BALAJI AMINES LIMITEDenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-12-16 · Balaji Amines Limited was started in IDA, Bollaram of Telangana State in the year

PRE FEASIBILITY REPORT

FOR

EXPANSION OF EXISTING SYNTHETIC ORGANIC CHEMICALS MANUFACTURING UNIT

BALAJI AMINES LIMITED

At

Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M),

Medak District, Telangana State - 502325

Contents

S. No. Description Page no. 1.0 Executive Summary 1 2.0 Introduction of The Project 2 2.1 Project Proponent. 2 2.2 Brief description of nature of the project. 2

2.3 Need for the project and its importance to the country and or region 2

2.4 Employment Generation(Direct and Indirect) due to the project 3

3.0 Project description 4 -6 3.1 Product and Production Capacity 7 3.2 Raw materials required and Quantities 7 3.3 Manufacturing Process 8 3.4 Resource – Utilize and Recycling 8

3.4.1 Water 8

3.4.2 Power Requirement 9 3.4.3 Fuel Requirement 9 3.5 Quantity of wastes to be generated 9

3.5.1 Waste Water Generation and utilization 9 3.5.2 Solid waste generation and Disposal 10

3.6 Schematic representations of the feasibility drawing which give information of EIA purpose. 10

4.0 Site Analysis 11 4.1 Connectivity 11 4.2 Land Form, Land use and Land ownership. 11 4.3 Existing Infrastructure 11 4.4 Soil classification 11 4.5 Climatic data from secondary sources. 12 4.6 Social Infrastructure available. 12 5.0 Planning brief 12 6.0 Proposed infrastructure 12 6.1 Industrial Area 12 6.2 Residential Area 12 6.3 Green Belt: 12 6.4 Social Infrastructure 12 6.5 Water management 13 6.6 Sewerage System 13

6.7 Industrial Waste Management 13 7.0 Rehabilitation and Resettlement (R&R) Plan 13 8.0 Project Schedule and Cost estimates 13 9.0 Analysis of project 14

LIST OF TABLES

Table No Description Page no. 2.1 Total Employment 3 3.1 Proposed Products and Quantities 7 3.2 Water Requirement Details 9 3.3 Wastewater generation and Treatment Method 9 3.4 Solid and hazardous waste generation and Disposal 10 8.1 Project Cost 13

LIST OF FIGURES

Figure No Description Page no. 1.1 Location Map 5 1.2 Google Earth Map Showing Balaji Amines Ltd 6

LIST OF FLOW CHART

Flow Chart No Description Page no.

3.1 Generalized Flow Chart for Synthetic organic chemicals Manufacturing

8


M/s. Balaji Amines Ltd. Page 1

1.0 EXECUTIVE SUMMARY

M/s. BALAJI AMINES LTD.(BAL) is a limited company (the plant was originally in

the name of Bhagyanagar Chemicals Ltd., which is a WOS of BAL having lease

agreement) and commenced its commercial operations in 1994, Focusing its

attention on developing technology for import substitute products without any kind of

pollution, introduced quality products DMAHCL, TMAHCL other HCLs and natural

products such as Solonesol, 10 DAB etc.

S. No Parameter Description

1 Project Location Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State - 502325

2 Category of Project as per EIA Notification & Amendments

5 F(A)

3 Project cost 3.0 Crores

4 Plot area 4.2 Acres

5 Proposed Products List of products are Enclosed

6 Resources

(I)Electricity Requirement 600 HP

Source of electricity TSSPDCL

D. G. Sets Existing : 375 KVA Proposed : 360 KVA

(II)Water consumption 135 KLD

Source of water TSIIC Supply

Waste water generation 57.50 KLD

7 Solid waste generation

Organic Residue – 901 Kg/Day Inorganic solid waste – 38 Kg/Day MEE salts – 1375.00 Kg/Day Spent carbon – 16 Kg/Day Coal ash from Boiler – 7050 Kg/Day ETP Sludge – 30 Kg/Day Solvent Distillation bottom Residue – 43 Kg/Day

8 Nearest Highway NH 9 – 6.2 KMs 9 Nearest Railway Station Lingampally Railway Station - 7.7 Km

10 Nearest Air Port Rajiv Gandhi International Airport - 36.0 KM



2.0 INTRODUCTION OF THE PROJECT

The objective of this pre- feasibility study is to provide information for the expansion

of unit of M/s. Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A

Bollaram, Jinnaram (M),Medak District, Telangana State - 502325

2.1 Project Proponent Mr. B. Jogeshwar Rao is the Plant Manager and is Graduate ( B.Sc ) in Chemistry

from Nobel College, Machilipatnam (Andhra University). He has over 35 years of

experience in Plant Management, Including process optimization and Process Scale

up. He has handled projects dealing with organic and inorganic compounds. He has

worked with companies like Pure Drugs Pvt.Ltd. and Vanilin and Fine Chemicals Ltd.

and MCA Chemicals Ltd., and well acquainted with Operations of chemicals plants,

safety and environment culture and other legal requirements.

