pH 4.5 7.5 7.5

2 TDS 28000 28000 <30

3 COD 27500 1500 <200

4 BOD3 7000 650 <50

675

ANNEXURE – 19

GIDC WATER SUPPLY

m/s. nutraplus india ltd. (unit-ii) plot no. c-198

Documents