2.2 Brief description of nature of the project. M/s. Balaji Amines Ltd. commenced its commercial operations in 1994 and

manufactures DMAHCL and Natural Products such as Solonesol and 10 DAB etc. at

Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak

District, Telangana State - 502325

2.3 Need for the project and its importance to the country and or region

We are the safest and largest manufacturer of DMAHCL products in India. The

market for DMAHCL and other products is increasing at the rate of 30% year on year

on volume basis. At present we only cater to Pharma sector. We are coming up with

highly efficient products that can cater to Healthcare industries. Hence a need is felt

to increase the present capacity of the plant and diversify to some of the new

generation products. The plant employs people from the local community. With

increase in plant capacity, the employment opportunity increases for the local

people. We are the only manufacturer of DMAHCL and other products in South India

and in future we intend to export this product to Global pharmaceutical industries.

With increase in volume the tax outgo to the govt will increase substantially.



2.4 Employment Generation (Direct and Indirect) due to the project

The unit has 20 permanent and 40 contractual employees. Apart from this there will

be significant indirect employment generation at the supplier firms and service

industry providing services to the company. Company shall be giving preference to

people from economically weaker sections for employment in various semi-

skilled/unskilled jobs thereby contributing to their upliftment. The details of total

employment in this unit shown in below Table 2.1.

TABLE 2.1: TOTAL EMPLOYMENT AFTER EXPANSION

Particulars No. of employees

Functional Area

Key managerial staff 10 Finance, Marketing, Production,

Quality control, R&D, Logistics etc.

Administration 5 Office work

Skilled and semi

skilled 80

Manufacturing, Maintenance, Stores

& Un skilled workers and contractors

Total 95



3.0 Project Description

M/s. Balaji Amines Limited was started in IDA, Bollaram of Telangana State in the

year 1994 to produce DMAHCL and other products and now proposing for expansion

of Existing Capacities with inclusion of new products apart from expanding DMAHCL

capacities as this product is mainly used in treating diabetes. As the incidence of

Diabetes has been growing rapidly, the capacity expansion is to meet the growing

demand. The process does not generate any effluent.

The Location map is shown at Figure -3.1 and Google earth map showing Balaji

Amines Ltd. plant is shown at Figure -3.2 .

The site central coordinates are Latitude : 17°32'54.20"N Longitude : 78°20'41.86"E

There are no archaeological, historical sites located nearby. Therefore, the project

site does not offer any negative impact on the local area, but rather has a positive

impact on socio economic conditions of the habitants around it.

The Balaji Amines Ltd. is 3 Km away from Nehru ORR and 6 Kms. from Lingampally

Railway Station.



FIGURE 3.1: LOCATION MAP

Balaji Amines Ltd. Plot No: 4 & 5, Beside Sub-Station-II, I.D.A, Bollaram, Jinnaram (M), Medak District, Telangana State - 502325



FIGURE 3.2: GOOGLE EARTH MAP SHOWING BALAJI AMINES LTD



3.1 Product and Production Capacity

M/s. Balaji Amines Ltd. is proposes to produce below mentioned products with

Manufacturing Capacity 1510 MT/Month and the list of product is shown in Table3.1.

Table3.1: Proposed Products and Quantity

S. No Product Name CAS No’s Quantity Kg/Month

1 16-Alpha hydroxyPrednisolone 13951-70-7 200.00

2 Beclomethasone Dipropionate 4419-39-0 200.00

3 Betamethasone 17-valerate 2152-44-5 500.00

4 Betamethasone Acetate 987-24-6 250.00

5 Betamethasone dipropionate 5593-20-4 500.00

6 Betamethasone Sodium Phosphate 151-73-5 250.00

7 Budesonide 51333-22-3 700.00

8 Ciclesonide 141845-82-1 1500.00

9 Dimethylamine Hydrochloride 506-59-2 12,00000.00

10 Emtricitabine 143491-57-0 600.00

11 Flumetasone Pivalate 2002-29-1 525.00

12 Fluticasone Furoate 397864-44-7 500.00

13 Lamivudine 134678-17-4 400.00

14 Mometasone Furoate 105102-22-5 500.00

15 Nadolol 42200-33-9 400.00

16 Povidone Iodine 25655-41-8 200000.00

17 PVP-A Copolymer Series 25086-89-9 50000.00

18 VP/DMAEMA Quaternized(PQ-11) 53633-54-8 50000.00

Total 1,507,025.00

3.2 Raw materials required and Quantities

All the raw materials required for manufacturing of above products will be sourced

from local/Non local market. The required raw materials and quantities are enclosed

as Annexure.



3.3 Manufacturing Process:

The manufacturing process of bulk drugs consists of chemical synthesis extending

to stages of processing involving different type of chemical reactions. The

generalized Flow chart for synthetic organic chemicals manufacturing is shown in

Flow chart 3.1. FLOW CHART 3.1: GENERALIZED FLOW CHART FOR SYNTHETIC ORGANIC

CHEMICALS MANUFACTURING

3.4 Resource – Utilize & Recycling

3.4.1 Water Water requirement of the project for domestic and industrial activity during operation

phase will be 135.00 KLD. The water requirement will be met through TSIIC supply.

The detailed water requirement shown in below Table 3.2.



Table 3.2: WATER REQUIREMENT DETAILS

S. No Purpose Water Requirement In KLD 1 Process 21.00 2 Washings 3.00 3 Boiler Make up 36.00 4 Cooling towers Make up 63.00 5 Scrubbing system 2.00 6 DM Plant 2.00 7 Domestic 4.00 8 Gardening 4.00

Total 135.00

3.4.2 Power Requirement Power requirement of proposed project will be made available through TSPCPDCL.

The total power requirement for the unit after expansion is 850 Hp respectively.

Proposing to Install 360 KVA DG set In addition to existing 375 KVA DG to meet the

emergency power requirement of the plant for the proposed Expansion.

3.5 Quantity of wastes to be generated 3.5.1 Waste Water Generation and utilization

Total effluent generated in the project is 57.50 KLD. The process waste water from

Process, floor Washes, scrubbers, QC and R&D are evaporated in MEE with stripper

and ATFD after neutralization. The condensate from MEE and ATFD will be

collected and treated in effluents treatment plant along with effluents from utilities

followed by RO. RO rejects will be send back to MEE and RO Permeate will be re-

used back.

To treat the sewage generated due to domestic activities will be disposed through

septic tank following by soak pit.

Table3.3: WASTEWATER GENERATION

S. No

Unit HTDS

In KLD

LTDS In

KLD

Effluent Generation

In KLD Method of Disposal

1 Process 18.00 11.00 29.00 HTDS Sent to stripper followed by MEE and ATFD. Condensate will be send to ETP followed by RO.

LTDS Effluents sent to ETP followed by

2 Washings 0.00 3.00 3.00

3 Boiler Make up 6.00 0.00 6.00

4 Cooling towers Make up

0.00 12.00 12.00



S. No

Unit HTDS

In KLD

LTDS In

KLD

Effluent Generation

In KLD Method of Disposal

5 Scrubbing system 2.00 0.00 2.00 RO system.RO Rejects sent to MEE system and RO Permeate to Reuse.

6 DM Plant 2.00 0.00 2.00

7 Domestic 0.00 3.50 3.50 Septic tank followed by soak pit

Total 28.00 29.50 57.50

3.5.2 Solid waste generation and Disposal

The following solid waste will be generated like Used drums & Tins, and Used Oil

etc.

The types of Hazardous and non Hazardous wastes generated from the project,

method of disposal is shown in below table-3.4.

Table 3.4: Solid & Hazardous waste generation and Disposal S.

No. Name of the Solid Waste Quantity In Kg/Day Disposal Method

1 Organic Residue 901.00 Sent to Cement Industries 2 Inorganic solid waste 38.00 Sent to TSDF 3 MEE salts 1375.00 Sent to TSDF 3 Spent carbon 16.00 Sent to Cement Industries 4 Coal ash from Boiler 7050.00 Sent to Brick manufacturers 5 ETP Sludge 30.00 Sent to TSDF

6 Solvent Distillation bottom Residue 43.00 Sent to Cement Industries

7 Used Oils & Grease 500 Ltrs/Annum

SPCB Authorized Agencies for Reprocessing/Recycling

8 Detoxified Containers, Liners Etc 1000 No’s/Month

After Detoxification sent back to suppliers/SPCB Authorized Parties

9 Used Lead Acid Batteries 2 No’s/Annum Send back to suppliers for buyback of New Batteries

3.6 Schematic representations of the feasibility drawing which give

information of EIA purpose.

The applicability of the S.O 1533 for the proposed project was explored by

considering different possibilities & provision made in the said notification.

Considering the products & project location of the proposed project it is noticed that

the proposed project falls under Category 5 (f) “A” of the Schedule-I of EIA



Notification SO 1533.

As per the provision of the SO 1533, it is necessary to get Environmental Clearance

by applying to MoEF along with the Environmental Impacts Assessment Study

Report for the proposed project prior to commissioning of the project activities.

Therefore the EIA is required to conduct to comply with provisions of SO 1533 made

for Category 5(f) “A” of schedule –I of the notification.

4.0 Site Analysis

4.1 Connectivity

Balaji Amines Ltd. is located at Plot No: 4 & 5, Beside Sub-Station-II, I.D.A,

Bollaram, Jinnaram (M), Medak District, Telangana State - 502325

The nearest habitation from the site is Bollaram at a distance of 0.5 Km (N).

The nearest railway station is Lingampally Railway Station at a distance of 7.7

KMs from the site (SSW).

The nearest airport is Rajiv Gandhi International Airport at a distance of 36.00

KM.

The Nearest road ways NH 9 – 6.2 Km.

4.2 Land Form, Land use and Land ownership. Balaji Amines Ltd is an existing unit. There would be no any change in Land Use,

Land Cover or Topography of plot. Green belt is already developed in the plant

premises.

4.3 Existing Infrastructure. Project is a located very nearer to Nehru ORR Highway ( NH-2 KM) and the city is

located (i.e Hyderabad -12.0 Kms) and the basic infrastructure is already there. The

plant is well connected with Road and Railway facilities

4.4 Soil classification

The district is mainly covered by two types of soils i.e black and chalka (Sandy

looms) covering 55% and 45% respectively of the total area.



4.5 Climatic data from secondary sources.

Temperature Maximum: 42.20o C Minimum: 10.0 o C

Normal annual rainfall 811.9mm

4.6 Social Infrastructure available.

Well developed social infrastructure facilities are available at nearby Habitations. 5.0 Planning Brief

Proposed expansion activities will be started after getting statutory clearance form

related authorities. The project will be completed within two years.

Further project activities will take care of all the rules and regulation of statutory

authority and provide the control measure and devices to achieve the standard

norms.

6.0 Proposed Infrastructure

6.1 Industrial Area

The infrastructure and other facilities are already well developed in nearby Mandal

head quarter and other villages.

6.2 Residential Area

The employees who will work in the industry will be living in nearby Bollaram or

Hyderabad & there no proposal for creating residential area for employees.

6.3 Green Belt: 33 % of Green Belt will be developed and it will be maintained. 6.4 Social Infrastructure: Facilities like road and communication are good; Banks, ATM's and medical facilities are also adequate in the area. Amenities: Education- schools including middle, secondary and higher secondary schools,

social welfare hostels are available and technical education colleges are plenty in the

nearby areas.



Medical and Health- Community Health Centre, & Primary Health center Are available near village and also there is a ESI dispensary in Bollaram Village. Power and water- All the villages are electrified and drinking water facilities are extended to all villages. Rail and Road- The project site is very well connected by road through Nehru ORR, South Central railways etc.

6.5 Water management

Water requirement will be met through IDA Supply. 6.6 Sewerage System:

Domestic waste water will be disposed off through soak pit system.

6.7 Industrial Waste Management: The Hazardous waste sent to TSDF.

7.0 Rehabilitation and Resettlement (R & R) Plan

Rehabilitation & Resettlement (R&R) plan is not applicable to proposed project.

8.0 Project Schedule & Cost Estimates

Expansion activities will be started after getting statutory clearance from concerned

authorities. The project will be completed within two years.

This Expansion will provide benefits to the local people in terms of sustainable

development in terms of economical and social welfare.

The project cost for proposed Project is 3.00 Crores will be used for constructing

additional building, Equipments, Machinery, ZLD System and Air pollution control

Equipments.

TABLE 8.1: PROJECT COST

S. No Particulars Rs. Crores

1 Land 0

3 Plant & Machinery 2.50

4 Working Capital Margin 0.50

Total 2.50



9.0 Analysis of proposal (Final Recommendations)

Local people will get direct employment. which will in turn develop all the

stakeholders.

Local people will get some contracts of supply and services to get indirect

income.

Company will contribute in improving education and health facilities in nearby areas under CSR activities.

Documents

BALAJI AMINES LIMITEDenvironmentclearance.nic.in/writereaddata/Online/TOR/0_0... · 2015-12-16 · Balaji Amines Limited was started in IDA, Bollaram of Telangana State in the year